Vaillant TURBOmax VUW 282/1 E User guide

TURBOmax VUW 242/1 E
TURBOmax VUW 282/1 E
Wall hung room sealed fan assisted
combination boilers
INSTRUCTIONS FOR INSTALLATION AND SERVICING
HEATING, CONTROLS, HOT WATER.

2
Page
1. Introduction 3
2. Boiler Specification 4
2.1 Technical Data 4
2.2 Dimensions 5
2.3 Boiler connections 5
2.4 Function diagram 6
3. General Requirements 7
3.1 Related documents 7
3.2 Boiler location 7
3.3 Gas supply 8
3.4 Flue system 8
3.5 Air supply 10
3.6 Electricity supply 10
3.7 Guide to system requirements 10
4. Boiler installation sequence 13
4.1 General 13
4.2 Boiler delivery 13
4.3 Preparation of boiler location 14
4.4 Installing the flue system 16
4.5 Mounting the boiler 16
4.6 Connecting the flue assembly
to the boiler 17
4.7 Electrical installation 19
4.8 Controls 20
5. Commissioning 22
5.1 Preliminary electrical checks 22
5.2 Gas supply 22
5.3 Water supply 22
5.4 Filling the heating system 23
5.5 Initial system flush ('cold') 23
5.6 Initial lighting 24
5.7 Gas inlet working pressure 25
5.8 Main burner pressure 25
5.9 Adjusting central heating
output (range rating) 26
5.10 Functional checks 27
5.11 Checking flame
supervision device 28
5.12 Final system flush ('hot') 28
5.13 Fitting case 28
5.14 Handing over to user 29
Page
6. Servicing 29
6.1 Initial inspection 29
6.2 Routine maintenance 30
6.3 Re-commissioning the boiler 31
7. Parts replacement 32
7.1 Initial preparation 32
7.2 Fan 34
7.3 Air pressure switch 34
7.4 Burner 35
7.5 Electrodes 35
7.6 Temperature sensor (NTC) 36
7.7 Gas valve 36
7.8 Main Heat exchanger 37
7.9 CH expansion vessel 38
7.10 Transformer 39
7.11 Overheat thermostat 39
7.12 Pump 39
7.13 Automatic air release 40
7.14 Automatic bypass 40
7.15 Diverter valve 40
7.16 Pressure and temperature
gauge 41
7.17 Differential pressure switch 41
7.18 DHW microswitch 42
7.19 DHW heat exchanger 42
7.20 Circuit boards 43
8. Fault finding 44
8.1 Introduction 44
8.2 Logical fault finding procedure 44
8.3 Fault finding charts 45
9. Electrical diagrams 54
9.1 Functional flow diagram 54
9.2 Wiring diagram 55
9.3 Schematic appliance
circuit diagram 56
10. Short parts list 57
11. Supplementary LPG
information 59
Leave these instructions with the user
when the installation is completed.

33
1. Introduction Note: This boiler must be installed
and serviced by a competent person
in accordance with the Gas Safety
(Installation and Use) Regulations
1994. In the UK 'CORGI' Registered
Installers undertake the work to a
safe and satisfactory standard.
The TURBOmax 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 or 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,
bypass, expansion vessel and diverter
valve.
TURBOmax boilers carry 'CE' Mark.
This demonstrates that the boilers fulfill
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 (Directive
89/336/EEC), the Low Voltage
Directive (73/23/EEC), the Boiler
Efficiency Directive (92/42/EEC) and
the Boiler (Efficiency) Regulations
1993.
TURBOmax meets the requirements of
Statutory Instrument ‘The Boiler (Effi-
ciency) Regulations 1993 and
therefore is deemed to meet the
requirements of Directive 92/42/EEC
on the efficiency requirements for new
hot-water boilers fired with liquid or
gaseous fuels.
The TURBOmax range consists of
models with outputs for domestic hot
water of 24 and 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. Flue extensions and
additional bends and elbows are
available for increased siting flexibility.
(The boiler is 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.
Natural Gas and LPG versions of the
boiler are available.
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 inlet 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 TURBOmax has built-in diagnostic
indicator lights which illuminate in
sequence giving information on the
boiler status when operating and per-
formance of key components to aid in
commissioning and fault finding.
The data badge is fitted on the bottom
of the combustion chamber.
See text of General Requirements for
Installation Requirements or notes.

TURBOmax VUW 242/1 E VUW 282/1 E units
Countries of Destination GB, IE
Maximum CH heat input 29.3 34.2 kW
(100,000) (116,600) (Btu/h)
CH heat output range 9.6-24.0 11.2-28.0 kW
(32,800-81,900) (38,200-95,500) (Btu/h)
Maximum DHW heat input 29.3 34.2 kW
(100,000) (116,600) (Btu/h)
Maximum DHW heat output range 9.6-24.0 11.2-28.0 kW
(32,800-81,900) (38,200-95,500) (Btu/h)
DHW flow rate @ 35 °C rise 10 11.5 l/min
Mains water pressure required for max. flow rate 0.8 1.0 bar
Minimum water flow rate 2.7 2.7 l/min
Mains water pressure required for min flow rate 0.3 0.3 bar
Maximum inlet water pressure 10 10 bar
Inlet gas working pressure required (Natural Gas) 20 20 mbar
Gas supply (G20) Gross C.V. (s.t.) 37.8 37.8 MJ/m3
Gas burner pressure max. rate 10.0 10.6 mbar
Gas burner pressure ignition rate 2.0 2.0 mbar
Gas rate max (DHW) 2.79 3.26 m3/h
Main burner jet size 16 x 7/120 18 x 7/120 no. x size
CH flow temperature range 40-90 40-90 °C
Minimum CH water flow (for 20 °C rise) 1,032 1,204 l/h
Pump pressure available 0.25 0.25 bar
8l expansion vessel pre-charge pressure 0.75 0.75 bar
Maximum CH system pressure 3.0 3.0 bar
Connections
Heating flow / return 22 22 mm
Cold water inlet 15 15 mm
DHW outlet 15 15 mm
Gas inlet 15 15 mm
Pressure relief discharge pipework (min) 15 15 mm
Weight 47 48 kg
Primary water content 0.7 0.7 litres
Electrical supply
Voltage 230/50 230/50 V~/Hz
2 x internal fuses 2 2 A
1 x internal fuse 1.25 1.25 A
external fuse 3 3 A
Power input 130 130 W
4
2. Boiler specification
2.1 Technical data
Supplementary LPG information on page 59.

55
1021
880
95.5
480
120 max. 995* max. 995 *
1a
1a
190
1b
2
765438
35
50 380
120
GW 547/1
fig. 1
2.3 Boiler connections
1 Compression union (flow of
heating system)
2 Service valve (flow of heating
system)
3 Domestic hot water connection
4 Compression Union (gas)
5 Gas service valve (supplied with
the boiler)
6 Cold water connection with
shut-off valve
7 Service valve (return of heating
system)
8 Compression union (return of
heating system)
9 Pressure relief valve
200
124
50
35
70
25
12 3456789
GW 546/1
fig. 2
2.2 Dimensions
(All dimensions in mm)
1a Air/flue duct to the rear
1b Air/flue duct to the side
2 Appliance bracket
3 Heating system return (22 mm)
4 Cold water connection (15 mm)
5 Gas connection (15 mm)
6 Hot water connection (15 mm)
7 Heating system flow (22 mm)
8 Pressure relief valve outlet
(3/4in BSP)
* with standard horizontal flue
accessory.
(max. = 2965 mm with extensions)

66
1
9
2
3
4
5
6
78
1
9
2
3
4
5
6
78
υ
0
0
60
90
120
4
321
30
1
2
3
4
5
7
6
8
9
10
11
12
13
14
15
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
GW 573/2GB
fig. 3
2.4 Function diagram
1 Air duct
2 Air pressure switch
3 Combustion chamber
4 Temperature sensor (NTC)
5 Ignition electrodes
6 Modulating burner
7 Overheat thermostat
8 Fully modulating automatic gas
valve
9 DHW heat exchanger
10 Indicator lights (LED’s)
11 Maximum radiator temperature
control
12 Maximum hot water temperature
control
13 Central heating control and
lockout reset
14 Main on/off control
15 CH flow service valve
16 Gas service valve
17 Flue gas duct
18 Fan
19 High efficiency heat exchanger
20 Flame sensing electrode
21 Differential pressure switch
22 Expansion vessel charging valve
23 Expansion vessel
24 Automatic air vent
25 Circulating pump
26 Diverter valve
27 Water switch (DHW)
28 Water section
29 Temperature and Pressure gauge
30 Automatic bypass valve
31 Pressure relief valve
32 CH return service valve
33 Cold water shut off valve

7
3. General requirements 3.1 Related documents
The installation of the boiler must be
in accordance with the relevant
requirements of Gas Safety (Installation
and Use) Regulations 1994, Health
and Safety Document No. 635 (The
Electricity at Work Regulations 1989),
BS7671 (IEE Wiring Regulations) and
the byelaws of the local Water
Undertaking. 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 60 kW:
- 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.
BRITISH GAS PUBLICATION DM2:
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 1994
3.2 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 (I.E.E. 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
electricity should be so situated that it
cannot be touched 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 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
accordancewith British Gas Publication
DM2 'Guide for Gas Installations in
Timber Framed Housing'.

8
3.3 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.
3.4 Flue system
The standard horizontal flue system
(Art. No. 300 807) is suitable for
installations up to 995 mm measured
from the centre of the boiler flue outlet
to the outside face of the wall (A, fig.
4). Flue extensions (Art. No. 300 802)
are available to extend this length up
to 2965 mm. Both 90°elbows
(Art. No. 300 808) and 45°bends
(Art. No. 300 809) are also available
to increase siting flexibility.
A vertical flue system is also available
(Art. No. 300 800).
TURBOmax boilers may also be used
in SE- duct applications (SE- duct flue
system available Art. No. 300810)
Refer to the flue installation instructions
for full details.
A max = 2965 mm
GW 579/2
fig. 4

3.4.1 Flue Termination
1. The terminal must be positioned
such that the combustion products can
disperse freely at all times.
2. 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.
3. If the terminal is fitted less than 2m
above a balcony, above ground or
above a flat roof to which people
have access, then a suitable guard
must be provided and fitted (available
from Tower Flue Components,
Tonbridge, TN9 1TB: reference TFC
type K3).
Table 1:
Terminal position for fan-assisted flue
(minimum distance - see fig. 5)
A- Directly below an openable mm
window or other opening
(e.g. air brick) 300
B- Below gutters, soil pipes
or drain pipes 25
C- Below eaves 25
D- Below balconies 25
(below car port roof 200)
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 facing a
terminal 600
I- From a terminal facing a
terminal 1200
J- From an opening in a
car port (e.g. door, window)
into a dwelling 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
9
A
BCD
A
G
H, I
FJ
BFM
L
L
KK
G
G
FF
E
fig. 5
GW 595/1
Where a terminal is fitted less than
1m below a plastic gutter or less than
0.5 m below painted eaves or any
other painted surface then a suitable
shield at least 1m long should be
fitted to protect the surface.
Note: Vertical flues must not terminate
within 600 mm of an openable
window, air vent or any other
ventilation opening.

10
3.5 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.
3.5.1 Cupboard or compartment air
supply
TURBOmax Room Sealed Combination
Boilers are very high efficiency
appliances.
As a consequence the heat loss from
the appliance casing during operation
is very low. For cupboard and
compartment installations it is therefore
not necessary to provide any high or
low level permanent air vents for
cooling purposes.
3.6 Electricity supply
A 230 V~ 50Hz single phase
electricity supply fused to 3 amps must
be provided in accordance with the
latest edition of BS7671 (I.E.E. Wiring
Regulations) and any other local
regulations that may apply.
THIS APPLIANCE MUST BE EARTHED.
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
double-pole switch with a 3mm
contact separation on both poles may
be used.
3.7 Guide to system
requirements
3.7.1 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 the
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 cleasing
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 Sentinel,
Grace Dearborn Ltd, Widnes,
Cheshire, WA8 8UD.
Tel: [phone].