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