Vaillant turboMAX pro 24/2 E User guide

For the installer
24/2 E
28/2 E
GB
Instructions for Installation and Servicing
turboMAX pro
Wall hung room sealed fan assisted
combination and system boilers
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Table of Contents
Instructions for Installation and Servicing turboMAX pro R32
1 List of Contents . . . . . . . . . . . . . . . . . . . . . 3
1 1 Contents included with boiler (turboMAX pro)3
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 4
2 1 General Information 4
2 2 EC designation 4
3 Boiler Specification . . . . . . . . . . . . . . . . . . . 5
3 1 Technical data 5
3 2 Boiler connections 6
3 3 Functional diagram 6
4 General Requirements . . . . . . . . . . . . . . . . . 7
4 1 Related documents 7
4 2 Boiler location 7
4 3 Gas supply 7
4 4 Flue system 7
4 4 1 Top outlet flue system 8
4 4 2 Rear outlet flue system 8
4 4 3 Extended top outlet flue system 8
4 4 4 Flue termination 9
4 5 Air supply 9
4 6 Cupboard or compartment ventilation 9
4 7 Electrical supply 9
4 8 Guide to system requirements 10
4 8 1 Water circulation system 10
4 8 2 Filling and make up 10
4 8 3 Pressure relief valve 10
4 8 4 Pressure gauge 10
4 8 5 Expansion vessel 10
4 8 6 Circulating pump 11
4 8 7 System by-pass 11
4 8 8 Venting 11
5 Boiler Installation Sequence . . . . . . . . . . . . 12
5 1 General 12
5 2 Using boiler template 13
5 3 Fitting the boiler hanging bracket 13
5 4 Install the flue system 14
5 5 Fitting the boiler 14
5 6 Removing boiler casing 14
5 7 Gas supply 14
5 8 Cold water mains inlet and hot water outlet 15
5 9 Central heating flow and return pipework 15
5 10 Connect the flue system to the boiler 16
5 11 Electrical installation 16
5 12 Connection to the main supply 16
5 13 Electronic board layout 17
5 14 Controls 18
Commissioning Part I . . . . . . . . . . . . . . . . . 20
6 1 Preliminary electrical checks 20
6 2 Gas supply 20
6 3 Cold water supply 20
6 4 Filling the heating system 20
6 5 Initial system flush („cold“) 20
7 Gas supply adjustments (Commissioning Part II) 21
71 Gas inlet working pressure 21
72 Main burner pressure 21
7 3 Adjusting the central heating output
(range rating) 22
74 Burner pressure and gas rate 23
75 Fit combustion chamber cover 24
76 Fit boiler casing 24
8 Functional checks (Commissioning Part III) . 25
8 1 Functional checks 25
8 2 Functional check of operation 25
8 3 Adjusting pump speed 26
8 4 Handing over to the user 26
9 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9 1 Initial inspection 27
9 2 Cleaning the burner and primary heat
exchanger 28
10 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . 29
10 1 Introduction 29
10 2 Logical fault finding procedure 29
11 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11 1 Functional flow diagram . . . . . . . . . . . . . . . 37
11 2 Wiring diagram 38
Benchmark gas boiler commissioning
checklist..................................... 39
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List of contents
Instructions for Installation and Servicing turboMAX pro R3 3
1 List of contents
1.1 Contents included with boiler
Ensure that all contents are included before commen-
cing installation
Note!
DO NOT remove the boiler from the polystrene
base at this stage.
Fig. 1.1: Items supplied with unit (turboMAX pro)
8
7
6
2
5
4
I
0
3
9
0
Item Quantity Description
1 1 Boiler
2 1 Flue restriction ring
3 1 Cold water inlet valve
4 3 Flow and return service value, gas service
valve
5 5 Copper tails for water outlet connection
6 1 Template
7 1 Guarantee Card
8 1 Installation and connection accessories and
PRV packages incl DHW outlet union nut
9 3 Installation and Servicing, Users and Flue
Installation Instructions
10 1 Hanging bracket
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2 Introduction
2.1 General Information
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 under-
take the work to a safe and satisfactory
standard.
The turboMAX pro 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 boiler has been designed for
use with a sealed central heating system, and comes
fully tested and assembled with a built in circulating
pump, expansion vessel and diverter valve
The turboMAX pro has an output for domestic hot water
of 24 or 28 kW The boiler is 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 system are available, rear flue outlet, top outlet
(with turret) concentric flue system (100 mm outside
diameter) and an extended concentric flue system
(125 mm outside diameter) Flue extensions and additio-
nal bends and elbows are available for both flue systems
to increase the siting flexibility The boiler is not suitable
for external installation This boiler is available in Natural
Gas An optional LPG conversion kit is available If desi-
red, an inhibitor may be used in the system Guidance on
the use of inhibitors is contained in these instructions
The boiler contains a domestic hot water heat exchan-
ger The temperature in the 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 pipe-
work, a scale reducer may be fitted
turboMAX pro combination boilers have a built in dia-
gnostic system which indicates the operational status of
the boiler This feature provides key information to aid
commissioning and fault finding
2 Introduction
Instructions for Installation and Servicing turboMAX pro R34
The data badge is fitted on the rear of the control panel
See text of General Requirements for installation requi-
rements or notes
Vaillant ltd support the Benchmark initiative
In this installation manual you will find the Benchmark
gas boiler commissioning checklist It is very important
that this is completed correctly at the time of installati-
on and commissioning
Important!
When tightening or slackening screwed connec-
tions always use suitable open-ended spanners
(not pipe wrench, or extensions, etc.).
Incorrect use and/or unsuitable tools can lead to
damage being caused (e.g. gas or water leakage)!
2.2 EC designation
turboMAX pro (24/28) a carry the "CE" Mark This
demonstrates that the boilers fulfil the essential require-
ments of the Gas Appliance Directive(90/396/EEC) and
the Gas Appliance (Safety) Regulations 1992
The "CE" Mark also demonstrates that the boilers comp-
ly 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
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Boiler Specification 3
Instructions for Installation and Servicing turboMAX pro R3 5
turboMAX pro 24/2 E turboMAX pro 28/2 E Units
(VUW GB 242/2-3) (VUW GB 282/2-3)
Maximum CH heat input (net) 297 (101 000) 31 1 (106 200) kW (Btu/h)
CH heat output range (80/60 °C) 8 9 - 24 10 4 - 28
(30 400 - 81 900) (35 500 - 95 500) kW (Btu/h)
Maximum DHW heat input (net) 26 7 (91 200) 31 1 (106 200) kW (Btu/h)
SEDBUK Band D D
SAP Seasonal Efficiency 79 6 79 7 %
DHW heat output 24 28 kW
DHW flow rate ∆T = 35 °C rise 9 8 11 5 l/min
DHW flow rate at factory set
temperature rise (∆T 42 °C) 8 2 9 5 l/min
Mains water pressure required
for max flow rate 0 5 0 5 bar
Minimum water flow rate 1 5 1 5 l/min
Mains water pressure required
for min flow rate 0 15 0 15 bar
Maximum inlet water pressure 10 10 bar
Inlet gas working pressure
required (natural gas) 20 20 mbar
Gas supply (G20) Gross CV (s t ) 378 378 MJ/m3
Gas burner pressure max rate (natural gas) G 20 9 8 10 8 mbar
(LPG 3+) G 30/31 28 - 30/37 28 - 30/37 mbar
Gas burner pressure ignition rate G 20 1 9 1 8 mbar
G 30/31 3 9/5 4 3 8/5 3 mbar
Gas rate max (DHW) - 2 8 3 3 m3/h
CH temperature flow range 35 - 82 35 - 82 °C
Minimum CH water flow
(for 20 °C rise) 1032 1203 l/h
Pump pressure available 0 25 (25) 0 25 (25) bar (KPa)
Expansion vessel
pre-charge pressure 0 75 0 75 bar
Maximum CH system pressure 3 3 bar
Weight 42 45 kg
Primary water content 2 0 2 0 l
Electrical supply 230/50 230/50 V~/Hz
External fuse 3 3 A
Power input 150 150 W
Case height 800 800 mm
Case width 440 440 mm
Case depth 338 338 mm
3 Boiler Specification
3.1 Technical Data
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3 Boiler Specification
Instructions for Installation and Servicing turboMAX pro R36
3.3 Functional Diagram
Fig. 3.2: Functional Diagram
1 Air duct
2Fan
3 Main heat exchanger
4 Temperature sensor (NTC I)
5 Flame sensing electrodes
6 Modulating burner
7 Fully modulating automatic gas value
8 Maximum hot water temperature control
9 Maximum 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)
21 Main on/off control
22 Pressure gauge
23 Indicator lights
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
C
C
1
2
3
4
5
7
8
9
10
11
12
13
14
15
17
1
18
19
21
22
23
24
25
2
27
28
29
30
31
3.2 Boiler connections
Fig. 3.1: Connection diameters turboMAX pro
Key:
1 Heating system return (22 mm tail)
2 Cold water connection with shut off valve
(15 mm tail)
3 Gas connection (15 mm tail)
4 Hot water connection (15 mm tail)
5 Heating system flow (22 mm tail)
6 Flue outlet (100 mm flue with turret)
7 Hanging bracket
8 Rear flue outlet
0
7
6
264638
45
6
5
00
00
35 35
432
30 80
48
8
543 2
902
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General Requirements 4
Instructions for Installation and Servicing turboMAX pro R3 7
4 General Requirements
4.1 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
(WaterFittings) Regulations It should also be in accor-
dance with the relevant requirements of the Local
Authority, Building Regulations, Building Standards
(Scotland) Regulations and the relevant recommendati-
ons of the following British Standard; Including current
amendments to Approved Documents Part L and J :
BBSS 55444400::Flues and ventilation of gas fired boilers not
exceeding 70 kW net:
- Part 1: Flues
- Part 2: Ventilation
BBSS 55444499::Specification for forced circulation hot water
for domestic premises
BBSS 555544::Specification for gas hot water supplies for
domestic premises
BBSS 770000::Services supplying water for domestic use
within buildings and their curtilages
BBSS 779988::Specification for installation of gas fired
boilers not exceeding 70 kW input net
BBSS 889911::Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd family gas)
BBSS 77559933:: 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 Benchmark Code of Practice
Building Regulations Approved Documents Part L 2002
Part J 2002
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
4.2 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
Note!
Where a room sealed boiler is installed in a
room containing a bath or shower, any electrical
switch or boiler control utilising mains electrici-
ty should be so situated that it cannot be tou-
ched by a person using the 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 desi-
gned and constructed specifically for this purpose (An
existing cupboard or compartment may be used provi-
ded that it is modified for the purpose) Details of essen-
tial 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“
4.3 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
4.4 Flue system
Note!
The boilers are delivered ready for installation
utilising a top outlet flue assembly. For installa-
tion with a rear outlet flue assembly refer to
the boiler flue outlet adaptation instructions
supplied with the rear flue accessory.
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4 General Requirements
4.4.2 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
Fig. 4.3: Art.-No. 303 817
4.4.3 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 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 availa-
ble (Art No 303 600)
Refer to flue system installation instructions for full
details
Fig. 4.4: Art.-No. 303 09
70
03
70
5
800
Instructions for Installation and Servicing turboMAX pro R38
4.4.1 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 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
Fig. 4.1: Art.-No. 303 807
A vertical flue system is also available
(Art No 303 800)
Refer to flue system installation instructions for full
details
Fig. 4.2: Art.-No. 303 800
48 285
603
48
800
48
4
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General Requirements 4
Instructions for Installation and Servicing turboMAX pro R3 9
4.4.4 Flue termination
The following details refer to both flue systems
a The terminal must be positioned such that the pro-
ducts 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 bal-
cony, 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 provi-
ded and fitted (made by Tower Flue Components,
Tonbridge, TN9 1TB)
Note!
Vertical flues must not terminate within
00 mm of an openable window, air vent or any
other ventilation opening.
The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building
Fig. 4.5: Flue termination
A
BCD
A
G
H, I
FJ
BFM
L
L
K
K
G
G
FF
E
A
A
1) In addition, the terminal should not be nearer than 150mm 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 buil-
ding directly opposite, and b) so that the products of combustion
are not directly directed to discharge across a boundary
4.5 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
4. Cupboard or compartment ventilation
The boilers are very high efficiency appliances As a con-
sequence the heat loss from the appliance casing during
operation is very low For cupboard or compartment in-
stallations it is therefore not necessary to provide any high
or low level permanent air vents for cooling purposes
4.7 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 supp-
ly must provide a means of completely isolating the boi-
ler and its ancillary controls Isolation is preferably by
the use of a fused three pin plug and unswitched shutte-
red 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
Terminal position for fan-assisted flue
(minimum distance) mm
A1) Directly below an openable, above an opening
or horizontal to an opening i e air brick, opening
window or other, etc 300
B Below gutters, soil pipes or drain pipes 25
C Below eaves 25
D Below balconies (below car port roof) 25
E From vertical drain pipes and soil pipes 25
F From internal or external corners 25
G Above ground or balcony level 300
H From a surface or boundary facing a terminal 600*
H From a terminal facing a terminal 1200
J From an opening in a car port (e g door, window)
into a dweling 1200
K Vertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
M Distance from adjacent wall for vertical Flue 500
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4 General Requirements
Instructions for Installation and Servicing turboMAX pro R310
Important!
This appliance must be earthed.
4.8 Guide to system requirements
4.8.1 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
Important:
To prevent the formation of deposits and pre-
vent serious damage to the appliance and
system , cleansers must be used carefully and
must be completely removed by thoroughly
flushing the system. Cleansers should only be
left in systems for a maximum of 24 hours.
This cleansing must 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, GE Betz Widnes, Cheshire,
WA8 8UD Tel: [phone]
4.8.2 Filling and make up
The system can be filled using the built in filling loop
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)
4.8.3 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 connection for a discharge pipe, which
must be of no less than 15 mm in diameter The
Pressure Relief Valve must not be used for draining
purposes
4.8.4 Pressure gauge
This is factory fitted to the boiler and indicates the
primary circuit pressure to facilitate filling and
testing.
4.8.5 Expansion vessel
The 24 kW boiler incorporate a 6 litre expansion vessel
which is suitable 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
The 28 kW 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 moder-
nization 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
Vessel Volume [L]
Initial system pressure (bar) 1.0 1.5
Pressure relief valve setting (bar) 3.0
Total water content of system ltres
25 2 7 3 9
50 5 4 78
100 10 9 15 6
125 13 6 19 5
150 16 3 23 4
175 19 1 27 3
200 21 8 31 2
225 24 5 35 1
250 27 2 39 0
275 30 0 42 9
300 32 7 46 8
325 35 7 50 7
350 38 1 54 6
375 40 9 58 5
400 43 6 62 4
425 46 3 62 4
450 49 0 58 5
475 51 8 74 1
500 54 5 78 0
For system volumes other than those given
above, multiply the system volume by the
factor across 0 109 0 156
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General Requirements 4
Instructions for Installation and Servicing turboMAX pro R3 11
4.8. Circulating pump
The circulating pump is included in the boiler The pump
head available for the heating system is shown in
fig 4 6
Fig. 4. : Pump specifications
4.8.7 System by-pass
An automatic system by-pass is included within the boi-
ler The boiler is suitable for use in systems with ther-
mostatic radiator valves and no additional by-pass is
required
4.8.8 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
0 100 200 300 400 500 00 700 800 900 1000 1100 1200 1300 1400
50
100
150
200
250
300
350
400
450
500
550
00
50
700
Volume flow [l/h]
Lift [mbar]
setting III
setting II
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Fig. 5.2: Free space required for installation
Selecting position of boiler
Refer to „Boiler location“ for information regarding sit-
ing the appliance In general the boiler must be positio-
ned 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 terminati-
on section and the air/flue duct can be installed in
accordance with the flue installation instructions sup-
plied
• All necessary pipework can be connected, including
the pressure relief valve
Note!
Should it be necessary to run system pipework
to above the boiler within the width of the
casing, use the optional top connection acces-
sory (Art.No. 30 251).
50
5
200
500
5
I
0
020
60
9030
°C
bar
4
3
2
0
5 Boiler Installation Sequence
Instructions for Installation and Servicing turboMAX pro R312
5 Boiler Installation Sequence
5.1 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 clearan-
ces 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
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“.
Fig. 5.1: Dimensions of boiler
440
800
338
I
0
020
60
9030
°C
bar
4
3
2
0
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Boiler Installation Sequence 5
Instructions for Installation and Servicing turboMAX pro R3 13
5.2 Using boiler template
Fix the paper template to the wall ensuring that the cor-
rect flue exit point has been identified, ensure that the
template is vertical
The template shows
- The position of the fixing holes for the boiler moun-
ting bracket (1)
- The position of the connections
- The position of the flue exit hole
- Upper hole (2) indicates top outlet flue with flue tur-
ret facing rearward
- Lower hole (3) indicates rear outlet 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
Fig. 5.3: Using Boiler template
55
2 0
24 63 2200/202/240/242/280/282/824/828 Pro/Plus
60/ 00
07/2002
2
3
1
turboMAX only
Note!
Use alternative fixing holes where necessary.
Identify correct flue exit
Mark the centre of the selected air/flue duct and its cir-
cumference, 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 installati-
on instructions provided with the boiler
Remove the template from the wall and plug the drilled
holes using the wallplugs supplied
5.3 Fitting the boiler hanging bracket
Fix the hanging bracket (2) to the wall using the screws
supplied (it may be necessary to use additional or
alternative fixings to ensure adequate support)
Fig. 5.4: Free space required for installation
Note!
If the boiler is to be fitted in a timber framed
building ensure that the bracket is secured to a
substantial part of the timber frame capable of
taking the weight of the boiler.
3
402
7 74,5
2,5
1
1
2
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5.7 Gas supply
• Connect the 15 mm compression gas service cock (1)
supplied with the appliance (2) and tighten
• Connect a gas supply pipe of not less than 15 mm
diameter to the gas service cock
• Tighten all connections
(Ensure the gas supply pipework is adequately sized
such that a 20 mbar gas pressure is available at the
boiler inlet at full flow rate)
Fig. 5. : Fitting the gas connection
I
0
1
2
5 Boiler Installation Sequence
Instructions for Installation and Servicing turboMAX pro R314
5.4 Install the flue system
Install the flue system (refer to separate air/flue duct
installation instructions)
5.5 Fitting the boiler
• Lift the boiler (3) up to the wall so that it is slightly
above the hanging bracket (1)
Note!
Lift the boiler from either side at the bottom
edge.
• Lower the boiler slowly onto the hanging bracket so
that the cross member at the rear of the boiler fully
engages onto the hanging bracket
5. Removing boiler casing
• Turn both securing fasteners (1) anti-clockwise by 90°
to release control panel (2)
• Pull the case (3) forward at the bottom to disengage
from the securing clips
• Lift the case slightly to clear the top locations and pull
forward to remove
Fig. 5.5: Remove of boiler casing
3
I
0
2
I
0
90°90°
1
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Boiler Installation Sequence 5
Instructions for Installation and Servicing turboMAX pro R3 15
5.8 Cold water mains inlet and hot water outlet
Flush all foreign matter from the mains supply before
connecting to the boiler
• Connect the cold water service valve (1) to the cold
inlet water connection (3) of the appliance with the
washer (2) provided and tighten
• Connect the cold water inlet pipe copper tail to the
cold water service valve and tighten
• Connect the 15 mm hot water outlet copper tail (4) to
the hot water outlet connection of the appliance (6)
with the washer provided (5) and tighten
Note!
The hot water outlet union nut is packed in with
the PRV fitting pack.
Fig. 5.7: Fitting the hot and cold water connections
1
2
3
4
I
0
5.9 Central heating flow and return pipework
Before connecting the heating circuit to the boiler appli-
ance, all pipework and radiators must be thoroughly
flushed to remove any installation debris
• Connect the central heating flow (4) and return (1) ser-
vice valves to the appliance (6 and 3) with the washers
provided (2 and 5) and tighten the nuts Ensure that
the valve spindles face downwards and the drain
points face to either side of the boiler
• Connect the central heating pipework to the flow (4)
and return (1) tails
Pressure Relief Valve
Connect a discharge pipe not less than 15 mm diameter
to the outlet of this valve
The discharge pipework should be as short as possible
and installed with a continuous fall away from the boiler
The pipe should terminate in a position which ensures
that any discharge of water or steam from the valve
cannot create a hazard to persons in or about the premi-
ses, or cause damage to any electrical components or
external wiring, and the point of discharge should be
clearly visible (see diagram in plastic bag)
Fig. 5.8: Central heating flow and return pipework
I
0
4
1
2
3
5
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5 Boiler Installation Sequence
Fig. 5.9: Wiring system
Fig. 5.10: Exposed rear view of switchgear cabinet
• Connect the power supply cord as follows (Fig 5 11)
Green/yellow (earth) wire: boiler terminal Earth sign
Blue (neutral) wire: boiler terminal N
Brown (live) wire: boiler terminal L
Note!
DO NOT use boiler terminal connections 7-8-9.
• Refit the terminal box cover by pushing into place
until it clips back into position
• Raise the control panel and secure in place
2
1
3
NL987543
RT 24V 230V RT 230V
Instructions for Installation and Servicing turboMAX pro R316
5.10 Connect the flue system to the boiler
• Refer to separate air/flue duct installation instructions
included with the boiler
5.11 Electrical installation
General requirements
Important!
All electrical work shall be carried out by a
competent person and shall comply with
BS7 71 (IEE Regulations).
The boiler is supplied for connection to 230 V, ~ 50 Hz
supply fused at 3 A rating
Connection to the mains supply shall be made via a
fused 3 pin plug to an unswitched shuttered socket,
both complying to the requirements of BS1363
(Alternatively, connection may be made via a 3 A fused
double pole isolator having a contact separation of at
least 3 mm in all poles and supplying the boiler and con-
trols only)
The point of connection to the mains supply must allow
complete electrical isolation of the boiler and its ancil-
lary controls It should be readily accessible and adja-
cent to the boiler A 3 core flexible cord according to
BS6500 tables 6, 8 or 16 (3 x 0 75 to 3 x 1 5 mm2)
should be used
Warning!
This appliance must be earthed.
Important!
Ensure that all cords pass through the cable
clamps in the rear of the control box and are
securely fixed. Ensure that the power supply is
connected such that the current carrying con-
ductors become taut before the earth conductor
should the supply cord slip from the cable
clamp.
Warning!
Mains connection terminals L and N remain live
even when the boiler on/off control is switched
off.
5.12 Connection to the main supply
• Lower the control panel
• Unclip the terminal box cover (1) from the control
panel (2)
• Feed the power supply cord in to the appliance as
shown (fig 5 9)
• Use cable clamps
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Boiler Installation Sequence 5
Instructions for Installation and Servicing turboMAX pro R3 17
Abb. 0.0 Bildunterschrift
Fig. 5.11 Connection wiring
NL987
F3
543
24V 230V
F1
5.13 Electronic board layout
Socket X2 for internal unit components
Socket X4 for minority reversing
Socket X7 for accessory box connection
Socket X8 for VRC-VC connection
Room thermostat, 230 V: connections 3, 4 and 5
Mains power supply: connections L, N and earth
Socket X12: pump connection
Socket X14: gas valve connection
Socket X13: fan unit connection
Do not
use!
833792_41GB_012005.qxd 09.03.2005 16:47 Uhr Seite 17

5 Boiler Installation Sequence
Connection details for external time switches and
boiler terminal strip.
Fig 5 13 shows the connection details where a time
switch is used without a room thermostat to control the
boiler
Attention!
The arrowed numbers indicate connection into
the relevant terminal in the boiler terminal strip.
If a room thermostat is to be connected in addition to a
time switch the wire between the time switch „ON“ ter-
minal and boiler terminal 4 should be broken by the
contacts of the room thermostat (see schematic layout,
Fig 5 14)
Vaillant optional plug in timer accessories
Refer to the instructions supplied with the optional
accessories for connection details
Upon completion of all electrical connections refit the
terminal box cover by pushing into place The cover is
secured by two locking clips
Instructions for Installation and Servicing turboMAX pro R318
Fig. 5.13 Connection details for time switch
LN 234
LN 3 4
1
ACL Drayton
Tempus 1, Tempus 2
Lyfestyle LP111, LP711
ACL Drayton
Switchmaster
SM300
ACL Drayton
Switchmaster 980
Danfoss Randall
103 Series
Danfoss Randall
Set 1E, TS975
Danfoss Randall
TS715
Grässlin Towerchron
QE1, QM1
Honeywell
ST 10A, ST 100C
Horstmann
Channel Plus
H11, H17, 425 Coronet
Horstmann
Centaur Plus
C11, C17
LN 234
LN 4 3
1
Potterton Myson
EP 4002, EP 5002
Smiths Timeguard
SupplyMASTER
FST11, FST17
Sunvic
Select 107
N1 AB C
N4
2
L
L3
34
12 5E
4L3N
3
E
NE 234
NE
1
L
L3
5
4
LN 234
LN 3 4
1
LN 234
LN 34
1
LN 234
LN 3 4
1
NE 234
NE
1
L
L3
5
4
NE 234
NE
1
L
L34
LN 234
LN 3 4
1
LN 234
LN 3 4
1
AB DLN
LN
C
N
E
3
12
4
345E
12 4
432/L
1/N
35 mains supply
LN E
E
Landis & Staefa
RWB7, RWB30
5.14 Controls
External electrical controls
The boiler terminals 3, 4 and 5 are for connecting
external electrical controls such as a time switch and/or
room thermostat Terminals 3 and 4 are linked together
when the boiler is supplied If external controls are used,
this link must be removed, and the controls connected
across terminals 3 and 4
Terminal 5 is an additional neutral connection for exter-
nal neutrals such as from the anticipator of a room
thermostat
Connection of external controls
Connection details for programmable room
thermostats.
Fig I 12 shows the connection details where a pro-
grammable room thermostat (time switch with built in
room thermostat) is used to control the boiler
Attention!
The arrowed numbers indicate connection into
the relevant terminal in the boiler terminal strip.
Fig. 5.12 Connection details for programmable thermostats
LN 234
LN 3 4
1
ACL Drayton
Lyfestyle PT271, PT371
ACL Drayton
Digistat 2, 3, 4
ACL Drayton
Digistat RF - SCR Receiver
Danfoss Randall
TP4, TP5, TP5E
Danfoss Randall
TP5E RF with receiver RX1
Danfoss Randall
TP75
Grässlin Towerchron
RTC7
Honeywell
CM 1, CM 7, CM31, CM37
Horstmann
Centaurstat 1, 7
Landis & Staefa
REV 11, REV 15, REV 22
12
34
3
Sunvic
TLX 501
Sunvic
TLX RFP, TLX RFD
Vaillant
VRT 230, 220
N1 3
N3
2
L
L4
32
43
1
LN 234
LN 34
1
BC 2341 A
3
5
4
12
34
3
AB
34
C
12 4
34
3
LL1
34
Smiths Timeguard
ProgramaSTAT PRT11, PRT17 LN 4
LN
3
34
12
34
3
LN 234
LN 34
1
345
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Boiler Installation Sequence 5
Instructions for Installation and Servicing turboMAX pro R3 19
Fig. 5.14
Thermostatic radiator valves
The boiler has a built in automatic bypass valve making
it ideal for use in systems with thermostatic radiator val-
ves (no separate system bypass is required)
For optimum fuel economy it is recommended that
where TRV’s are used they are used in conjunction with
a programmable room thermostat or separate timer and
room thermostat to ensure complete boiler shut down
when the heating demand is satisfied (The radiator in
the room containing the room thermostat should not be
fitted with a TRV)
Frost protection
The boiler has an integral frost thermostat which is desi-
gned for protection of the boilerTo protect remote or
exposed parts of the heating system or property additio-
nal frost protection measures must be taken such as the
installation of an external frost thermostat This frost
thermostat should be connected across the boiler termi-
nals 3 and 4, in parallel with any external heating con-
trols External frost protection cannot be used when
plug in timers have been fitted
Circulating pump
The boiler incorporates a built in circulating pump that
is fully prewired (no additional wiring is necessary) The
pump incorporates an automatic overrun period after
the boiler switches off
Anti-cycling ‘economiser’ control
The boiler incorporates a built in anti-cycling control to
ensure that energy wasteful short cycling of the boiler
cannot occur This control prevents the boiler from re-
igniting for a preset period of 5 minutes after central
heating operation (the hot water operation is unaffected
by this control and hot water can be drawn at any time)
Note!
To temporarily override the anti-cycling control
turn the main boiler on/off switch to the off
position „0“ and then back to the on position
„I“ after a few seconds.
3
987
MAINS
SUPPLY
230 V
50 Hz
L
L
LN
N
NN
20 VDCDO NOT USE IN UK!
3 A FUSE SWITCH
CONTACTS
ROOM
THERMOSTAT
CLOCK
45
Automatic pump spin control (APS)
The boiler incorporates a built in control which will spin
the built in circulating pump and operate the diverter
valve (turboMAX only) once in a 24 hour period This
control helps to prevent seizure when the boiler is not
operated for a period of time This control is not active
when the power supply to the appliance is turned off
833792_41GB_012005.qxd 09.03.2005 16:47 Uhr Seite 19

6 Commissioning Part I
Instructions for Installation and Servicing turboMAX pro R320
Commissioning Part I
.1 Preliminary electrical checks
Check the electrical installation by carrying out short
circuit, earth continuity and resistance to earth tests
and a check for correct polarity
.2 Gas supply
The complete gas installation including the gas meter
must be inspected, tested for soundness and purged in
accordance with BS 6891
The gas supply to the boiler can be purged by slacke-
ning the gas service valve beneath the boiler Ensure
that there is adequate ventilation, extinguish all naked
flames and do not smoke whilst purging
After purging, the gas service valve connection must be
retightened and tested for soundness (The boiler itself
does not require purging as this will be done by the
automatic burner sequence control)
.3 Cold water supply
Open all domestic hot water taps supplied by the boiler,
turn on the mains water supply to the boiler and open
the mains water isolating valve below the boiler
Water will now flow through the boiler to the hot taps
Starting with the lowest tap supplied, turn the hot taps
off one at a time until the hot water pipework is purged
of air Check all hot and cold water pipework for leaks
.4 Filling the heating system
Proceed as follows to fill the system:
• Open all radiator valves on the system
• Fill the system via the seperate filling point
• Open the valve slowly and fill the unit with water until
the required pressure has been acheived (2)
• Bleed the air from the radiators
• The boiler is equipped with an automatic air release
valve To allow this to vent the boiler, the cap top must
be slackened by 1 - 2 turns (This cap must be left
slackened during operation to ensure any residual air
or system gases are released)
• Close the filling valve (1) and disconnect the temporary
connection
• Now check the water pressure in the unit again (and
add more water if necessary)
.5 Initial system flush (“cold“)
The whole of the heating system must be flushed out at
least twice: once cold, and once hot as instructed later
Open all radiator and heating valves and the boiler CH
service valves and drain the heating system and boiler
completely from the lowest points of the system via 1/2”
BSP drain taps (opened full bore to remove any installa-
tion debris prior to lighting the boiler)
Refill the heating system Check the operation of the
pressure relief valve by rotating the knob on the valve
Now check the water pressure in the unit again (and add
more water if necessary)
Fig. .1: Filling / draining the heating system
Close the filling valve (1) and disconnect the temporary
connection
2
5
3
4
1
833792_41GB_012005.qxd 09.03.2005 16:47 Uhr Seite 20