Vaillant TURBOmax Pro 2 E Wartungshandbuch

INSTRUCTIONS FOR INSTALLATION AND SERVICINGTURBOmax Pro 28/2 EWall hung room sealed fan assisted combination boilersThe code of practice for the insta

10GENERAL REQUIREMENTSGas SupplyThe gas supplier should ensure theavailability of an adequate supply ofgas.A gas meter may only be connectedto the ser

11GENERAL REQUIREMENTSTop outlet flue system(100 mm outside diameter)The top outlet horizontal flue system(Art. No. 303 807) is suitable forinstallati

12GENERAL REQUIREMENTSFlue terminationThe following details refer to bothflue systems.a. The terminal must be positionedsuch that the products of comb

13GENERAL REQUIREMENTSCupboard or compartmentventilationTURBOmax Pro combination boilersare very high efficiency appliances.As a consequence the heat

14GENERAL REQUIREMENTSGuide to system requirementsWater circulation systemDetailed recommendations for thewater circulation system are given inBS 6798

15GENERAL REQUIREMENTSExpansion vesselThe 28 kW boiler incorporates a 10 litre expansion vessel which is suitable for a sealed heating systemwith a ma

16GENERAL REQUIREMENTS0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 140050100150200250300350400450500550600650700Volume flow [l/min]Lift [

17GENERAL REQUIREMENTS15052005005I00120609030°Cbar43210Euro B/S 022/1440800338I00 120609030°Cbar43210Euro B/S 023/1GeneralPreparation of boiler locati

55210124163 03240/242/280/282/824/828 Pro/Plus60/10007/2000124163_0313218BOILER INSTALLATION SEQUENCEUsing boiler templateFix the paper template to th

I033201312226,527131105105120120609030°Cbar43210Euro B/S 043/119BOILER INSTALLATION SEQUENCEFig. I.4: Fitting the boilerFitting the boiler● Lift the b

2TABLE OF CONTENTSIntroductionBoiler SpecificationGeneral RequirementsBoiler Installation SequenceGeneral information . . . . . . . . . . . . . . . .

3I02I090°90°1Euro B/S 041/1Fig. I.5: Remove of boiler casing20BOILER INSTALLATION SEQUENCERemoving boiler casing● Turn both securing fasteners (1)anti

21BOILER INSTALLATION SEQUENCEGas supply● Connect the 15 mm compressiongas service cock (1) supplied withappliance and tighten.● Connect a gas supply

22BOILER INSTALLATION SEQUENCECold water mains inletand hot water outletFlush all foreign matter from the mainssupply before connecting to the boiler.

23BOILER INSTALLATION SEQUENCECentral heating flow andreturn pipeworkBefore connecting the heating circuitto the boiler appliance, all pipeworkand rad

24BOILER INSTALLATION SEQUENCEElectrical installationGeneral requirementsAll electrical work shall be carried outby a competent person and shall compl

25BOILER INSTALLATION SEQUENCECautionMains connection terminals Land N remain live even whenthe boiler on/off control isswitched off.● Refit the termi

26BOILER INSTALLATION SEQUENCEEuro B/S 048/1Socket X2 for internal unit componentsSocket X4 for minority reversing valveSocket X7 for accessory box co

27BOILER INSTALLATION SEQUENCEControlsExternal electrical controlsThe boiler terminals 3, 4 and 5 arefor connecting external electrical controls such

28BOILER INSTALLATION SEQUENCEFor optimum fuel economy it is recommended that where TRV’s areused they are used in conjunctionwith a programmable room

29BOILER INSTALLATION SEQUENCEFit boiler casing● Carefully push case (1) onto theboiler such that the locating pointseither side at the top of the boi

3TABLE OF CONTENTSGas supply adjustments(Commissioning Part II)ServicingFault FindingIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . .

30COMMISSIONING PART IPreliminary electricalchecksCheck the electrical installation bycarrying out short circuit, earth continuity and resistance to e

31COMMISSIONING PART I

32COMMISSIONING PART I2534Fig. Com. 1: Draining the heating systemEor B/S 207/0GB_Pro

33COMMISSIONING PART IInitial system flush(„cold“)The whole of the heating system mustbe flushed out at least twice: oncecold, and once hot as instruc

34GAS SUPPLY ADJUSTMENTS(COMMISSIONING PART II)12Euro B/S 034/0Gas inlet workingpressureTo check the gas inlet working pressu-re:● Lower the front pan

35GAS SUPPLY ADJUSTMENTS(COMMISSIONING PART II)1a1323a2aEuro B/S 035/0Main burner pressure● The burner pressure on this appliance has been factory set

36GAS SUPPLY ADJUSTMENTS(COMMISSIONING PART II)Adjusting the centralheating output (range rating)The TURBOmax Pro is fully modulating for central heat

37GAS SUPPLY ADJUSTMENTS(COMMISSIONING PART II)1)15 °C, 1013 mbar, dry2)The nozzles are stamped with the values shown inthis table. The marking corres

38FUNCTIONAL CHECKS(COMMISSIONING PART III)I0Functional checksProcedureOnce the unit has been installed andthe gas supply has been checked,operate the

39FUNCTIONAL CHECKS(COMMISSIONING PART III)OperationThe Vaillant TURBOmax Pro is equipped with a set of diagnosticindicator lights to show the operati

4LIST OF CONTENTSContents included withboilerEnsure that all contents are includedbefore commencing installation.DO NOT remove the boiler from thepoly

40FUNCTIONAL CHECKS(COMMISSIONING PART III)Heating system● Ensure that the power on indicatoris illuminated (1).● Ensure that the maximum radiatortemp

41FUNCTIONAL CHECKS(COMMISSIONING PART III)Adjusting pump speedThe unit is fitted with a two-speedpump.The pump is delivered with the switch(1) set to

42FUNCTIONAL CHECKS(COMMISSIONING PART III)Set the maximum radiator temperaturecontrol to the desired setting.Set the maximum hot water temperature co

SERVICING43Before commencing any servicing ormaintenance work, carry out an initialinspection of the system as follows:● Inspect the flue, pipework an

44SERVICINGCleaning the burner andprimary heat exchanger● Turn off the boiler.● Isolate the electrical supply to theboiler.● Remove the boiler case as

45PARTS REPLACEMENTEnsure that ALL regulationsare observed.Fig. E.1: GeneralEuro B/S 006/0GBSafety instructions The following safety instructions are

4613452Euro B/S 158/1Electrodes● Refer to the important informationand initial preparation on page 45.● Remove combustion chambercover by unclipping t

47PARTS REPLACEMENT124389576Fig. E.4: FanEuro B/S 162/0Fan● Refer to the important informationand initial preparation on page 45.● Remove combustion c

483126574Euro B/S 297/0910813141112Euro B/S 298/0PARTS REPLACEMENTFig. E.5a: Gas valveFig. E.5b: Gas valveGas valve● Refer to the important informatio

49PARTS REPLACEMENTTemperature sensors(NTC’S)● Refer to the important informationand initial preparation on page 45.● Identify which sensor(s) is to b

5INTRODUCTIONThe TURBOmax Pro is a fully automatic, wall mounted, room sealedcombination boiler for central heatingand domestic hot water. Domestic ho

50PARTS REPLACEMENT1423Fig. E.8: Expansion vesselEuro B/S 164/0Expansion vesselPlease note: In the unlikely event of afailure of the CH expansion vess

51PARTS REPLACEMENTElectronic control board● Refer to the important informationand initial preparation on page 45.● Lower control box. ● Unclip the te

52Air pressure switch● Refer to the important informationand initial preparation on page 45.● Remove clips (6) and lift out pressure switch (7).● Disc

53System bypass● Refer to the important informationand initial preparation on page 45.● Release central heating water pressure.● Remove spring clip (2

54PARTS REPLACEMENT221Fig. E.15: Pressure gaugeEuro B/S171/014635Fig. E.16: Aqua sensorEuro B/S 172/0GB_ProPressure gauge● Refer to the important info

55PARTS REPLACEMENTDHW heat exchanger ● Refer to the important informationand initial preparation on page 45.● Release central heating water pressure.

56I0Fig. E.19: Functional checkEuro B/S 058/0Checking functionsProcedureOn completion operate the system runto ensure that the boiler is workingcorrec

57FAULT FINDINGFlame indicator (yellow)Illuminates when flame is recognisedby the flame monitoring system.(A flashing indicator shows that anNTC senso

58FAULT FINDINGEnsure boiler mainON/OFF control is setto position "1" Yes Go to sheet CCheck electrical supply, appliance fuses and on/off c

59FAULT FINDINGSheet BCheck operation of pump and fanTurn off the main ON/OFF control to the"0" positionDiconnect the power supply to the bo

6BOILER SPECIFICATIONTechnical dataTURBOmax Pro 28/2 E( VUW GB 282/2-3)UnitsCH heat output range (80/60 °C)10.4 - 28 (35 500 - 95 500)kW (Btu/h)DHW he

60FAULT FINDINGCheck central heating and controlsEnsure that radiator temperature control knobis set to vertical position and that any internaltimer (

61FAULT FINDINGDoes fan run after approx. 30 secs.?Check flue and ignition systemNoCheck pitot tube (in fan outlet) and airhoses are not obstructed an

62FAULT FINDINGCheck gas valve and central heating system pressureDoes burner light 1stattempt?Does burner light within 3ignition attempts?NoYesCheck

63FAULT FINDINGDoes flame indicator glow andflames increase in size to full gasrate after approx. 2 mins?YesDoes burner flame modulate/ goout when rad

64FAULT FINDINGDraw hot water at high rate YesCheck hot water flow rate and temperature.Compare with technical data, if flow is notsufficient check in

65FAULT FINDING

66DIAGRAMSPOWER SUPPLYF2AL2N1MAIN SWITCHMAINTRANSFORMER230V20VAIRPRESSURESWITCHFANPUMPNTC FLOWTEMPERATURESENSORFLAMESENSORGASVALVEAQUASENSORF1,25ANTC

67DIAGRAMSSwitchgear cabinetU100X3T 2= F2T 1,25 = F3X2X2X1242311213141516171819202122234567891011X6DiagnosisX2AquasensorPressure sensorNTC returnNTC e

68SHORT PARTS LISTDescription Part No. Key No.Burner, natural gasBurner chamber group: 031501Distributor tube: 126753 Er.1Ignition electrodeFlame sens

69SHORT PARTS LISTEr.1 Er.3Er.4 Er.6Er.7 Er.8 Er.9Er.10 Er.11 Er.12Euro B/S 143/0Euro B/S 148/0Euro B/S 147/0Euro B/S 146/0Euro B/S 156/0Euro B/S 152/

7BOILER SPECIFICATIONBoiler connections0763105921456510010035 3543213018011488543 21Fig. B.1: Connection diametersEuro B/S 024/2Key:1 Heating system r

70SHORT PARTS LISTEr.13 Er.14Er.17Er.15Euro B/S 149/0Euro B/S 145/0Euro B/S 178/0Euro B/S 150/0Er.16Euro B/S 155/1

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83 41 11 GB11 · 02/2002 Mü · Printed on 100 % recycled paper · Subject to alterationHead OfficeVaillant Ltd., Vaillant House,Medway City Estate, Trid

8BOILER SPECIFICATIONCC123456789101112131415171618192122232425262728293031Functional Diagram1 Air duct2 Fan3 Main heat exchanger4 Temperature sensor (

9GENERAL REQUIREMENTSEnsure that ALL regulationsare observed.Fig. R.1Euro B/S 006/0_GBRelated DocumentsThe installation of the boiler must bein accord