Vaillant TURBOmax Plus SERIES User guide

INSTRUCTIONS FOR INSTALLATION AND SERVICING
TURBOmax Plus 824/2 E, 828/2 E
Wall hung room sealed fan assisted combination boilers
THERMOcompact 615/2 E, 620/2 E, 624/2 E, 628/2 E
Wall hung room sealed fan assisted system boilers
The code of practice for the installation,
commissioning & servicing of central heating systems

2
TABLE OF CONTENTS
Introduction
Boiler Specification
General Requirements
Boiler Installation Sequence
General Information . . . . . . . . . . . . . . . . . . . . . . . . . .6
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
List of Contents Contents included with boiler (TURBOmax Plus) . . . . . . . .4
Contents included with boiler (THERMOcompact) . . . . . . .5
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Boiler connections (TURBOmax Plus) . . . . . . . . . . . . . . . .8
Boiler connections (THERMOcompact) . . . . . . . . . . . . . .8
Functional diagram (TURBOmax Plus) . . . . . . . . . . . . . . .9
Functional diagram (THERMOcompact) . . . . . . . . . . . . .10
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . .11
Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Top outlet flue system . . . . . . . . . . . . . . . . . . . .13
Rear outlet flue system . . . . . . . . . . . . . . . . . . . .13
Extended top outlet flue system . . . . . . . . . . . . . .13
Flue termination . . . . . . . . . . . . . . . . . . . . . . . .14
Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Cupboard or compartment ventilation . . . . . . . . . . . . . .15
Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Guide to system requirements . . . . . . . . . . . . . . . . . . .16
Water circulation system . . . . . . . . . . . . . . . . . .16
Filling and make up . . . . . . . . . . . . . . . . . . . . .16
Pressure relief valve . . . . . . . . . . . . . . . . . . . . .16
Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . .16
Expansion vessel . . . . . . . . . . . . . . . . . . . . . . .17
Circulating pump . . . . . . . . . . . . . . . . . . . . . . .18
System by-pass . . . . . . . . . . . . . . . . . . . . . . . . .18
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
DHW expansion vessel accessory . . . . . . . . . . . .18
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Preparation of boiler location . . . . . . . . . . . . . . .19
Selecting position of boiler . . . . . . . . . . . . . . . . .19
Using boiler template . . . . . . . . . . . . . . . . . . . . . . . . .20
Fitting the boiler hanging bracket . . . . . . . . . . . . . . . . .21
Install the flue system . . . . . . . . . . . . . . . . . . . . . . . . .21
Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Removing boiler casing . . . . . . . . . . . . . . . . . . . . . . .22
Gas supply (TURBOmax Plus) . . . . . . . . . . . . . . . . . . .23
Cold water mains inlet and hot water outlet
(TURBOmax Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Central heating flow and return pipework
(TURBOmax Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Gas supply (THERMOcompact) . . . . . . . . . . . . . . . . . .26
Central heating flow and return pipework
(THERMOcompact) . . . . . . . . . . . . . . . . . . . . . . . . . .27
Connection to a Vantage unvented cylinder
(THERMOcompact) 28
Connect the flue system to the boiler . . . . . . . . . . . . . . .28
Electrical installation general requirements . . . . . . . . . . .30
Connection to the main supply . . . . . . . . . . . . . . . . . .31
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fit boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
TURBO
max
THERMO
compact

3
TABLE OF CONTENTS
Gas supply adjustments
(Commissioning Part II)
Servicing
Fault Finding Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Logical fault finding procedure . . . . . . . . . . . . . . . . . .73
Status mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Diagnostic modes . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Fault finding charts . . . . . . . . . . . . . . . . . . . . . . . . . .78
Diagrams Functional flow diagrams . . . . . . . . . . . . . . . . . . . . . .85
Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Short parts list Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Cleaning the burner and primary heat exchanger . . . . . .58
Parts replacement Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Temperature sensors (NTCs) . . . . . . . . . . . . . . . . . . . .63
Main heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . .63
Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Electronic control board . . . . . . . . . . . . . . . . . . . . . . .65
Main transformer . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . .66
Automatic bypass . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Diverter valve (TURBOmax Plus only) . . . . . . . . . . . . . .68
Aqua sensor (TURBOmax Plus only) . . . . . . . . . . . . . . .68
DHW heat exchanger (TURBOmax Plus only) . . . . . . . . .69
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .69
Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . .70
Functional checks
(Commissioning Part III)
Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Functional check of operation . . . . . . . . . . . . . . . .53/54
Adjusting pump speed . . . . . . . . . . . . . . . . . . . . . . . .55
Final system flush (hot) . . . . . . . . . . . . . . . . . . . .55
Handing over to the user . . . . . . . . . . . . . . . . . . . . . .56
Gas inlet working pressure . . . . . . . . . . . . . . . . . . . . .44
Main burner pressure . . . . . . . . . . . . . . . . . . . . . . . . .45
Adjusting the central heating output (range rating) . . . . .46
Adjusting the ignition rate . . . . . . . . . . . . . . . . . . . . . .48
Adjusting to the maximum heat load (nominal load) . . . .49
Burner pressure and gas rate . . . . . . . . . . . . . . . . .50/51
Commissioning Part I Preliminary electrical checks . . . . . . . . . . . . . . . . . . . .39
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Cold water supply (TURBOmax Plus only) . . . . . . . . . . .39
Filling the heating system (TURBOmax Plus) . . . . . . . . . .40
Filling the heating system (THERMOcompact) . . . . . . . . .42
Initial system flush (`cold`) . . . . . . . . . . . . . . . . . . .41/43
TURBO
max

4
LIST OF CONTENTS
Contents included with
boiler (TURBOmax Plus)
Ensure that all contents are included
before commencing installation.
DO NOT remove the boiler from the
polystrene base at this stage.
TURBOmax Plus
4
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
10
11
11
11
BEDIENUNGSANLEITUNG
Instructions for Installation
9
12
8
1
2
7
6
VRC-VC
C
o
0
I
C
o
3
5
Fig. L.1: Items supplied with unit (TURBOmax Plus)
Table L.1: Items supplied with unit (TURBOmax Plus)
Euro B/S 086/0GB_Plus
Item Quantity Description
1 1 Boiler
2 1 Flue restriction ring
3 1 Controls cover door
5 1 Cold water inlet valve
6 3 Flow and return service value, gas service valve
4 1 Lower cover plate (packed in bottom packaging)
7 5 Copper tails for gas and water pipework
8 1 Template
9 2 Guarantee Card and Benchmark log book
10 1Installation and connection accessories and
PRV packages incl. DHW outlet union nut
11 3Installation and Servicing, Users and Flue Installation
Instructions
12 1Hanging bracket

5
LIST OF CONTENTS
Contents included with
boiler (THERMOcompact)
Ensure that all contents are included
before commencing installation.
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
9
10
10
10
BEDIENUNGSANLEITUNG
Instructions for Installation
8
11
7
1
6
5
2
VRC-VC
C
o
0
I
C
o
3
4
Fig. L.2: Items supplied with unit (THERMOcompact)
Table L.2: Items supplied with unit (THERMOcompact) * for THERMOcompact 624/628 only
Euro B/S_VC_025/0
DO NOT remove the boiler from the
polystrene base at this stage.
Item Quantity Description
1 1 Boiler
2 1Flue restriction ring
3 1 Controls cover door
6 3 Copper tails for gas and water pipework
4 1 Lower cover plate (packed in bottom packaging)
7 1 Template
8 2 Guarantee Card and Benchmark log book
9 1 Installation and connection accessories and
PRV packages
11 1Hanging bracket
5 3 Flow and return service value, gas service valve
THERMOcompact
10 3Installation and Servicing, Users and Flue Installation
Instructions

6
INTRODUCTION
THERMOcompact boiler
The THERMOcompact is a fully
automatic, wall mounted, room sealed
system boiler for central heating and
domestic hot water (where a separate
indirect hot water storage cylinder is
also incorporated in the system).
The THERMOcompact range consists
of models with outputs of 15, 20,
24 kW and 28 kW.
All THERMOcompact boilers are
available in Natural Gas. The 20 and
28 kW versions are also available in
LPG.
General Notes
The boilers have been designed for
use with a sealed central heating
system, and come fully tested and
assembled with a built in circulating
pump, expansion vessel and diverter
valve (TURBOmax Plus only). The boi-
lers are not suitable for use on open
vented systems.
The boilers are easily sited on any
internal wall and can be installed
with either a horizontal or vertical
RSF (room sealed fan assisted) flue.
Two types of flue systems are
available, the standard concentric flue
system (100 mm outside diameter)
and a larger diameter concentric flue
system (125 mm outside diameter)
which allows longer flue lengths to be
achieved. Flue extensions and
additional bends and elbows are
available for both flue systems to
increase the siting flexibility.
There is also a 100 mm diameter
concentric flue accessory which
connects to the alternative rear flue
outlet on the boiler for direct through
the wall installations. The boilers are
not suitable for external installation.
If desired, an inhibitor may be used
in the system. Guidance on the use of
inhibitors is contained in these
instructions.
All boilers have a built in diagnostic
system which indicates the
This feature provides key information
to aid commissioning and fault
finding.
The data badge is fitted on the rear
of the control panel.
See text of General Requirements for
installation requirements or notes.
Vaillant Ltd. support the Benchmark
initiative.
Within the information pack, you will
find a Benchmark Log Book. It is
very important that this is completed
correctly at the time of installation,
commissioning and handover to the
user.
Note: This boiler must be installed
and serviced by a competent person
in accordance with the Gas Safety
(Installation and Use) Regulations
1998. In the UK „CORGI“
registered installers undertake the
work to a safe and satisfactory
standard.
General Information
TURBOmax Plus boiler
EC designation
TURBOmax Plus (824/828) and
THERMOcompact boilers
(615/620/624/628) carry the "CE"
Mark. This demonstrates that the boi-
lers fulfil the essential requirements of
the Gas Appliance Directive
(90/396/EEC) and the Gas
Appliance (Safety) Regulations 1992.
The "CE" Mark also demonstrates that
the boilers comply with the
requirements of the Electromagnetic
Compatibility Directive
(89/336/EEC), the Low Voltage
Directive (72/23/EEC), the Boiler
Efficiency Directive (92/42/EEC) and
the Boiler (Efficiency) Regulations
1993.
The TURBOmax Plus is a fully
automatic, wall mounted, room sealed
combination boiler for central heating
and domestic hot water. Domestic hot
water is supplied directly from the
boiler, without requiring a copper
cylinder, cold water tank, feed and
expansion tank and associated
pipework. Domestic hot water has
priority over central heating.
The TURBOmax Plus range consists of
models with outputs for domestic hot
water of 24 kW and 28 kW. Both
versions are available in natural gas
and LPG.
TURBOmax Plus combination boilers
incorporate a warmstart facility that
keeps the domestic hot water heat
exchanger hot, providing an
instantaneous delivery of domestic hot
water.
The temperature in the domestic hot
water heat exchanger is limited by
the boiler control system and it is not
necessary to install a scale reducer on
the cold mains to the boiler.
However, in exceptionally hard water
areas to prevent scale formation in
the property hot water system
pipework, a scale reducer may be
fitted.
The heating system can be filled using
the built-in filling loop contained
within the boiler.

7
BOILER SPECIFICATION
Technical data
THERMOcompact
615/2 E
(VU GB 152/2-5) Units
CH heat output range
(80/60 °C) 6.5 - 15 (22300 - 51200) kW (Btu/h)
DHW heat output --- kW
DHW flow rate ∆T = 35 °C rise --- l/min
DHW flow rate at factory set
temperature rise (∆T 42 °C) --- l/min
Mains water pressure required
for max. flow rate --- bar
Maximum inlet water pressure --- bar
Inlet gas working pressure
required (natural gas) 20 mbar
Gas burner pressure ignition rate 2.3 mbar
Gas rate max. (DHW) --- m3/h
Weight 38 kg
Primary water content 2.0 l
Maximum CH heat input (net 16.5 (56.100) kW (Btu/h)
Mains water pressure required
for min. flow rate --- bar
Minimum water flow rate --- l/min
Gas supply (G20) Gross CV (s.t.) 37.8 MJ/m3
Gas burner pressure max. rate 10.5 mbar
CH temperature flow range 35 - 82 °C
Minimum CH water flow
(for 20 °C rise) 650 l/h
Pump pressure available 0.25 (25) bar (KPa)
Expansion vessel
pre-charge pressure 0.75 bar
Maximum CH system pressure 3 bar
Electrical supply 230/50 V~/Hz
External fuse 3 A
Power input 150 W
Maximum DHW heat input (net) --- kW (Btu/h)
THERMOcompact
628/2 E
(VU GB 282/2-5)
TURBOmax Plus
828/2 E
(VUW GB 282/2-5)
10.4 - 28
(35500 - 95500)
28
11.5
9.5
0.5
37.8
10
10.8
20
1.8
3.3
43/45
2.0
31.1 (106200)
0.15
1.5
35 - 82
1203
0.25 (25)
0.75
3
230/50
3
150
31.1 (106200)
Case height 800 mm800
Case width 440 mm440
Case depth 338 mm338
THERMOcompact
624/2 E
(VU GB 242/2-5)
TURBOmax Plus
824/2 E
(VUW GB 242/2-5)
8.9 - 24
(30400 - 81900)
24
9.8
8.2
0.5
37.8
10
800
9.8
440
20
1.9
2.8
41/43
2.0
26.7 (91200)
0.15
1.5
35 - 82
1032
0.25 (25)
0.75
3
230/50
338
3
150
26.7 (91200)
THERMOcompact
620/2 E
(VU GB 202/2-5)
7.7 - 20
(26300 - 68300)
---
---
---
---
37.8
---
800
9.6
440
20
1.8
---
39
2.0
22.0 (74.800)
---
---
35 - 82
860
0.25 (25)
0.75
3
230/50
338
3
150
---

8
BOILER SPECIFICATION
Key:
1Heating system return
(22 mm tail)
2Cold water connection with shut
off valve (15 mm tail)
3Gas connection (15 mm tail)
4Hot water connection
(15 mm tail)
5Heating system flow
(22 mm tail)
6Flue outlet (100 mm flue with
turret)
7Hanging bracket
8Rear flue outlet
Boiler connections
(TURBOmax Plus)
7
543 21
148
6
8
310
592
145
6
5
100100
35 35
432
130 180
1
Fig. B.1: Connection diameters TURBOmax Plus
Euro B/S 090/2
Key:
1Heating system return
(22 mm tail)
2Gas connection (15 mm tail)
3Heating system flow
(22 mm tail)
4Flue outlet (100 mm flue with
turret)
5Hanging bracket
6Rear flue outlet
Boiler connections
(THERMOcompact)
5
32 1
148
4
6
310
592
145
4
3
100100
2
130 180
1
Fig. B.2: Connection diameters THERMOcompact
Euro B/S_VC_009/2
TURBOmax Plus THERMOcompact

BOILER SPECIFICATION
9
Functional Diagram
(TURBOmax Plus)
u
C
C
i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
1Air duct
2Fan
3Main heat exchanger
4Temperature sensor (NTC I)
5Flame sensing electrodes
6Modulating burner
7Fully modulating automatic gas
value
8Maximum hot water temperature
control
9Maximum radiator temperature
control
10 Diverter valve
11 DHW heat exchanger
12 Automatic bypass valve
13 CH flow service valve
14 Hot water outlet
15 Gas service valve
16 Cold water service valve
17 CH return service valve
18 Pressure relief valve
19 Aqua sensor (DHW flow switch)
20 Temperature sensor (NTC III)
21 Main on/off control
22 Pressure gauge
23 Display
24 Expansion vessel
25 Expansion vessel charging valve
26 Circulating pump
27 Automatic air vent
28 Ignition electrode
29 Temperature sensor (NTC II)
30 Air pressure switch
31 Flue gas duct
Fig. B.3: Functional Diagram TURBOmax Plus
Euro B/S 196/0
TURBOmax Plus

10
BOILER SPECIFICATION
Functional Diagram
(THERMOcompact)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
1Air duct
2Fan
3Main heat exchanger
4Temperature sensor (NTC I)
5Flame sensing electrodes
6Modulating burner
7Fully modulating automatic gas
value
8This control has no function on
this boiler
9Maximum radiator temperature
control
10 Automatic bypass valve
11 CH flow service valve
12 Gas service valve
13 CH return service valve
14 Pressure relief valve
15 Main on/off control
16 Pressure gauge
17 Display
18 Expansion vessel
19 Expansion vessel charging valve
20 Circulating pump
21 Automatic air vent
22 Ignition electrode
23 Temperature sensor (NTC II)
24 Air pressure switch
25 Flue gas duct
Fig. B.4: Functional Diagram THERMOcompact
Euro B/S_VC_079/0
THERMOcompact

11
GENERAL REQUIREMENTS
Ensure that ALL regulations
are observed.
Fig. R.1
Euro B/S 006/0_GB
Related Documents
The installation of the boiler must be
in accordance with the relevant
requirements of Gas Safety
(Installation and Use) Regulations
1998, Health and Safety Document
No. 635 (The Electricity at Work
Regulations 1989), BS7671
(IEE Wiring Regulations) and the
Water Supply (Water Fittings)
Regulations. It should also be in
accordance with the relevant
requirements of the Local Authority,
Building Regulations, Building
Standards (Scotland) Regulations and
the relevant recommendations of the
following British Standards:
BS 5440: Flues and ventilation of
gas fired boilers not exceeding
70 kW net:
- Part 1: Flues
- Part 2: Ventilation
BS 5449: Specification for forced
circulation hot water for domestic
premises.
BS 5546: Specification for gas hot
water supplies for domestic premises.
BS 6700: Services supplying water
for domestic use within buildings and
their curtilages.
BS 6798: Specification for
installation of gas fired boilers not
exceeding 60 kW input.
BS 6891: Specification for
installation of low pressure gas
pipework up to 28 mm (R1) in
domestic premises (2nd family gas).
BS 7593: Treatment of water in
domestic hot water central heating
systems.
Institute of Gas Engineers Publication
IGE/UP/7/1998: Guide for
Installation in Timber Framed
Housing.
Important: The appliance must be
installed and serviced by a
competent person as stated in the
Gas Safety (Installation and Use)
Regulations 1998.
Preliminary remarks
This appliance should only be
installed in conjunction with a Vaillant
flue system.
Install the flue system as detailed in
the separate flue installation
instructions supplied with this boiler.

12
GENERAL REQUIREMENTS
Gas Supply
The gas supplier should ensure the
availability of an adequate supply of
gas.
A gas meter may only be connected
to the service pipe by the supplier of
gas or their contractor.
An existing meter should be checked
to ensure that it is capable of passing
the rate of gas supply required.
Installation pipes should be fitted in
accordance with BS 6891.
Pipework from the meter to the boiler
must be of an adequate size. Do not
use pipes of a smaller size than the
boiler gas connection (15 mm).
The complete installation must be
tested for soundness and purged as
described in BS 6891.
Boiler location
The location chosen for the boiler
must permit the provision of a
satisfactory flue termination. The
location must also provide adequate
space for servicing and air circulation
around the boiler. The boiler may be
installed in any room, although
particular attention is drawn to the
requirements of BS7671 (IEE
Regulations) and, in Scotland, the
electrical provisions of the Building
Standards (Scotland) Regulations, in
respect of the installation of a boiler
in a room containing a bath or
shower.
Where the installation of the boiler
will be in an unusual location, special
procedures may be necessary and BS
5546 and BS 6798 give detailed
guidance on this aspect. The boiler
must be mounted on a flat, vertical
wall, which must be sufficiently robust
to take the weight of the boiler. The
boiler may be installed on a
combustible wall, subject to the
requirements of the Local Authorities
and Building Regulations.
A compartment used to enclose the
boiler must be designed and
constructed specifically for this
purpose. (An existing cupboard or
compartment may be used provided
that it is modified for the purpose).
Details of essential features of
cupboard/compartment design
including airing cupboard
installations are given in BS 6798.
If the boiler is to be fitted in a timber
framed building, it should be fitted in
accordance with Institute of Gas
Engineers Publication
IGE/UP/7/1998 „Guide for Gas
Installation in Timber Framed
Housing“.
Note: Where a room sealed boiler
is installed in a room containing a
bath or shower, any electrical switch
or boiler control utilising mains
electricity should be so situated that
it cannot be touched by a person
using the bath or shower.

13
GENERAL REQUIREMENTS
Top outlet flue system
(100 mm outside diameter)
The top outlet horizontal flue system
(Art. No. 303 807) is suitable for
installations up to 720 mm measured
from the centre of the boiler flue outlet
to the outside face of the wall.
Flue extensions are available to
extend this length up to 5.3 m for
15/20 kW; 4.5 m for 24 kW and
3.2 m for 28 kW.
Both 90° bends and 45° elbows are
also available to increase siting
flexibility.
A vertical flue system is also available
(Art. No. 303 800).
Refer to flue system installation
instructions for full details.
Rear outlet flue system
(100 mm outside diameter)
The rear outlet horizontal flue system
(Art. No. 303 817) is suitable for
installations up to 600 mm wall
thickness.
Extended top outlet flue system
(125 mm outside diameter)
A top outlet horizontal flue system of
125 mm outside diameter is also
available (Art. No. 303 609) and
can be used to achieve flue lengths of
up to 12.9 m for 15/20/24 kW;
10 m for 28 kW.
Both 45° and 90° bends and elbows
are also available to increase siting
flexibility.
A vertical 125 mm concentric flue
system is also available
(Art. No. 303 600).
Refer to flue system installation
instructions for full details.
Flue system
Note: The boilers are delivered
ready for installation utilising a top
outlet flue assembly. For installation
with a rear outlet flue assembly refer
to the boiler flue outlet adaptation
instructions supplied with the rear
flue accessory.
48
800
48
4
Fig. R.2: Art.-No. 303 807
LAS Euro B/S 037/0
48 1285
603
Fig. R.3: Art.-No. 303 800
LAS Euro B/S 036/0
800
Fig. R.4: Art.-No. 303 817
LAS Euro B/S 073/0
Fig. R.5: Art.-No. 303 609
GU LAZ 082/0
70
1103
70
15

14
GENERAL REQUIREMENTS
A
BCD
A
G
H, I
FJ
BFM
L
L
KK
G
G
FF
E
A
A
Flue termination
The following details refer to both
flue systems.
a. The terminal must be positioned
such that the products of
combustion can disperse freely at
all times.
b. In certain weather conditions a
plume of water vapour may be
visible from the flue terminal.
Positions where this could be a
nuisance should be avoided.
c. If the terminal is fitted less than
2 m above a balcony, above
ground or above a flat roof to
which people have access then a
suitable terminal guard;
280 mm x 280 mm x 270 mm
deep, must be provided and fitted
(made by Tower Flue Components,
Tonbridge, TN9 1TB).
Fig. R.6: Flue termination
Terminal position for fan-assisted flue (minimum distance) mm
A1) 300
Note: Vertical flues must not
terminate within 600 mm of an
openable window, air vent or any
other ventilation opening.
BBelow gutters, soil pipes or drain pipes 25
CBelow eaves 25
DBelow balconies (below car port roof) 25
EFrom vertical drain pipes and soil pipes 25
FFrom internal or external corners 25
GAbove ground or balcony level 300
IFrom a terminal facing a terminal 1200
KVertically from a terminal on the same wall 1500
LHorizontally from a terminal on the same wall 300
MDistance from adjacent wall for vertical Flue 500
GW 595/2
Where a terminal is fitted less than
1 m below a plastic gutter or less
than 0.5 m below painted eaves or
any other painted surface then a sui-
table shield at least 1 m long should
be fitted to protect the surface.
1) In addition, the terminal should not be nearer
than 150 mm to an opening in the building fabric
formed for the purpose of accommodating a built-in
element such as a window.
* BS 5440-1 It is recommended that a fanned flue
terminal should be positioned as follows: a) at least
2m from an opening in a building directly opposite,
and b) so that the products of combustion are not
directly directed to discharge across a boundary.
JFrom an opening in a car port (e.g. door, window)
into a dweling 1200
HFrom a surface or boundary facing a terminal 600*
Directly below an openable, above an opening or
horizontal to an opening i.e. air brick, opening
window or other , etc

15
GENERAL REQUIREMENTS
Cupboard or compartment
ventilation
The boilers are very high efficiency
appliances. As a consequence the
heat loss from the
appliance casing during operation is
very low. For cupboard or
compartment installations it is
therefore not necessary to provide
any high or low level permanent air
vents for cooling purposes.
Air supply
Detailed recommendations for air
supply are given in BS 5440: Part 2.
It is not necessary to have an air vent
in the room or internal space in which
the boiler is installed.
Electrical supply
A 230 V, ~ 50 Hz single phase
electricity supply fused to 3 Amp.
must be provided in accordance with
the latest edition of BS7671 (IEE
Wiring Regulations) and any other
local regulations that may apply.
The method of connection to the
mains electricity supply must provide
a means of completely isolating the
boiler and its ancillary controls.
Isolation is preferably by the use of a
fused three pin plug and unswitched
shuttered socket outlet, both
complying with the requirements of
BS 1363. Alternatively, a 3 Amp.
fused doublepole switch with a 3 mm
contact separation on both poles may
be used.
This appliance must be earthed.

16
GENERAL REQUIREMENTS
Guide to system
requirements
Water circulation system
Detailed recommendations for the
water circulation system are given in
BS 6798 and BS 5449: Part 1 (for
small bore and micro bore central
heating systems).
Pipework not forming part of the
useful heating surface should be
insulated to help prevent heat loss
and possible freezing, particularly
where pipes are run through roof
spaces and ventilated underfloor
spaces.
Draining taps must be located in
accessible positions which permit the
draining of the whole system
including the boiler and the hot water
system. Draining taps should be at
least 1/2 in. BSP nominal size and
be in accordance with BS 2879.
The boiler is suitable for use with
minibore or microbore systems.
Copper tubing to BS 2871: Part 1
should be used for water carrying
pipework. All capillary joints in all
DHW pipework must be made with
lead free solder.
Particularly where a new boiler is to
be fitted to an existing system, it is
good practice that the system is
thoroughly cleansed. This cleansing
should take place prior to the fitting
of the new boiler and be in
accordance with BS 7593.
For advice on the application of
system cleansers contact either
Sentinel, Betz Dearborn Ltd. Widnes,
Cheshire, WA8 8UD.
Tel: [phone]
or:
Fernox
Alpha-Fry Technologies
Tandem House
Marlow Way, Beddington Farm Road
Croydon CRO 4xS
Tel. [phone]
Fernox technical
help line 01799 550811
Filling and make up
The system can be filled using the
built in filling loop (TURBOmax Plus
only) or via a separate filling point
fitted at a convinient position on the
heating circuit (THERMOcompact).
The connection must be removed
when filling is completed. Where
local Water Authority regulation does
not allow temporary connection, a
sealed system filler pump with break
tank must be used. The heating
system will not be filled automatically
from the domestic hot water side.
(Alternative methods of filling sealed
systems are given in BS 5449).
Pressure relief valve
A pressure relief valve is provided
with the boiler. This safety device is
required on all sealed C.H. systems
and is preset at 3 bar and provided
with a 15 mm compression connec-
tion for a discharge pipe, which must
be of no less than 15 mm in dia-
meter. The Pressure Relief Valve must
not be used for draining purposes.
Pressure gauge
This is factory fitted to the boiler and
indicates the primary circuit pressure
to facilitate filling and testing.

17
GENERAL REQUIREMENTS
Expansion vessel
The 15 and 20 kW THERMOcompact
boilers as well as the 24 kW
TURBOmax Plus boiler incorporate a
6 litre expansion vessel which is suit-
able for a sealed heating system with
a maximum water content of 60 litres.
A 10 litre expansion vessel kit is
available as an optional accessory
for for the TURBOmax Plus 24 kW
boiler and the 15 and 20 kW
THERMOcompact boilers.
The 28 kW TURBOmax Plus and 24,
28 kW THERMOcompact boilers
incorporate a 10 litre expansion
vessel which is suitable for a sealed
heating system with a maximum water
content of 100 litres.
If the nominal capacity of the built in
expansion vessel is not sufficient for
the heating system (for instance in
case of modernization of old open
systems) an additional expansion
vessel can be installed external to the
boiler. It should be fitted in the return
pipe as close as possible to the boiler
in accordance with BS 5449: Part 1.
Guidance on the sizing of an
additional expansion vessel is given
in Table R.2.
Table R.2: Sizing of additional expansion vessel
Vessel Volume [L]
Initial system pressure (bar) 1.0 1.5
Pressure relief valve setting (bar) 3.0
Total water content of system
litres
25
50
100
125
150
175
200
225
250
275
300
325
350
375
400
425
450
475
500
2.7
5.4
10.9
13.6
16.3
19.1
21.8
24.5
27.2
30.0
32.7
35.7
38.1
40.9
43.6
46.3
49.0
51.8
54.5
3.9
7.8
15.6
19.5
23.4
27.3
31.2
35.1
39.0
42.9
46.8
50.7
54.6
58.5
62.4
66.3
70.2
74.1
78.0
For system volumes other than those given above,
multiply the system volume by the factor across 0.109 0.156

18
GENERAL REQUIREMENTS
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
50
100
150
200
250
300
350
400
450
500
550
600
650
700
Volume flow [l/min]
Lift [mbar]
Pump switch in position II (pre-delivery setting)
Pump switch in position I
Fig. R.7: Pump specifications
Euro B/S_VC_010/0GB
Pump specifications Circulating pump
The circulating pump is included in
the boiler. The pump head available
for the heating system is shown in
fig. R.7.
System by-pass
An automatic system by-pass is
included within the boiler. The boiler
is suitable for use in systems with
thermostatic radiator valves and no
additional by-pass is required.
Venting
The boiler is fitted with an automatic
air vent. Additional provision should
be made to enable the heating system
to be vented during filling and
commissioning either by automatic air
vents or manually.
DHW expansion vessel accessory
(TURBOmax Plus only)
A DHW expansion vessel kit
(Art. No. 306 237) is available as an
optional extra from Vaillant Ltd. This
expansion vessel kit should be fitted
to the boiler whenever, either a stop
valve of the loose jumper type or a
non return valve are present in the
cold water mains supply to the boiler.

BOILER INSTALLATION SEQUENCE
19
General
Preparation of boiler location
Clearances required
Mount the boiler on a flat and vertical
area of wall of sufficient area for the
boiler plus the required clearances for
installation and servicing.
The clearances are as detailed below
and are shown on the installation
template supplied with the boiler:
- 150 mm below the boiler
- 5 mm on either side of the boiler
- 210 mm on top of the boiler
- 500 mm in front of the boiler*
* Clearance is only required to
enable easier access to the boiler
for servicing and may be provided
by an openable door, etc.
Selecting position of boiler
Refer to „Boiler location“ for
information regarding siting the
appliance. In general the boiler must
be positioned such that:
●There is adequate space around
the boiler for service and
maintenance.
●The boiler can be correctly flued,
i.e. the flue terminal position is
sited in accordance with the flue
termination section (see page 14)
and the air/flue duct can be
installed in accordance with the
flue installation instructions
supplied.
●All necessary pipework can be
connected, including the pressure
relief valve.
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
yyyyyyyyyy
yyyyyyyyyy
yyyyyyyyyy
yyyyyyyyyy
yyyyyyyyyy
yyyyyyyyyy
yyyyyyyyyy
yyyyyyyyyy
yyyyyyyyyy
yyyyyyyyyy
,y
,y
,
,
y
y
,y
,,yy
Fig. I.2: Free space required for installation
Euro B/S 088/0GB
Note: If the boiler is to be fitted in a
timber framed building, it should be
fitted in accordance with Institute of
Gas Engineers Publication
IGE/UP/7/1998 „Guide for Gas
Installations in Timber Framed
Dwellings“.
440
800
338
, , , , , y y y y y
,,,,,,yyyyyy
,,,yyy
,,yy{|
,,yy{|
,yz|
,yz|
Fig. I.1: Dimensions of boiler
Euro B/S 089/0
Note: Should it be necessary to run
system pipework to above the boiler
within the width of the casing, use
the optional top connection
accessory (Art.No. 306 251).

20
BOILER INSTALLATION SEQUENCE
5
5
210
124163 03240/242/280/282/824/828 Pro/Plus
60/100
07/2000
Fig. I.3: Using Boiler template
124163_03
Using boiler template
Fix the paper template to the wall
ensuring that the correct flue exit
point has been identified, ensure that
the template is vertical.
The template shows
- The position of the fixing holes for
the boiler mounting bracket (1).
- The position of the connections.
- The position of the flue exit hole.
- Upper hole (2) indicates top outlet
flue with flue turret facing
rearward.
- Lower hole (3) indicates rear out-
let flue exiting directly through
wall.
Mark the position of the hanging
bracket fixing holes (1).
Drill 2 holes Ø 8 mm for the hanging
bracket.
Identify correct flue exit.
Mark the centre of the selected air/
flue duct and its circumference, e.g.
by drilling through the template. For
installation of a rear exit outlet please
refer to the installation instructions of
the rear exit outlet kit
(Art. No. 303 817).
Other flue options
Flue instructions for other flue systems
such as vertical RSF flues, flues run to
the side of the boiler and the use of
additional bends etc. are detailed in
the flue installation instructions
provided with the boiler.
Remove the template from the wall
and plug the drilled holes using the
wallplugs supplied.
Note: Use alternative fixing holes
where necessary.
1
3
2
240/242/280/282/615/620/624/628/824/828 Pro/Plus TURBOmax only