Vaillant TURBOmax Pro 28/2 E User guide

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INSTRUCTIONS FOR
INSTALLATION AND SERVICING
TURBOmax Pro 28/2 E
Wall hung room sealed fan assisted combination boilers
The code of practice for the installation,
commissioning & servicing of central heating systems
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TABLE OF CONTENTS
Introduction
Boiler Specification
General Requirements
Boiler Installation Sequence
General information . . . . . . . . . . . . . . . . . . . . . . . . . .5
EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
List of Contents Contents included with boiler . . . . . . . . . . . . . . . . . . . .4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Boiler connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Rear outlet flue system . . . . . . . . . . . . . . . . . . . .11
Top outlet flue system . . . . . . . . . . . . . . . . . . . .11
Extended top outlet flue system . . . . . . . . . . . . . .11
Flue termination . . . . . . . . . . . . . . . . . . . . . . . .12
Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Cupboard or compartment ventilation . . . . . . . . . . . . . .13
Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Guide to system requirements . . . . . . . . . . . . . . . . . . .14
Water circulation system . . . . . . . . . . . . . . . . . .14
Filling and make up . . . . . . . . . . . . . . . . . . . . .14
Pressure relief valve . . . . . . . . . . . . . . . . . . . . .14
Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . .14
Expansion vessel . . . . . . . . . . . . . . . . . . . . . . .15
Circulating pump . . . . . . . . . . . . . . . . . . . . . . .16
System by-pass . . . . . . . . . . . . . . . . . . . . . . . . .16
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
DHW expansion vessel accessory . . . . . . . . . . . .16
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Preparation of boiler location . . . . . . . . . . . . . . .17
Selecting position of boiler . . . . . . . . . . . . . . . . .17
Using boiler template . . . . . . . . . . . . . . . . . . . . . . . . .18
Fitting the boiler hanging bracket . . . . . . . . . . . . . . . . .19
Install the flue system . . . . . . . . . . . . . . . . . . . . . . . . .19
Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Removing boiler casing . . . . . . . . . . . . . . . . . . . . . . .20
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Cold water mains inlet and hot water outlet . . . . . . . . . .22
Central heating flow and return pipework . . . . . . . . . . .23
Connecting the flue system to the boiler . . . . . . . . . . . .24
Electrical installation general requirements . . . . . . . . . . .25
Connecting to the main supply . . . . . . . . . . . . . . . . . .26
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Fit boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Commissioning Part I Preliminary electrical checks . . . . . . . . . . . . . . . . . . . .31
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Filling the heating system . . . . . . . . . . . . . . . . . . . . . .33
Draining the heating system . . . . . . . . . . . . . . . . . . . .33
Initial system flush (`cold`) . . . . . . . . . . . . . . . . . . . . . .33

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TABLE OF CONTENTS
Gas supply adjustments
(Commissioning Part II)
Servicing
Fault Finding Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Logical fault finding procedure . . . . . . . . . . . . . . . . . .57
Fault finding charts . . . . . . . . . . . . . . . . . . . . . . . . . .58
Diagrams Functional flow diagram . . . . . . . . . . . . . . . . . . . . . . .66
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Short parts list Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Cleaning the burner and primary heat exchanger . . . . . .44
Parts replacement Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Temperature sensors (NTCs) . . . . . . . . . . . . . . . . . . . .49
Main heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . .49
Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Electronic control board . . . . . . . . . . . . . . . . . . . . . . .51
Main transformer . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . .52
System bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Aqua sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
DHW heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .55
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .55
Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . .56
Functional checks
(Commissioning Part III)
Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Adjusting pump speed . . . . . . . . . . . . . . . . . . . . . . . .41
Final system flush (hot) . . . . . . . . . . . . . . . . . . . .41
Handing over to the user . . . . . . . . . . . . . . . . . . . . . .42
Gas inlet working pressure . . . . . . . . . . . . . . . . . . . . .34
Main burner pressure . . . . . . . . . . . . . . . . . . . . . . . . .35
Adjusting the central heating output (range rating) . . . . .36
Burner pressure and gas rate . . . . . . . . . . . . . . . . . . .37

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LIST OF CONTENTS
Contents included with
boiler
Ensure that all contents are included
before commencing installation.
DO NOT remove the boiler from the
polystrene base at this stage.
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
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BEDIENUNGSANLEITUNG
Instructions for Use
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1
2
5
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Fig. L.1: Items supplied with unit
Table L.1: Items supplied with unit
Euro B/S 021/1 GB_Pro
Item Quantity Description
1 1 Boiler
2 1 Flue restriction rings
3 1 Cold water inlet valve
5 1 Copper tail for hot water outlet connection
6 1 Template
4 3 Flow and return service valve, gas service valve
7 1 Guarantee Card and Benchmark log book
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 1Hanging bracket

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INTRODUCTION
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 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
additional 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 desired, 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 exchanger. 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
pipework, a scale reducer may be
fitted.
TURBOmax Pro combination boilers
have a built in diagnostic system
which indicates the operational status
of the boiler. 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, commisioning and hando-
ver to the user.
Note: This boiler must be installed
and service 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
EC designation
TURBOmax Pro boilers (VUW GB
282/2-3) carry the „CE“ Mark. This
demonstrates that the boilers 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.

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BOILER SPECIFICATION
Technical data
TURBOmax Pro 28/2 E
( VUW GB 282/2-3) Units
CH heat output range (80/60 °C) 10.4 - 28
(35 500 - 95 500) kW (Btu/h)
DHW heat output 28 (95 500) kW (Btu/h)
DHW flow rate ∆T =35 °C rise 11.5 l/min
DHW flow rate at factory set temperature rise (∆T 42 °C) 9.5 l/min
Mains water pressure required for max. flow rate 0.5 bar
Minimum water flow rate 1.5 l/min
Mains water pressure required for min. flow rate 0.15 bar
Maximum inlet water pressure 10 bar
Inlet gas working pressure required (natural gas) 20 mbar
Gas burner pressure ignition rate 1.8 mbar
Gas rate max. (DHW) 3.3 m3/h
Weight 45 kg
Primary water content 2.0 l
Maximum CH heat input (net) 31.1 (106 200) kW (Btu/h)
Gas supply (G20) Gross CV (s.t.) 37.8 MJ/m3
Gas burner pressure max. rate 10.8 mbar
CH temperature flow range 35 - 82 °C
Minimum CH water flow (for 20 °C rise) 1203 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) 31.1 (106 200) kW (Btu/h)
Case height 800 mm
Case width 440 mm
Case depth 338 mm

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BOILER SPECIFICATION
Boiler connections
0
7
6
310
592
145
6
5
100100
35 35
432
130 180
1
148
8
543 21
Fig. B.1: Connection diameters
Euro B/S 024/2
Key:
1Heating system return
(22 mm compression)
2Cold water connection with shut
off valve (15 mm compression)
3Gas connection (15 mm
compression)
4Hot water connection
(15 mm tail)
5Heating system flow
(22 mm compression)
6Flue outlet (100 mm flue with
turret)
7Hanging bracket
8Rear flue outlet

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BOILER SPECIFICATION
C
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
16
18
19
21
22
23
24
25
26
27
28
29
30
31
Functional Diagram
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 Service valve
17 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
Fig. B.2: Functional Diagram
Euro B/S 196/0

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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.

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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.