turbomax plus and thermocompact

Transcription

1 Fr the installer Instructins fr Installatin and Servicing turbmax plus and thermompat Wall hung rm sealed fan assisted cmbinatin and system bilers 84/ E 88/ E 837 E 65/ E 60/ E 64/ E 68/ E 637 E GB

2 Table f ntents Page List f ntents ntents included with biler (turbmax plus) 4. ntents included with biler (thermompat) 4 Intrductin General Infrmatin General ntes E designatin Biler Specificatin Technical data Biler cnnectins (turbmax plus) Biler cnnectins (thermompat) Functinal diagram (turbmax plus) Functinal diagram (thermompat) General Requirements Related dcuments Biler lcatin Gas supply Flue system Tp utlet flue system Rear utlet flue system Extended tp utlet flue system Flue terminatin Air supply upbard r cmpartment ventilatin Electrical supply Guide t system requirements Water circulatin system Filling and make up Pressure relief valve Pressure gauge Expansin vessel irculating pump System by-pass Venting Biler Installatin Sequence General Using biler template Fitting the biler hanging bracket Install the flue system Fitting the biler Remving biler casing Gas supply (turbmax plus) ld water mains inlet and ht water utlet (turbmax plus) entral heating flw and return pipewrk (turbmax plus) Gas supply (thermompat) entral heating flw and return pipewrk (thermompat) nnectin t a Vantage unvented cylinder. (thermompat) Page 5.3 nnect the flue system t the biler Electrical installatin nnectin t the main supply Electrnic bard layut ntrls (turbmax plus biler) ntrls (thermompat biler) Thermstatic radiatr valves Frst prtectin irculating pump Anti-cycling ecnmiser cntrl mmissining Part I Preliminary electrical checks Gas supply ld water supply (turbmax plus nly) Filling the heating system (turbmax plus) Filling the heating system (thermompat) Initial system flush ("cld ) Gas supply adjustments (mmissining Part II) 6 7. Gas inlet wrking pressure Main burner pressure Adjusting the central heating utput (range rating) Adjusting t the maximum heat lad (nminal lad) Adjusting the ignitin rate hecking and adjusting t the perating pint (turbmax plus 837E and thermompat 637E nly) Setting r adjusting the mid-setting pint Fit cmbustin chamber cver Fit biler casing Functinal checks (mmissining Part III) Functinal checks Functinal check f peratin (turbmax plus nly) Functinal check f peratin (thermompat nly) Adjusting pump speed Handing ver t the user Servicing Initial inspectin leaning the burner and primary heat exchanger Instructins fr Installatin and Servicing turbmax plus and thermompat R

3 Table f ntents Page 0 Fault Finding Intrductin Indicatr lights (turbmax plus nly) Indicatr lights (thermompat nly) Lgical fault finding prcedure Status Mdes Diagnstic Mde Fault cdes Fault memry Fault finding charts Diagrams Functinal flw diagrams Wiring diagrams Instructins fr Installatin and Servicing turbmax plus and thermompat R 3

4 0 I VR-V 0 I VR-V List f cntents List f cntents. ntents included with biler (turbmax plus) Ensure that all cntents are included befre cmmencing installatin. Nte! DO NOT remve the biler frm the plystrene base at this stage.. ntents included with biler (thermompat) Ensure that all cntents are included befre cmmencing installatin. Nte! DO NOT remve the biler frm the plystrene base at this stage Fig..: Items supplied with unit (turbmax plus) Fig..: Items supplied with unit (thermompat) Item Quantity Descriptin Item Quantity Descriptin Biler Flue restrictin ring 3 ntrls cver dr 4 Lwer cver plate (packed in bttm packaging) 5 ld water inlet valve 6 3 Flw and return service value, gas service valve 7 5 pper tails fr gas and water pipewrk 8 Template 9 Guarantee ard and Benchmark lg bk 0 Installatin and cnnectin accessries and PRV packages incl. DHW utlet unin nut 3 Installatin and Servicing, Users and Flue Installatin Instructins Hanging bracket Biler Flue restrictin ring 3 ntrls cver dr 4 Lwer cver plate (packed in bttm packaging) 5 3 Flw and return service value, gas service valve 6 3 pper tails fr gas and water pipewrk 7 Template 8 Guarantee ard and Benchmark lg bk 9 Installatin and cnnectin accessries and PRV packages 0 3 Installatin and Servicing, Users and Flue Installatin Instructins Hanging bracket 4 Instructins fr Installatin and Servicing turbmax plus and thermompat R

5 Intrductin Intrductin. General Infrmatin Nte! This biler must be installed and serviced by a cmpetent persn in accrdance with the Gas Safety (Installatin and Use) Regulatins 998. In the UK "ORGI registered installers undertake the wrk t a safe and satisfactry standard. turbmax plus biler The turbmax plus is a fully autmatic, wall munted, rm sealed cmbinatin biler fr central heating and dmestic ht water. Dmestic ht water is supplied directly frm the biler, withut requiring a cpper cylinder, cld water tank, feed and expansin tank and assciated pipewrk. Dmestic ht water has pririty ver central heating. The turbmax plus range cnsists f mdels with utputs fr dmestic ht water f 4 kw, 8 kw and 37 kw. All turbmax plus bilers are available in Natural Gas. The 4 and 8 kw versins are als available in LPG. turbmax plus cmbinatin bilers incrprate a warmstart facility that keeps the dmestic ht water heat exchanger ht, prviding an instantaneus delivery f dmestic ht water. The temperature in the dmestic ht water heat exchanger is limited by the biler cntrl system and it is nt necessary t install a scale reducer n the cld mains t the biler. Hwever, in exceptinally hard water areas t prevent scale frmatin in the prperty ht water system pipewrk, a scale reducer may be fitted. The heating system can be filled using the built-in filling lp cntained within the biler. thermompat biler The thermompat is a fully autmatic, wall munted, rm sealed system biler fr central heating and dmestic ht water (where a separate indirect ht water strage cylinder is als incrprated in the system). The thermompat range cnsists f mdels with utputs f 5, 0, 4, 8 kw and 37 kw. All thermompat bilers are available in Natural Gas. The 0 and 8 kw versins are als available in LPG. systems are available, the standard cncentric flue system (00 mm utside diameter) and a larger diameter cncentric flue system (5 mm utside diameter) which allws lnger flue lengths t be achieved. Flue extensins and additinal bends and elbws are available fr bth flue systems t increase the siting flexibility. There is als a 00 mm diameter cncentric flue accessry which cnnects t the alternative rear flue utlet n the biler fr direct thrugh the wall installatins. The bilers are nt suitable fr external installatin. If desired, an inhibitr may be used in the system. Guidance n the use f inhibitrs is cntained in these instructins. All bilers have a built in diagnstic system which indicates the peratinal status f the biler. This feature prvides key infrmatin t aid cmmissining and fault finding. The data badge is fitted n the rear f the cntrl panel. See text f General Requirements fr installatin requirements r ntes. Vaillant Ltd. supprt the Benchmark initiative. Within the infrmatin pack, yu will find a Benchmark Lg Bk. It is very imprtant that this is cmpleted crrectly at the time f installatin, cmmissining and handver t the user..3 E designatin turbmax plus (84/88/837) and thermompat bilers (65/60/64/68/637) carry the "E" Mark. This demnstrates that the bilers fulfil the essential requirements f the Gas Appliance Directive(90/396/EE) and the Gas Appliance (Safety) Regulatins 99. The "E" Mark als demnstrates that the bilers cmply with the requirements f the Electrmagnetic mpatibility Directive (89/336/EE), the Lw Vltage Directive (7/3/EE), the Biler Efficiency Directive (9/4/EE) and the Biler (Efficiency) Regulatins General Ntes The bilers have been designed fr use with a sealed central heating system, and cme fully tested and assembled with a built in circulating pump, expansin vessel and diverter valve (turbmax plus nly). The bilers are nt suitable fr use n pen vented systems. The bilers are easily sited n any internal wall and can be installed with either a hrizntal r vertical RSF (rm sealed fan assisted) flue. Tw types f flue Instructins fr Installatin and Servicing turbmax plus and thermompat R 5

6 3 Biler Specificatin 3 Biler Specificatin 3. Technical Data turbmax plus turbmax plus turbmax plus 84/ E 88/ E 837 E Units (VUW GB 4/-5) (VUW GB 8/-5) (VUW GB 36/-5) Maximum H heat input (net) 6.7 (9,00) 3. (06,00) 3. (06,00) kw (Btu/h) H heat utput range (80/60 ) * (36,.9) (30,400-8,900) (35,500-95,500) (37,00-95,500) kw (Btu/h) Maximum DHW heat input (net) 6.7 (9,00) 3. (06,00) 40.5 (38,300) kw (Btu/h) SEDBUK Band D D D SAP Seasnal Efficiency % DHW heat utput kw DHW flw rate T = 35 rise l/min DHW flw rate at factry set temperature rise ( T 4 ) l/min Mains water pressure required fr max. flw rate bar Minimum water flw rate l/min Mains water pressure required fr min. flw rate bar Maximum inlet water pressure bar Inlet gas wrking pressure required (natural gas) mbar Gas supply (G0) Grss V (s.t.) MJ/m 3 Gas burner pressure max. rate mbar Gas burner pressure ignitin rate.9.8. mbar Gas rate max. (DHW) m 3 /h H temperature flw range Minimum H water flw (fr 0 rise) ** l/h Pump pressure available 0.5 (5) 0.5 (5) 0.5 (5) bar (KPa) Expansin vessel pre-charge pressure bar Maximum H system pressure bar Weight kg Primary water cntent.0.0. l Electrical supply 30/50 30/50 30/50 V~/Hz External fuse A Pwer input W ase height mm ase width mm ase depth mm * factry setting; ** at factry setting 6 Instructins fr Installatin and Servicing turbmax plus and thermompat R

7 Biler Specificatin 3 thermompat thermompat thermompat thermompat thermompat 65/ E 60/ E 64/ E 68/ E 637 E Units (VU GB 5/-5) (VU GB 0/-5) (VU GB 4/-5) (VU GB 8/-5) (VU GB 36-5) Maximum H heat input kw (net) (56,00) (74,800) (9,00) (06,00) (38,300) (Btu/h) H heat utput range kw (80/60 ) (,300-5,00) (6,300-68,300) (30,400-8,900) (35,500-95,500) (35,800-6,000) (Btu/h) SEDBUK Band D D D D D SAP Seasnal Efficiency % Inlet gas wrking pressure required (natural gas) mbar Gas supply (G0) MJ/m 3 Grss V (s.t.) Gas burner pressure mbar max. rate Gas burner pressure mbar ignitin rate H temperature flw range Minimum H water flw (fr 0 rise) l/h Pump pressure available 0.5 (5) 0.5 (5) 0.5 (5) 0.5 (5) 0.7 (7) bar (KPa) Expansin vessel pre-charge pressure bar Maximum H bar system pressure Weight kg Primary water cntent l Electrical supply 30/50 30/50 30/50 30/50 30/50 V~/Hz External fuse A Pwer input W ase height mm ase width mm ase depth mm Instructins fr Installatin and Servicing turbmax plus and thermompat R 7

8 3 Biler Specificatin 3. Biler cnnectins (turbmax plus) Key: Heating system return ( mm tail) Gas cnnectin (5 mm tail) 3 Heating system flw ( mm tail, mm fr 637) 4 Flue utlet (00 mm flue with turret) 5 Hanging bracket 6 Rear flue utlet 3.4 Functinal Diagram (turbmax plus) u 8 Fig. 3.: nnectin diameters turbmax plus Key: Heating system return ( mm tail) ld water cnnectin with shut ff valve (5 mm tail) 3 Gas cnnectin (5 mm tail, mm fr 837) 4 Ht water cnnectin (5 mm tail) 5 Heating system flw ( mm tail) 6 Flue utlet (00 mm flue with turret) 7 Hanging bracket 8 Rear flue utlet 3.3 Biler cnnectins (thermompat) i Fig. 3.: nnectin diameters thermompat Fig. 3.3: Functinal Diagram turbmax plus Key: Air duct Fan 3 Main heat exchanger 4 Temperature sensr (NT I) 5 Flame sensing electrdes 6 Mdulating burner 7 Fully mdulating autmatic gas value 8 Maximum ht water temperature cntrl 9 Maximum radiatr temperature cntrl 0 Diverter valve DHW heat exchanger Autmatic bypass valve 3 H flw service valve 4 Ht water utlet 5 Gas service valve 6 ld water service valve 7 H return service valve 8 Pressure relief valve 9 Aqua sensr (DHW flw switch) 0 Temperature sensr (NT III) Main n/ff cntrl 8 Instructins fr Installatin and Servicing turbmax plus and thermompat R

9 Biler Specificatin 3 Pressure gauge 3 Display 4 Expansin vessel 5 Expansin vessel charging valve 6 irculating pump 7 Autmatic air vent 8 Ignitin electrde 9 Temperature sensr (NT II) 30 Air pressure switch 3 Flue gas duct 9 Expansin vessel charging valve 0 irculating pump Autmatic air vent Ignitin electrde 3 Temperature sensr (NT II) 4 Air pressure switch 5 Flue gas duct 3.5 Functinal Diagram (thermompat) Fig. 3.4: Functinal Diagram thermompat Key: Air duct Fan 3 Main heat exchanger 4 Temperature sensr (NT I) 5 Flame sensing electrdes 6 Mdulating burner 7 Fully mdulating autmatic gas value 8 This cntrl has n functin n this biler 9 Maximum radiatr temperature cntrl 0 Autmatic bypass valve H flw service valve Gas service valve 3 H return service valve 4 Pressure relief valve 5 Main n/ff cntrl 6 Pressure gauge 7 Display 8 Expansin vessel Instructins fr Installatin and Servicing turbmax plus and thermompat R 9

10 4 General Requirements 4 General Requirements 4. Related Dcuments The installatin f the biler must be in accrdance with the relevant requirements f Gas Safety (Installatin and Use) Regulatins 998, Health and Safety Dcument N. 635 (The Electricity at Wrk Regulatins 989), BS767 (IEE Wiring Regulatins) and the Water Supply (Water Fittings) Regulatins 999, r the Water Bylaws 000 (Sctland). It shuld als be in accrdance with the relevant requirements f the Lcal Authrity, Building Regulatins, Building Regulatins (Sctland), Building Regulatins (Nrthern Ireland) and the relevant recmmendatins f the fllwing British Standard; Including current amendments t Apprved Dcuments Part L and J.: BS 5440: Flues and ventilatin f gas fired bilers nt exceeding 70 kw net: - Part : Flues - Part : Ventilatin BS 5449: Specificatin fr frced circulatin ht water fr dmestic premises. BS 5546: Specificatin fr gas ht water supplies fr dmestic premises. BS 6700: Services supplying water fr dmestic use within buildings and their curtilages. BS 6798: Specificatin fr installatin f gas fired bilers nt exceeding 70 kw input net. BS 689: Specificatin fr installatin f lw pressure gas pipewrk up t 8 mm (R) in dmestic premises ( nd family gas). BS 7593: Treatment f water in dmestic ht water central heating systems.institute f Gas Engineers Publicatin IGE/UP/7/998: Guide fr Installatin in Timber Framed Husing. Benchmark de f Practice. Building Regulatins Apprved Dcuments Part L 00 Part J 00. Imprtant! The appliance must be installed and serviced by a cmpetent persn as stated in the Gas Safety (Installatin and Use) Regulatins 998. In IE, the installatin must be in accrdance with the current editin f IS 83 'Dmestic Gas Installatins', the current Building Regulatins and reference shuld be made t the current ETI rules fr electrical installatin. Preliminary remarks This appliance shuld nly be installed in cnjunctin with a Vaillant flue system. Install the flue system as detailed in the separate flue installatin instructins supplied with this biler. 4. Biler lcatin The lcatin chsen fr the biler must permit the prvisin f a satisfactry flue terminatin. The lcatin must als prvide adequate space fr servicing and air circulatin arund the biler. The biler may be installed in any rm, althugh particular attentin is drawn t the requirements f BS767 (IEE Regulatins), the electrical prvisins f the Building Regulatins (Sctland) and in IE the current editin f IS 83 and the current ETI rules, in respect f the installatin f a biler in a rm cntaining a bath r shwer. Nte! Where a rm sealed biler is installed in a rm cntaining a bath r shwer, any electrical switch r biler cntrl utilising mains electricity shuld be s situated that it cannt be tuched by a persn using the bath r shwer. Where the installatin f the biler will be in an unusual lcatin, special prcedures may be necessary and BS 5546 and BS 6798 give detailed guidance n this aspect. The biler must be munted n a flat, vertical wall, which must be sufficiently rbust t take the weight f the biler. The biler may be installed n a cmbustible wall, subject t the requirements f the Lcal Authrities and Building Regulatins. A cmpartment used t enclse the biler must be designed and cnstructed specifically fr this purpse. (An existing cupbard r cmpartment may be used prvided that it is mdified fr the purpse). Details f essential features f cupbard/cmpartment design including airing cupbard installatins are given in BS 689. In IE the current editin f IS 83. If the biler is t be fitted in a timber framed building, it shuld be fitted in accrdance with Institute f Gas Engineers Publicatin IGE/UP/7/998 "Guide fr Gas Installatin in Timber Framed Husing. 4.3 Gas Supply The gas supplier shuld ensure the availability f an adequate supply f gas. A gas meter may nly be cnnected t the service pipe by the supplier f gas r their cntractr. An existing meter shuld be checked t ensure that it is capable f passing the rate f gas supply required. Installatin pipes shuld be fitted in accrdance with BS 689. Pipewrk frm the meter t the biler must be f an adequate size. D nt use pipes f a smaller size than the biler gas cnnectin (5 mm, mm fr 837/637). The cmplete installatin must be tested fr sundness and purged as described in BS Instructins fr Installatin and Servicing turbmax plus and thermompat R

11 General Requirements Flue system Nte! The bilers are delivered ready fr installatin utilising a tp utlet flue assembly. Fr installatin with a rear utlet flue assembly refer t the biler flue utlet adaptatin in the flue instructins Tp utlet flue system (00 mm utside diameter) The tp utlet hrizntal flue system (Art. N ) is suitable fr installatins up t 70 mm measured frm the centre f the biler flue utlet t the utside face f the wall. Flue extensins are available t extend this length up t 5.3 m fr 5/0 kw; 4.5 m fr 4 kw and 3. m fr 8/37 kw. Bth 90 bends and 45 elbws are als available t increase siting flexibility. A vertical flue system is als available (Art. N ). Refer t flue system installatin instructins fr full details Rear utlet flue system (00 mm utside diameter) The rear utlet hrizntal flue system (Art. N ) is suitable fr installatins up t 600 mm wall thickness. Fig. 4.3: Art.-N Extended tp utlet flue system (5 mm utside diameter) A tp utlet hrizntal flue system f 5 mm utside diameter is als available (Art. N ) and can be used t achieve flue lengths f up t.9 m fr 5/0/4 kw; 0 m fr 8/37 kw. Bth 45 and 90 bends and elbws are als available t increase siting flexibility. A vertical 5 mm cncentric flue system is als available (Art. N ). Refer t flue system installatin instructins fr full details. Fig. 4.: Art.-N A vertical flue system is als available (Art. N ). Refer t flue system installatin instructins fr full details Fig. 4.4: Art.-N Fig. 4.: Art.-N Instructins fr Installatin and Servicing turbmax plus and thermompat R

12 4 General Requirements Flue terminatin The fllwing details refer t bth flue systems. a. The terminal must be psitined such that the prducts f cmbustin can disperse freely at all times. b. In certain weather cnditins a plume f water vapur may be visible frm the flue terminal. Psitins where this culd be a nuisance shuld be avided. c. If the terminal is fitted less than m abve a balcny, abve grund r abve a flat rf t which peple have access then a suitable terminal guard; must be prvided and fitted (Mdel K3 - made by Twer Flue mpnents, Tnbridge, TN9 TB). Nte! Vertical flues must nt terminate within 600 mm f an penable windw, air vent r any ther ventilatin pening. The flue assembly shall be s placed r shielded as t prevent ignitin r damage t any part f the building. A ) Terminal psitin fr fan-assisted flue (minimum distance) Directly belw an penable, abve an pening r hrizntal t an pening i.e. air brick, pening mm windw r ther, etc 300 B Belw gutters, sil pipes r drain pipes 5 Belw eaves 5 D Belw balcnies (belw car prt rf) 5 E Frm vertical drain pipes and sil pipes 5 F Frm internal r external crners 5 G Abve grund r balcny level 300 H Frm a surface r bundary facing a terminal 600* H Frm a terminal facing a terminal 00 J Frm an pening in a car prt (e.g. dr, windw) int a dweling 00 K Vertically frm a terminal n the same wall 500 L Hrizntally frm a terminal n the same wall 300 M Distance frm adjacent wall fr vertical Flue 500 H, I A G F J E Fig. 4.5: Flue terminatin A A G A BD F F B F M G L K L K ) In additin, the terminal shuld nt be nearer than 50mm t an pening in the building fabric frmed fr the purpse f accmmdating a built-in element such as a windw. * BS It is recmmended that a fanned flue terminal shuld be psitined as fllws: a) at least m frm an pening in a building directly ppsite, and b) s that the prducts f cmbustin are nt directed t discharge acrss a bundary. 4.5 Air supply Detailed recmmendatins fr air supply are given in BS 5440: Part. It is nt necessary t have an air vent in the rm r internal space in which the biler is installed. 4.6 upbard r cmpartment ventilatin The bilers are very high efficiency appliances. As a cnsequence the heat lss frm the appliance casing during peratin is very lw. Fr cupbard r cmpartment installatins it is therefre nt necessary t prvide any high r lw level permanent air vents fr cling purpses. 4.7 Electrical supply A 30 V, ~ 50 Hz single phase electricity supply fused t 3 Amp. must be prvided in accrdance with the latest editin f BS767 (IEE Wiring Regulatins) and any ther lcal regulatins that may apply. In IE, reference shuld be made t the current editin f the ETI rules. The methd f cnnectin t the mains electricity supply must prvide a means f cmpletely islating the biler and its ancillary cntrls. Islatin is preferably by the use f a fused three pin plug and unswitched shuttered scket utlet, bth cmplying with the Instructins fr Installatin and Servicing turbmax plus and thermompat R

13 General Requirements 4 requirements f BS 363. Alternatively, a 3 Amp. fused dubleple switch with a 3 mm cntact separatin n bth ples may be used. Imprtant! This appliance must be earthed. 4.8 Guide t system requirements 4.8. Water circulatin system Detailed recmmendatins fr the water circulatin system are given in BS 6798 and BS 5449: Part (fr small bre and micr bre central heating systems). Pipewrk nt frming part f the useful heating surface shuld be insulated t help prevent heat lss and pssible freezing, particularly where pipes are run thrugh rf spaces and ventilated underflr spaces. Draining taps must be lcated in accessible psitins which permit the draining f the whle system including the biler and the ht water system. Draining taps shuld be at least / in. BSP nminal size and be in accrdance with BS 879. The biler is suitable fr use with minibre r micrbre systems. pper tubing t BS 87: Part shuld be used fr water carrying pipewrk. All capillary jints in all DHW pipewrk must be made with lead free slder. Particularly where a new biler is t be fitted t an existing system, it is gd practice that the system is thrughly cleansed. This cleansing shuld take place prir t the fitting f the new biler and be in accrdance with BS Fr advice n the applicatin f system cleansers cntact either Sentinel, GE Betz. Widnes, heshire, WA8 8UD. Tel: r: Fernx Alpha-Fry Technlgies Tandem Huse Marlw Way, Beddingtn Farm Rad rydn RO 4xS Tel Fernx technical help line (Alternative methds f filling sealed systems are given in BS 5449) Pressure relief valve A pressure relief valve is prvided with the biler. This safety device is required n all sealed.h. systems and is preset at 3 bar and prvided with a 5 mm cmpressin cnnectin fr a discharge pipe, which must be f n less than 5 mm in diameter. The Pressure Relief Valve must nt be used fr draining purpses Pressure gauge This is factry fitted t the biler and indicates the primary circuit pressure t facilitate filling and testing Expansin vessel The 5 and 0 kw thermompat bilers as well as the 4 kw turbmax plus biler incrprate a 6 litre expansin vessel which is suitable fr a sealed heating system with a maximum water cntent f 60 litres. A 0 litre expansin vessel kit is available as an ptinal accessry fr fr the turbmax plus 4 kw biler and the 5 and 0 kw thermompat bilers. The 8, 37 turbmax plus and 4, 8, 37 kw thermompat bilers incrprate a 0 litre expansin vessel which is suitable fr a sealed heating system with a maximum water cntent f 00 litres. If the nminal capacity f the built in expansin vessel is nt sufficient fr the heating system (fr instance in case f mdernizatin f ld pen systems) an additinal expansin vessel can be installed external t the biler. It shuld be fitted in the return pipe as clse as pssible t the biler in accrdance with BS 5449: Part. Guidance n the sizing f an additinal expansin vessel is given in Table n page Filling and make up The system can be filled using the built in filling lp (turbmax plus nly) r via a separate filling pint fitted at a cnvinient psitin n the heating circuit (thermompat). The cnnectin must be remved when filling is cmpleted. Where lcal Water Authrity regulatin des nt allw temprary cnnectin, a sealed system filler pump with break tank must be used. The heating system will nt be filled autmatically frm the dmestic ht water side. Instructins fr Installatin and Servicing turbmax plus and thermompat R 3

14 4 General Requirements Vessel Vlume [L] Initial system pressure (bar).0.5 Pressure relief valve setting (bar) 3.0 Ttal water cntent f system ltres Lift [mbar] Pump switch in psitin III (pre-delivery setting) Pump switch in psitin II Fig. 4.6: Pump specificatins 37 kw Vlume flw [l/min] System by-pass An autmatic system by-pass is included within the biler. The biler is suitable fr use in systems with thermstatic radiatr valves and n additinal by-pass is required Venting The biler is fitted with an autmatic air vent. Additinal prvisin shuld be made t enable the heating system t be vented during filling and cmmissining either by autmatic air vents r manually Fr system vlumes ther than thse given abve, multiply the system vlume by the factr acrss irculating pump The circulating pump is included in the biler. The pump head available fr the heating system is shwn in fig Lift [mbar] Pump switch in psitin III (Factry setting) Pump switch in psitin II Fig. 4.6: Pump specificatins -8 kw Vlume flw [l/hr] 4 Instructins fr Installatin and Servicing turbmax plus and thermompat R

15 Biler Installatin Sequence 5 5 Biler Installatin Sequence 5. General Preparatin f biler lcatin learances required Munt the biler n a flat and vertical area f wall f sufficient area fr the biler plus the required clearances fr installatin and servicing. The clearances are as detailed belw and are shwn n the installatin template supplied with the biler: - 50 mm belw the biler - 5 mm n either side f the biler - 0 mm n tp f the biler mm in frnt f the biler* * learance is nly required t enable easier access t the biler fr servicing and may be prvided by an penable dr, etc. Selecting psitin f biler Refer t "Biler lcatin fr infrmatin regarding siting the appliance. In general the biler must be psitined such that. There is adequate space arund the biler fr service and maintenance. The biler can be crrectly flued, i.e. the flue terminal psitin is sited in accrdance with the flue terminatin sectin and the air/flue duct can be installed in accrdance with the flue installatin instructins supplied. All necessary pipewrk can be cnnected, including the pressure relief valve. Nte! Shuld it be necessary t run system pipewrk t abve the biler within the width f the casing, use the ptinal tp cnnectin accessry (Art.N ). Nte! If the biler is t be fitted in a timber framed building, it shuld be fitted in accrdance with Institute f Gas Engineers Publicatin IGE/UP/7/998 "Guide fr Gas Installatins in Timber Framed Dwellings. ; y ; y ; y ; y Fig. 5.: Dimensins f biler 338 Fig. 5.: Free space required fr installatin Instructins fr Installatin and Servicing turbmax plus and thermompat R 5

16 5 Biler Installatin Sequence 5. Using biler template Fix the paper template t the wall ensuring that the crrect flue exit pint has been identified, ensure that the template is vertical. The template shws - The psitin f the fixing hles fr the biler munting bracket (). - The psitin f the cnnectins. - The psitin f the flue exit hle. - Upper hle () indicates tp utlet flue with flue turret facing rearward. - Lwer hle (3) indicates rear utlet flue exiting directly thrugh wall. Mark the psitin f the hanging bracket fixing hles (). Drill hles Ø 8 mm fr the hanging bracket. Nte! Use alternative fixing hles where necessary. Identify crrect flue exit Mark the centre f the selected air/flue duct and its circumference, e.g. by drilling thrugh the template. Fr installatin f a rear exit utlet please refer t the installatin instructins f the rear exit utlet kit (Art. N ). Other flue ptins Flue instructins fr ther flue systems such as vertical RSF flues, flues run t the side f the biler and the use f additinal bends etc. are detailed in the flue installatin instructins prvided with the biler. Remve the template frm the wall and plug the drilled hles using the wallplugs supplied. 5.3 Fitting the biler hanging bracket Fix the hanging bracket () t the wall using the screws supplied (). (it may be necessary t use additinal r alternative fixings t ensure adequate supprt) / , ,5 3 Fig. 5.4: Free space required fr installatin Nte! If the biler is t be fitted in a timber framed building ensure that the bracket is secured t a substantial part f the timber frame capable f taking the weight f the biler. turbmax nly 07/00 00/0/40/4/80/8/84/88 Pr/Plus 463 Fig. 5.3: Using Biler template 6 Instructins fr Installatin and Servicing turbmax plus and thermompat R

17 VR-V I 0 Biler Installatin Sequence Install the flue system Fit the flue restrictr t the biler (if required) and install the flue system (refer t separate air/flue duct installatin instructins fr further infrmatin). 5.5 Fitting the biler Lift the biler (3) up t the wall s that it is slightly abve the hanging bracket (). Nte! Lift the biler frm either side at the bttm edge. 5.7 Gas supply (turbmax plus) nnect the 5 mm cmpressin gas service cck () and 5 mm cpper utlet tail (mm cpper tail with 837) (3) as supplied with the appliance () and tighten. nnect a gas supply pipe f nt less than 5 mm diameter t the cpper tail (minimum mm gas supply pipe with 837). Tighten all cnnectins. (Ensure the gas supply pipewrk is adequately sized such that a 0 mbar gas pressure is available at the biler inlet at full flw rate). Lwer the biler slwly nt the hanging bracket s that the crss member at the rear f the biler fully engages nt the hanging bracket. 5.6 Remving biler casing Turn bth securing fasteners () anti-clckwise by 90 t release cntrl panel (). Pull the case (3) frward at the bttm t disengage frm the securing clips. Lift the case slightly t clear the tp lcatins and pull frward t remve. I I 0 3 Fig. 5.6: Fitting the gas cnnectin turbmax plus Fig. 5.5: Remve f biler casing 3 Instructins fr Installatin and Servicing turbmax plus and thermompat R 7

18 5 Biler Installatin Sequence 5.8 ld water mains inlet and ht water utlet (turbmax plus) Flush all freign matter frm the mains supply befre cnnecting t the biler. nnect the cld water service valve () t the cld inlet water cnnectin (3) f the appliance with the washer () prvided and tighten. nnect the 5 mm cld water inlet pipe cpper tail (4) t the cld water service valve () and tighten. nnect the 5 mm ht water utlet cpper tail (6) t the ht water utlet cnnectin f the appliance (8) with the washer prvided (7) and tighten. Nte! The ht water utlet unin nut is packed in with the PRV fitting pack. nnect the cld water service pipe and ht water utlet pipewrk t the cpper tails. I entral heating flw and return pipewrk (turbmax plus) Befre cnnecting the heating circuit t the biler appliance, all pipewrk and radiatrs must be thrughly flushed t remve any installatin debris. nnect the central heating flw (6) and return () service valves t the appliance (8 and 3) with the washers prvided ( and 7) and tighten the nuts. Ensure that the valve spindles face dwnwards and the drain pints face t either side f the biler. nnect the mm cpper pipe tails t the service valves as shwn in the illustratin and tighten the nuts. nnect the central heating pipewrk t the flw (9) and return (4) tails. Pressure Relief Valve nnect a discharge pipe nt less than 5 mm diameter t the utlet f this valve. The discharge pipewrk shuld be as shrt as pssible and installed with a cntinuus fall away frm the biler. The pipe shuld terminate in a psitin which ensures that any discharge f water r steam frm the valve cannt create a hazard t persns in r abut the premises, r cause damage t any electrical cmpnents r external wiring, and the pint f discharge shuld be clearly visible (see diagram in plastic bag). 4 I Fig. 5.7: Fitting the ht and cld water cnnectins turbmax plus Fig. 5.8: entral heating flw and return pipewrk turbmax plus 8 Instructins fr Installatin and Servicing turbmax plus and thermompat R

19 Biler Installatin Sequence Gas supply (thermompat) nnect the 5 mm cmpressin gas service cck () and 5 mm cpper utlet tail ( mm cpper tail with 637) (3) as supplied with the appliance and tighten. nnect a gas supply pipe f nt less than 5 mm diameter t the cpper tail (minimum mm with 637). Tighten all cnnectins. (Ensure the gas supply pipewrk is adequately sized such that a 0 mbar gas pressure is available at the biler inlet at full flw rate). 5. entral heating flw and return pipewrk (thermompat) Befre cnnecting the heating circuit t the biler appliance, all pipewrk and radiatrs must be thrughly flushed t remve any installatin debris. nnect the central heating flw (6) and return () service valves t the appliance (8 and 3), with the washers ( and 7) prvided and tighten the nuts. Ensure that the valve spindles face dwnwards and the drain pints face t either side f the biler. nnect the mm cpper pipe tails t the service valves as shwn in the illustratin and tighten the nuts. nnect the central heating pipewrk t the flw (9) and return (4) tails. 3 I 0 Pressure Relief Valve nnect a discharge pipe nt less than 5 mm diameter t the utlet f this valve. The discharge pipewrk shuld be as shrt as pssible and installed with a cntinuus fall away frm the biler. The pipe shuld terminate in a psitin which ensures that any discharge f water r steam frm the valve cannt create a hazard t persns in r abut the premises, r cause damage t any electrical cmpnents r external wiring, and the pint f discharge shuld be clearly visible (see diagram in plastic bag). I 0 Fig. 5.9: Fitting the gas cnnectin thermompat Fig. 5.0: entral heating flw and return pipewrk thermompat Instructins fr Installatin and Servicing turbmax plus and thermompat R 9

20 5 Biler Installatin Sequence 5. nnectin t a VANTAGE unvented cylinder (thermompat) Fr cnnecting a Vaillant VANTAGE unvented cylinder please refer t the VANTAGE installatin instructins prvided with the cylinder nnect the flue system t the biler Refer t separate air/flue duct installatin instructins included with the biler. 5.4 Electrical installatin General requirements Imprtant! All electrical wrk shall be carried ut by a cmpetent persn and shall cmply with BS767 (IEE Regulatins). The biler is supplied fr cnnectin t 30 V, ~ 50 Hz supply fused at 3 A rating. nnectin t the mains supply shall be made via a fused 3 pin plug t an unswitched shuttered scket, bth cmplying t the requirements f BS363. (Alternatively, cnnectin may be made via a 3 A fused duble ple islatr having a cntact separatin f at least 3 mm in all ples and supplying the biler and cntrls nly). The pint f cnnectin t the mains supply must allw cmplete electrical islatin f the biler and its ancillary cntrls. It shuld be readily accessible and adjacent t the biler. A 3 cre flexible crd accrding t BS6500 tables 6, 8 r 6 (3 x 0.75 t 3 x.5 mm ) shuld be used. Warning! This appliance must be earthed. Fig. 5.: Wiring system L N RT 4V 30V RT 30V Imprtant! Ensure that all crds pass thrugh the cable clamps in the rear f the cntrl bx and are securely fixed. Ensure that the pwer supply is cnnected such that the current carrying cnductrs becme taut befre the earth cnductr shuld the supply crd slip frm the cable clamp. Warning! Mains cnnectin terminals L and N remain live even when the biler n/ff cntrl is switched ff. 5.5 nnectin t the main supply Lwer the cntrl panel. Unclip the terminal bx cver () frm the cntrl panel. Feed the pwer supply crd in t the appliance as shwn (fig 5.). Use cable clamps. Fig. 5.: Expsed rear view f switchgear cabinet (picture shws turbmax appliance) nnect the pwer supply crd as fllws (Fig. 5.3). Green/yellw (earth) wire: biler terminal Earth sign Blue (neutral) wire: biler terminal N Brwn (live) wire: biler terminal L Nte! DO NOT use biler terminal cnnectins Refit the terminal bx cver by pushing int place until it clips back int psitin. Raise the cntrl panel and secure in place. 0 Instructins fr Installatin and Servicing turbmax plus and thermompat R

21 Biler Installatin Sequence Electrnic bard layut Scket X fr internal unit cmpnents Scket X4 fr diverter valve Scket X7 fr accessry bx cnnectin Scket X8 fr VR-V cnnectin Scket fr fan cntrl cable (637 and 837 nly) F3 4V 30V D nt use! L N Mains pwer supply: cnnectins L, N and earth Rm thermstat, 30 V: cnnectins 3, 4 and 5 Scket X: pump cnnectin Scket X4: gas valve cnnectin Scket X3: fan cnnectin Abb. 0.0 Bildunterschrift F Fig. 5.3: nnectin wiring Instructins fr Installatin and Servicing turbmax plus and thermompat R

22 5 Biler Installatin Sequence 5.7 ntrls (turbmax plus biler) External electrical cntrls The biler terminals 3, 4 and 5 are fr cnnecting external electrical cntrls such as a time switch and/r rm thermstat. Terminals 3 and 4 are linked tgether when the biler is supplied. If external cntrls are used, this link must be remved and the cntrls cnnected acrss terminals 3 and 4. Terminal 5 is an additinal neutral cnnectin fr external neutrals such as frm the anticipatr f a rm thermstat. nnectin f external cntrls nnectin details fr prgrammable rm thermstats. Fig. 5.4 shws the cnnectin details where a prgrammable rm thermstat (time switch with built in rm thermstat) is used t cntrl the biler. Attentin! The arrwed numbers indicate cnnectin int the relevant terminal in the biler terminal strip. AL Draytn Lyfestyle PT7, PT37 AL Draytn Digistat, 3, 4 AL Draytn Digistat RF - SR Receiver Danfss Randall TP4, TP5, TP5E Danfss Randall TP5E RF with receiver RX Danfss Randall TP75 Grässlin Twerchrn RT7 Hneywell M6, M67, M3, M37 Hrstmann entaurstat, 7 Landis & Staefa REV, REV 5, REV Smiths Timeguard PrgramaSTAT PRT, PRT7 Sunvic TLX 650 Sunvic TLX RFP, TLX RFD Vaillant VRT 30, 0 L N 3 4 L N 3 4 Fig. 5.4 nnectin details fr prgrammable thermstats L N 3 L N L N 3 4 L N 3 4 A B A B L L 3 4 L N 3 4 L N L N 3 4 L N nnectin details fr external time switches and biler terminal strip. Fig. 5.5 shws the cnnectin details where a time switch is used withut a rm thermstat t cntrl the biler. Attentin! The arrwed numbers indicate cnnectin int the relevant terminal in the biler terminal strip. If a rm thermstat is t be cnnected in additin t a time switch the wire between the time switch "ON terminal and biler terminal 4 shuld be brken by the cntacts f the rm thermstat (see schematic layut, Fig. 5.6). Vaillant ptinal plug in timer accessries Refer t the instructins supplied with the ptinal accessries fr cnnectin details. Upn cmpletin f all electrical cnnectins refit the terminal bx cver by pushing int place. The cver is secured by tw lcking clips. AL Draytn Tempus, Tempus Lyfestyle LP, LP7 AL Draytn Switchmaster SM300 AL Draytn Switchmaster 980 Danfss Randall 03 Series Danfss Randall Set E, TS975 Danfss Randall TS75 Grässlin Twerchrn QE, QM Hneywell ST60A, ST600 Hrstmann hannel Plus H, H7, 45 rnet Hrstmann entaur Plus, 7 Landis & Staefa RWB7, RWB30 Pttertn Mysn EP 400, EP 500 Smiths Timeguard SupplyMASTER FST, FST7 Sunvic Select 07 L N 3 4 L N 3 4 L N 3 4 L N 4 3 L N A B L N E 4 3 L N L N E 3 4 L N E 4 3 L N 3 4 L N 3 4 L N 3 4 L N 3 4 L N 3 4 L N 3 4 L N E 3 4 L N E 4 3 L N E 3 4 L N E 3 4 L N 3 4 L N 3 4 N A B D L N L N 3 4 L N 3 4 Fig. 5.5 nnectin details fr time switch E L N E mains supply 4 3 /L /N L N E E 4 3 E Instructins fr Installatin and Servicing turbmax plus and thermompat R

23 Biler Installatin Sequence 5 DO NOT USE IN UK! MAINS SUPPLY 30 V 50 Hz N L 0 VD LN A FUSE SWITH ONTATS ROOM THERMOSTAT nnectin details fr cntrl systems utilising 3 prt mtrised valve via external wiring centre/junctin bx Diagram nly applies t the specific cntrls mentined 3 amp fused main supply THERMOcmpact terminal strip Prgrammer fr prgrammer cnnectins see fig. 6.b L N L N E N L X** Y** Z** L N L N E ** see key belw External wiring centre/junctin bx* N L N L *D nt use pre-wired printed circuit bard type nt used Fig. 5.6 L N LOK 5.8 ntrls (thermompat biler) External electrical cntrls The biler terminals 3, 4 and 5 are fr cnnecting external electrical cntrls such as a prgrammer, rm thermstat, etc. Terminals 3 and 4 are linked tgether when the biler is supplied. If external cntrls are used, this link must be remved, and the cntrls cnnected acrss terminals 3 and 4. Terminal 5 is an additinal neutral cnnectin fr external cntrls. nnectin f external electrical cntrls N ylinder thermstat AL Draytn HTS3 Danfss Randall AT Twer S Hneywell L64 Hrstmann HT Siemens-Landis & Staefa RAM Sunvic SA 45 Fig E 3 E YL BK RED E EARTH Key: X entral heating n Y Ht water n Z Ht water ff E BLUE BROWN OR WHITE Rm thermstat Vaillant VRT 9090 AL Draytn Digistat, 3, 4 AL Draytn RTS, Danfss Randall RX- Danfss Randall RMT 30 Danfss Randall RET 30 Twer SS Hneywell T6360 Hrstmann HRT Siemens-Landys & Staefa RAD Sunvic TLX 000 series GREY 3 Prt mid psitin mtrised valve 4 ORANGE L N E E A N N L L 3 B E E E E nnectin details using an external wiring centre The biler shuld be cnnected t the system cntrls using an external wiring centre. Fig. 5.7, 5.8 shws cnnectin details fr a system utilising a 3 prt mid psitin mtrised valve, figure 5.9, 5.0 shws the cnnectin details fr a system utilising tw prt mtrised valves cnnected via an external wiring centre (Imprtant: the arrwed numbers indicate cnnectin int the relevant terminal f thre external wiring centre). Lifestyle LP4, LP 5, LP 7 Tempus 6, Tempus 7 Danfss Randall P 75, FP75 Nte: *Earth nt required Danfss Randall Set E, Set 3E Nte: *Earth nt required, Link L N L nt used 7 6 E N L nt used 7 6 E N L 3 4 * nt used 7 6 E N L 3 4 * nt used Grässlin Twerchrn QE N L nt used 7 6 Hneywell ST699B, ST799A L N Nte: Link L Hneywell ST600, ST6300, ST6400 nt used N L 3 4 Hrstmann hannel Plus H, H7 Nte: *Earth nt required, Link L Siemens-Landis & Staefa RWB, RWB nt used 7 6 E N L 3 4 * N L nt used nt used Pttertn Mysn EP 00, EP 300, EP 600 Nte: Link L - 5 Sunvic Select 07 E N L nt used N L nt used 7 6 Fig. 5.8 Instructins fr Installatin and Servicing turbmax plus and thermompat R 3

24 5 Biler Installatin Sequence nnectin details fr cntrl systems utilising x prt mtrised valves via external wiring centre/junctin bx Diagram nly applies t the specific cntrls mentined 3 amp fused main supply THERMOcmpact terminal strip Prgrammer fr prgrammer cnnectins see fig. 6.d L N E L N N L X** Y** Z** L N L N ** see key belw External wiring centre/junctin bx* N L N L *D nt use pre-wired printed circuit bard type nt used ylinder thermstat 0 7 E Rm thermstat L N E E A AL Draytn HTS3 Vaillant VRT E 3 Danfss Randall AT AL Draytn Digistat, 3, 4 YL BK RED N 3 L Twer S AL Draytn RTS, 3 B Hneywell L64 Danfss Randall RX- 3 4 Hrstmann HT Danfss Randall RMT 30 3 E N 3 L Siemens-Landis & Staefa RAM Danfss Randall RET E Sunvic SA 45 Twer SS 3 Hneywell T E Hrstmann HRT E Siemens-Landys & Staefa RAD 4 3 E Sunvic TLX 000 series E EARTH BLUE BROWN GREY ORANGE Ht water prt mtrised valve 4 E EARTH BLUE BROWN GREY ORANGE entral heating prt mtrised valve Thermstatic radiatr valves The biler has a built in autmatic bypass valve making it ideal fr use in systems with thermstatic radiatr valves (n separate system bypass is required). Fr ptimum fuel ecnmy it is recmmended that where TRV s are used they are used in cnjunctin with a prgrammable rm thermstat r separate timer and rm thermstat t ensure cmplete biler shut dwn when the heating demand is satisfied. (The radiatr in the rm cntaining the rm thermstat shuld nt be fitted with a TRV). 5.0 Frst prtectin The biler has an integral frst thermstat which is designed fr prtectin f the biler.t prtect remte r expsed parts f the heating system r prperty additinal frst prtectin measures must be taken such as the installatin f an external frst thermstat. This frst thermstat shuld be cnnected acrss the biler terminals 3 and 4, in parallel with any external heating cntrls. External frst prtectin cannt be used when plug in timers have been fitted. Fig. 5.9 Key: X entral heating n Y Ht water n Z Ht water ff Lifestyle LP4, LP 5, LP 7 Tempus 6, Tempus 7 Danfss Randall P 75, FP75 Nte: *Earth nt required Danfss Randall Set E, Set 3E Nte: *Earth nt required, Link L Grässlin Twerchrn QE Hneywell ST699B, ST799A Nte: Link L Hneywell ST600, ST6300, ST6400 Hrstmann hannel Plus H, H7 Nte: *Earth nt required, Link L Siemens-Landis & Staefa RWB, RWB9 Pttertn Mysn EP 00, EP 300, EP 600 Nte: Link L - 5 Sunvic Select 07 N L nt used 3 nt used 7 6 E N L nt used 3 nt used 7 6 E N L 3 4 * 5 3 nt used nt used 7 6 E N L * nt used 6 nt used N L nt used 3 nt used 7 6 L N nt used 7 nt used N L nt used 3 nt used 7 6 E N L * nt used 6 nt used N L nt used 3 nt used 7 6 E N L nt used 5 3 nt used 7 6 N L 3 4 nt used 5 3 nt used irculating pump The biler incrprates a built in circulating pump that is fully prewired (n additinal wiring is necessary). The pump incrprates an autmatic verrun perid after the biler switches ff. 5. Anti-cycling ecnmiser cntrl The biler incrprates a built in anti-cycling cntrl t ensure that energy wasteful shrt cycling f the biler cannt ccur. This cntrl prevents the biler frm reigniting fr a preset perid f 5 minutes after central heating peratin (the ht water peratin is unaffected by this cntrl and ht water can be drawn at any time). Nte! T temprarily verride the anti-cycling cntrl turn the main biler n/ff switch t the ff psitin 0 and then back t the n psitin I after a few secnds. Autmatic pump spin cntrl (APS) The biler incrprates a built in cntrl which will spin the built in circulating pump and perate the diverter valve (turbmax nly) nce in a 4 hur perid. This cntrl helps t prevent seizure when the biler is nt perated fr a perid f time. This cntrl is nt active when the pwer supply t the appliance is turned ff. Fig Instructins fr Installatin and Servicing turbmax plus and thermompat R

25 mmissining Part I 6 6 mmisining Part I 6. Preliminary electrical checks heck the electrical installatin by carrying ut shrt circuit, earth cntinuity and resistance t earth tests and a check fr crrect plarity. 6. Gas supply The cmplete gas installatin including the gas meter must be inspected, tested fr sundness and purged in accrdance with BS 689. In IE the current editin f IS 83. The gas supply t the biler can be purged by slackening the gas service valve beneath the biler. Ensure that there is adequate ventilatin, extinguish all naked flames and d nt smke whilst purging. After purging, the gas service valve cnnectin must be retightened and tested fr sundness. (The biler itself des nt require purging as this will be dne by the autmatic burner sequence cntrl) ld water supply (turbmax plus nly) Open all dmestic ht water taps supplied by the biler, turn n the mains water supply t the biler and pen the mains water islating valve belw the biler. Water will nw flw thrugh the biler t the ht taps. Starting with the lwest tap supplied, turn the ht taps ff ne at a time until the ht water pipewrk is purged f air. heck all ht and cld water pipewrk fr leaks. Fig. 6.: Fit biler casing 6.4 Filling the heating system (turbmax plus) Prceed as fllws t fill the system: Open all radiatr valves n the system. heck flexible filling lp is cnnected. Lcate the filling valve handle n the cld water inlet filling valve as shwn (). Open valve () fully. Remve filling valve handle and lcate n return filling valve (). Open the valve slwly and fill the unit with water until the required pressure has been acheived (3). Turn ff valve (). Remve valve handle and refit n cld water inlet filling valve (). Fully clse valve (). Bleed the air frm the radiatrs. The biler is equipped with an autmatic air release valve. T allw this t vent the biler, the cap tp must be slackened by - turns. (This cap must be left slackened during peratin t ensure any residual air r system gases are released). Instructins fr Installatin and Servicing turbmax plus and thermompat R 5

26 6 mmissining Part I Gas supply adjustments (m. Part II) Filling the heating system (thermompat) The biler and the heating system shuld be filled using a filling methd as described n page 3. Ensure that the biler H service valves are pen. Partially pen the filling valve and allw water t enter the system. Starting with the lwest radiatr, pen the radiatr air release until water (clear f bubbles) is emitted. Repeat this at all radiatrs until the cmplete system is full, all air lcks have been cleared and the biler pressure gauge reads.5 bar. Release any air frm the pump by slackening the centre screw. The biler is equipped with an autmatic air release valve. T allw this t vent the biler, the cap n the tp must be slackened by - turns. (This cap must be left slackened during biler peratin t ensure any residual air r system gases are released). heck the heating system and biler cnnectins are sund. 6.6 Initial system flush ( cld ) The whle f the heating system must be flushed ut at least twice: nce cld, and nce ht as instructed later. Open all radiatr and heating valves and the biler H service valves and drain the heating system and biler cmpletely frm the lwest pints f the system via / BSP drain taps (pened full bre t remve any installatin debris prir t lighting the biler). Refill the heating system. heck the peratin f the pressure relief valve by rtating the knb n the valve. Nw check the water pressure in the unit again (and add mre water if necessary). 7 Gas supply adjustments 7. Gas inlet wrking pressure T check the gas inlet wrking pressure: Lwer the frnt panel f the biler. Lwer the cntrl panel. Slacken the sealing screw () lcated at measuring pint P.IN. Attach U-gauge t the inlet test pint n the gas valve (). Ensure that the gas service valve is pen. Turn ff the biler at the main ON/OFF cntrl. Press and hld the + buttn, while pressing the buttn turn the main ON/OFF cntrl t the ON psitin. ntinue hlding + buttn until display alternates between P and P. Release + buttn. Press + buttn until P (full gas rate) is shwn in display. Press i buttn t perate biler at full gas rate. heck that the U-gauge is reading in the range between 8 and 0 mbar. If the pressure is nt within this range this shuld be investigated befre cntinuing with the cmmissining prcedure. Lwer pressures than this range are indicative f an incrrectly sized r partially blcked gas supply. Switch ff the biler at the main ON/OFF cntrl. Remve U-gauge, tighten test pint sealing screw (). Test fr sundness. Recrd appliance wrking gas inlet pressure (mbar) in the Benchmark Installatin, mmissining and Service Lg Bk. Fig. 7.: Gas inlet wrking pressure 6 Instructins fr Installatin and Servicing turbmax plus and thermompat R

27 Gas supply adjustments (mmissining Part II) 7 7. Main burner pressure The burner pressure n this appliance has been factry set and des nt require adjustment. T check the main burner pressure cnnect the U-Gauge as fllws depending n the gas type. Remve frnt case and cmbustin chamber cver. Nte! All measurements and adjustments t the gas valve must be dne with the cmbustin chamber cver remved. Fr natural gas appliances: Slacken the sealing screw () at test pint n the gas valve and attach ne arm f a U-gauge () t the test pint. Fr LPG appliances: Slacken the sealing screw (a) at test pint n the burner inlet gas pipe and attach ne arm f a U-gauge (a) t the test pint. nnectin fr Natural gas Turn ff the biler at the main ON/OFF cntrl. Press and hld the + buttn, while pressing the buttn turn the main ON/OFF cntrl t the ON psitin. ntinue hlding + buttn until display alternates between P and P. Release + buttn. Press + buttn until P is shwn in the display. P indicates the maximum gas rate and P indicates the ignitin rate. Press i buttn t perate biler at maximum gas rate. heck that the burner pressure is crrect as shwn in table 7. fr the apprpriate biler. T cancel selected P r P mde press the i and + buttns simultaneusly. turbmax plus nly Measure the dmestic ht water burner perating pressure (mbar), the heat input (kw), the inlet/utlet dmestic ht water temperatures ( ) and flw rate (l/min) by fully pening a ht water tap and recrd details in the biler lgbk. thermompat nly Recrd the heat input in the biler lgbk. After cmpletin f all tests tighten sealing screw, and check all test pints fr sundness (/a). nnectin fr LPG a 7.3 Adjusting the central heating utput (range rating) The bilers are fully mdulating fr central heating, and it is therefre nt necessary t range rate the biler. Hwever, if desired, it is pssible t range rate the biler, as fllws: nnect the U-gauge t check burner pressure. Use Table 7. (page 3-3) n t determine the central heating utput required. Nte the burner pressure setting. Turn n the central heating. Ensure that any thermstatic radiatr valves are pen and set t high. Simultaneusly press and release the + and - buttns t activate burner pressure mde. The biler will light at the factry set nminal gas rate. Attentin! DO NOT pen any ht water tap while carrying ut this prcedure (turbmax plus nly). a heck that the U-gauge reading crrespnds t the maximum burner pressure as detailed n the table. Identify required range rating setting and nte main burner pressure in mbar fr that utput. Adjust central heating utput range as shwn n page 9. Fig. 7. Instructins fr Installatin and Servicing turbmax plus and thermompat R 7

28 7 Gas supply adjustments (mmissining Part II) Nte! Fllwing adjustment f the central heating utput, the new utput can be checked using the gas rate table as detailed. Press the i buttn and a value between and 5 will be displayed. Use the + r - buttns t increase r decrease the value. Observe the U-gauge as the buttn is pushed and stp pushing when the required main burner pressure has been achieved. Fig. 7.3: Using burner pressure t check and adjust the heating system partial lad (picture shws a turbmax plus biler) Nte! This illustratin shws the U-tube pressure gauge cnnected t a system cnfigured t run n natural gas. When cnnecting the U-tube pressure gauge t a system running n LPG, please refer t Fig. 7. n page 7. Simultaneusly press the i and + buttns keys. After setting, press and hld the i buttn fr five secnds - r until the display stps flashing. The new setting value is nw memrised. The new main burner pressure can nw be checked. If the new utput is nt crrect repeat steps 3 t 5. ~ 5 s Keep the + buttn pressed until d.0 is displayed. (The display runs frm d.0 t d.99 befre restarting again at d.0.) T return t nrmal mde, press the i and + buttns simultaneusly. The adjustment mde is als cancelled if n buttn is pushed fr a perid f fur minutes. Recrd central heating perating pressure in the Benchmark Lg Bk alng with the heat input (kw) and temperature difference between flw and return. 8 Instructins fr Installatin and Servicing turbmax plus and thermompat R

29 Gas supply adjustments (mmissining Part II) Adjusting t the maximum heat lad (nminal lad) Und screw and remve the cap () turbmax nly: Set the DHW temperature cntrl t maximum and fire the biler at full rate by fully pening a ht water tap. thermompat nly: Turn ff the biler at the main ON/OFF cntrl. Press and hld the + buttn, while pressing the buttn turn the main ON/OFF cntrl t the ON psitin. ntinue hlding + buttn until display alternates between P and P. Release + buttn. Press + buttn until P (full gas rate) is shwn in display. Press i buttn t perate biler at full gas rate. Using a 0 mm spanner turn nut () t adjust the burner perating pressure. - Turn the nut () clckwise t increase the nminal lad - Turn the nut () anticlckwise t decrease the nminal lad. Adjust the burner pressure until it matches the maximum utput as detailed. Nw turn the 0 mm nut () anticlckwise until the burner pressure drps by apprx mbar. Nminal lad is nw crrectly adjusted. Refit the plastic cap (). Attentin! The plastic cap () must be fitted fr the gas valve assembly t functin crrectly. turbmax nly: Turn ff the ht water tap. thermompat nly: T cancel selected P r P mde press the i and + buttns simultaneusly. 7.5 Adjusting the ignitin rate Und screw and remve the cap (). turcmax nly: Discnnect the mdulating cil wires frm the gas valve, set the DHW temperature cntrl t maximum and fire the biler at full rate by fully pening a ht water tap. thermompat nly: Turn ff the biler at the main ON/OFF cntrl. Press and hld the + buttn, while pressing the buttn turn the main ON/OFF cntrl t the ON psitin. ntinue hlding + buttn until display alternates between P and P. Release + buttn. Press + buttn until P (ignitin rate) is shwn in display. Press i buttn t perate biler at full gas rate. Use a suitably sized screwdriver t turn the inner screw (). Turn the screw () clckwise t increase the ignatin rate Turn the screw () anticlckwise t decrease the ignatin rate Adjust the burner pressure until it matsches the ignitin rate as detailed n page 3 r 3. turbmax nly: Turn ff the ht water tap and recnnect the wires t the mdulating regulatr. thermompat nly: T cancel selected P r P mde press the i and + buttns simultaneusly. Nte! If installing/cmmissining a turbmax plus 837 r a thermompat 637 biler g t page 30. Attentin! The main burner pressure must be rechecked after adjusting the ignitin rate. Refit cap () and replace screw. Re-check ignitin and main burner pressures. After cmpletin f these tests tighten the sealing screw and check all jints and test pints fr sundness. Fig. 7.4: Adjusting the ignitin rate Instructins fr Installatin and Servicing turbmax plus and thermompat R 9

30 7 Gas supply adjustments (mmissining Part II) 7.6 hecking the gas valve mid setting pint (turbmax plus 837 and thermompat 637 nly) T ensure the mst efficient peratin f the biler a gas valve mid setting pint is necessary. This mid setting pint has been factry set and adjustment f this pint is nly required after exchanging either the electrnic circuit bard r gas valve r cnverting the biler t anther gas type. T check the mid setting pint prceed as fllws. Turn ff the biler at the main ON/OFF cntrl. Press and hld the + buttn, while pressing the buttn turn the main ON/OFF cntrl t the I ON psitin. ntinue hlding + buttn until display starts t alternate between the P numbers (P, P, P3, P, P and P3). Release + buttn. Press + buttn until P3 (mid setting pint) is shwn in display. Press i buttn t perate biler at mid setting pint. The burner pressure shuld nw read the mid setting pint pressure fr the gas type used, as detailed in the table belw. Nte! The "-" buttn has n functin in this mde, if the required pressure is exceeded during set up, this peratin shuld be recmmenced frm the beginning. When the pressure is crrect, t save the setting t memry, press and hld the "i" buttn until the display stps flashing. T cancel selected mde press the "i" and "+" buttns simultaneusly. Refit cap and replace screw. Re-check ignitin and main burner pressures. After cmpletin f these tests tighten the sealing screw and check all jints and test pints fr sundness. Gas type Natural Gas (G0) LPG (G30/3) Mid setting pint presure 5.3 mbar 5.3 mbar 7.7 Setting r adjusting the mid-setting pint Turn ff the biler at the main ON/OFF cntrl. Press and hld the + buttn, while pressing the buttn turn the main ON/OFF cntrl t the I ON psitin. ntinue hlding + buttn until display starts t alternate between the P numbers (P, P, P3, P, P and P3). Release + buttn. Press + buttn until P (fr natural gas) r "P 3" (fr LPG) is shwn in display. Press i buttn t perate biler at mid setting pint. The mid setting pint burner pressure is nw adjusted by pushing the "+" buttn until the gauge equals the pressure as detailed in the table belw. Prgram N. Gas type Mid setting pint P. Natural Gas (G0) 5.3 mbar P. Nt applicable fr GB - P.3 LPG (G30/3) 5.3 mbar 30 Instructins fr Installatin and Servicing turbmax plus and thermompat R

31 Gas supply adjustments (mmissining Part II) 7 Burner Pressure and gas rate Burner Pressure thermompat 65/ E Output[kW] Gas type Ignitin rate Natural gas H Burner pressure ) [mbar] Main burner jet mark ) fr G / 0 LPG 3 B/P Burner pressure ) [mbar] Main burner jet mark ) fr G / 07 fr G Burner Pressure thermompat 60/ E Output[kW] Gas type Ignitin rate Natural gas H Burner pressure ) [mbar] Main burner jet mark ) fr G / 0 LPG 3 B/P Burner pressure ) [mbar] Main burner jet mark ) fr G / 07 fr G Burner Pressure thermompat 64/ E, turbmax plus 84/ E Output[kW] Gas type Ignitin rate Natural gas H Burner pressure ) [mbar] Main burner jet mark ) fr G / 0 LPG 3 B/P Burner pressure ) [mbar] Main burner jet mark ) fr G / 07 fr G Burner Pressure thermompat 68/ E, turbmax plus 88/ E Output[kW] Gas type Ignitin rate Natural gas H Burner pressure ) [mbar] Main burner jet mark ) fr G / 0 LPG 3 B/P Burner pressure ) [mbar] Main burner jet mark ) fr G / 07 fr G Table 7.: Burner pressure ) 5, 03mbar, dry ) The nzzles are stamped with the mark shwn in this table. The marking crrespnds t the nzzle hle diameter multiplied by 00 Instructins fr Installatin and Servicing turbmax plus and thermompat R 3

32 7 Gas supply adjustments (mmissining Part II) Burner Pressure thermompat 637, turbmax plus 837 E Output[kW] Gas type Ignitin rate Natural gas H Burner pressure ) [mbar] Main burner jet mark ) fr G / 0 Setting-up prgram: P. LPG 3 B/P mid. setting pint pressure: 5.3 mbar Burner pressure ) [mbar] Main burner jet mark ) fr G / 07 fr G Setting-up prgram: P.3 Table 7.: Burner pressure mid. setting pint pressure: 5.3 mbar Gas Rate thermompat 65/ E Output[kW] Gas type Natural gas H Gas Rate ) [m 3 /h] Main burner jet mark ) fr G / 0 Gas Rate thermompat 60/ E Output[kW] Gas type Natural gas H Gas Rate ) [m 3 /h] Main burner jet mark ) per G / 0 Gas Rate thermompat 64/ E, turbmax plus 84/ E Output[kW] Gas type Natural gas H Gas Rate ) [m 3 /h] Main burner jet mark ) fr G / 0 Gas Rate thermompat 68/ E, turbmax plus 88/ E Output[kW] Gas types Natural gas H Gas Rate ) [m 3 /h] Main burner jet mark ) per G / 0 Gas Rate thermompat 637E, turbmax plus 837 E Output[kW] Gas type Natural gas H Gas Rate ) [m 3 /h] Main burner jet mark ) per G / 0 Table 7.: Gas flw rate ) 5, 03mbar, dry ) The nzzles are stamped with the mark shwn in this table. The marking crrespnds t the nzzle hle diameter multiplied by 00 3 Instructins fr Installatin and Servicing turbmax plus and thermompat R

33 VR-V I 0 Gas supply adjustments (m. Part II) Fit cmbustin chamber cver arefully re-fit the cmbustin chamber cver t the biler ensuring it is crrectly sealed. Secure cver with retaining clamps. 7.9 Fit biler casing arefully push case () nt the biler such that the lcating pints either side at the tp f the biler engage. Push the casing nt the securing clips at the bttm f the biler. lse cntrl panel (). Secure cntrl panel by turning bth securing fasteners (3) clckwise by 90. Fit and clse frnt dr (4). Fit lwer cver plate (5). 8 Functinal hecks 8. Functinal checks Prcedure Once the unit has been installed and the gas supply has been checked, perate the system t ensure that it is wrking crrectly. Operate the system, fllwing the perating instructins supplied with the biler. heck the system fr water leaks and escaping gas. heck that the flue has been crrectly installed, accrding t the fitting instructins supplied with the flue assembly. heck the burner fr crrect ignitin and flame picture. turbmax plus nly: heck the ht water system fr crrect peratin. heck the heating system fr crrect peratin. I Fig. 5.: Fit biler casing 5 Fig. 8. Test fr crrect functining 8. Functinal check f peratin (turbmax plus nly) This biler is fitted with indicatr lights t display the perating status f the biler. The status f the indicatrs in nrmal peratin will be as fllws. Biler in stand by mde Red lck ut indicatr () OFF. Yellw flame indicatr () OFF. Green warmstart indicatr (3): - ON Warmstart ON - OFF Warmstart OFF Ht water peratin Fully pen ht water tap. If biler is perating crrectly, the status f the indicatrs will be as fllws: Red lck ut indicatr () OFF. Instructins fr Installatin and Servicing turbmax plus and thermompat R 33

34 8 Functinal hecks (mmissining Part III) Yellw flame indicatr () ON. Green warmstart indicatr (3) FLASHING (ht water is being drawn frm the system). entral Heating peratin Operate the heating system. If biler is perating crrectly, the status f the indicatrs will be as fllws: Red lck ut indicatr () OFF. Yellw flame indicatr () ON (burner active). Green warmstart indicatr (3) ON, OFF r FLASHING (see abve). The LD display indicates the flw temperature (in ) f the biler in nrmal peratin. Fig. 8. Functinal check turbmax plus 8.3 Functinal check f peratin (thermompat nly) This biler is fitted with indicatr lights t display the perating status f the biler. The status f the indicatrs in nrmal peratin will be as fllws. Biler in stand by mde Red lck ut indicatr () OFF. Yellw flame indicatr () OFF. Green indicatr (3) has n functin. entral Heating/ht water peratin Operate the heating/ht water system. If biler is perating crrectly, the status f the indicatrs will be as fllws: Red lck ut indicatr () OFF. Yellw flame indicatr () ON (burner active). Green indicatr (3) OFF. The LD display indicates the flw temperature (in ) f the biler in nrmal peratin Adjusting pump speed The unit is fitted with a tw-speed pump. The pump is delivered with the switch () set t psitin III (Fig. 8.4.). Attentin! Imprtant nte: The biler shuld nly be perated at pump setting III because the heating capacity fr ht water is reduced when perated at pump setting II! It is pssible, hwever, t change the pump setting frm Level III t Level II manually when there is nise cming frm the heating system. Final system flush ( HOT ) Turn n the biler fr central heating and allw the biler and system t reach perating temperature. heck that the heating system is watertight. Turn the biler ff and rapidly drain bth biler and system while still ht. Refill the system and release all air. Release water frm the system until the system design pressure f.0 bar is attained. (The actual reading n the pressure gauge shuld ideally be 0.5 bar plus an additinal pressure crrespnding t the highest pint f the system abve the base f the biler - 0 m head equals an additinal bar reading n the pressure gauge. The minimum pressure shuld nt be less than bar in any installatin.) If the system is t be treated with an inhibitr it shuld be applied at this stage in accrdance with the manufacturers instructins. Further infrmatin can be btained frm Sentinel, GE Betz. Widnes, heshire, WA8 8UD. Tel: r Fernx, Alpha-Fry Technlgies, Tel: Discnnect the temprary filling cnnectin. Refit the biler casing. Attach the bttm cver t the biler. It may be necessary t apapt the bttm cver by remving the easy break sectins. 3 Fig. 8.3 Functinal check turbmax plus 34 Instructins fr Installatin and Servicing turbmax plus and thermompat R

35 Functinal hecks (mmissining Part III) 8 9 Servicing 9. Initial Inspectin T ensure the cntinued safe and efficient peratin f the biler it is recmmended that it is checked and serviced as necessary at regular intervals. The frequency f servicing will depend upn the particular installatin cnditins and usage, but in general nce per year shuld be adequate. It is the law that all servicing wrk is carried ut by a cmpetent persn (rgi registered). Imprtant! Befre starting any maintenance wrk: Fig. 8.4: Pump speed 8.5 Handing ver t the user Set the maximum radiatr temperature cntrl t the desired setting. Set the maximum ht water temperature cntrl t the desired setting. Instruct the user in the safe and efficient peratin f the biler, in particular the functin f: - The biler n/ff cntrl - The maximum radiatr temperature cntrl - The maximum ht water temperature cntrl (turbmax plus nly) - The pressure gauge Shw the user hw t perate any external cntrls. Explain t the user the imprtance f having the biler regularly serviced by a cmpetent servicing cmpany. T ensure regular servicing, it is strngly recmmended that arrangements are made fr a Maintenance Agreement. Please cntact Vaillant Service Slutins ( ) fr further details. Ensure the biler lg bk is fully cmpleted and leave with the end user. Failure t install and cmmissin this appliance t the manufacturers instructins may invaludate the warranty (Nte: This des nt affect yur statutry rights). Leave the user instructins, the biler lg bk and the installatin and servicing instructins with the user. Islate the mains electricity supply by discnnecting the plug at the scket utlet (if there is nly an islating switch remve the fuse frm the switch). Turn OFF the gas supply at the gas service valve fitted t the biler. Always test fr gas sundness and always carry ut functinal checks after any service wrk and after exchanging any gas carrying cmpnent. Always check earth cntinuity, plarity and resistance t earth with a multimeter after any service wrk and after exchanging any electrical cmpnent. Nte! The biler is fitted with a cmbustin analysis test pints n the frnt f the cmbustin chamber cver. A suitable cmbustin analyser can be cnnected t these pints t establish the cmbustin perfrmance f the biler. Befre cmmencing any servicing r maintenance wrk, carry ut an initial inspectin f the system as fllws: Inspect the flue, pipewrk and electrical cnnectins fr indicatins f damage r deteriratin. Inspect the air supply and ventilatin arrangements f the installatin. heck the heating and water system, in particular the cnditin f radiatr valves, evidence f leakage frm the heating system and dripping ht water taps. Functinal check f biler peratin arry ut a functinal check f the biler peratin as previusly detailed. Remve the appliance casing as detailed and perate the biler by fully pening a ht water tap. Inspect the burner peratin thrugh the viewing windw. heck that the flames are evenly cvering the surface f the burner. Inspect fr signs f excessive flame lift r sting. 9. leaning the burner and primary heat exchanger Turn ff the biler. Islate the electrical supply t the biler. Remve the biler case as described. Turn ff the gas service valve. Instructins fr Installatin and Servicing turbmax plus and thermompat R 35

36 9 Servicing Turn ff the biler H service valves. Turn ff the cld water inlet service valve. Release the three clamps (), remve the cmbustin chamber cver (). 9.. Fr thermompat 65, 637 and turbmax plus 837 Remve the flue gas cnnectr (a) n the fan. Remve the retaining spring (3). 5 kw: Pull the three cables (4) and tw tubes (5) frm the fan assembly. 37 kw: Remve bth plugs (nt illustrated) and bth hses (5) frm the fan. Remve the fan assembly (6). Remve the fur screws (7) and detach the frnt cver panel frm the cmbustin chamber (8). heck the burner (9) and heat exchanger fins (0) and remve any lse depsits with a sft brush. 9.. Fr thermompat 60, 64, 68, turbmax pr 4, 8 and turbmax plus 84, 88 Pull the three cables (4) and tw tubes (5) frm the fan assembly. Remve the fan assembly (6a, 6b, 6c). Remve the fur screws (7) and detach the frnt cver panel frm the cmbustin chamber (8). heck the burner (9) and heat exchanger fins (0) and remve any lse depsits with a sft brush. Reassemble in reverse rder. heck central heating expansin vessel. Nte! It is nt necessary t carry ut this check every year a check every three years shuld be sufficient. Release the system water pressure frm the biler. Remve valve cap frm expansin vessel charge pint. heck that the internal charge pressure f expansin vessel is between bar. If pressure is lwer than this the vessel shuld be re-pressurised using an air pump. Refit valve cap. Open central heating service valves and re-pressurise the biler and heating system if necessary. Fig. 9.a leaning the burner and primary heat exchanger (thermompat 65, 637 and turbmax plus 837) a a 6 6c Open the gas service valve. Turn n the mains pwer supply. Operate the biler and carry ut sundness, safety and functin checks. mplete the service interval recrd sectin in the lg bk and leave with the user. 8 6b Fig. 9.b leaning the burner and primary heat exchanger thermompat 60, 64, 68, turbmax pr 4, 8 and turbmax plus 84, Instructins fr

37 Servicing 9 0 Fault Finding 0. Intrductin The turbmax plus and thermompat bilers have an inbuilt advanced multifunctin diagnstic display t assist with fault finding in the unlikely event f a biler malfunctin. The display features the fllwing fur mdes: Nrmal Mde Under nrmal cnditins the biler display will shw the biler flw temperature, this indicates that the biler is perating crrectly after an internal self check. Status Mde The status display is helpful in diagnsing faults where a fault cde is nt displayed. Diagnstic Mde In rder t assist with the pinpinting f a particular fault it is pssible t use the biler display in a diagnstic mde t interrgate the biler abut the status f certain cmpnents. Fault Mde Shuld a fault develp in the biler the display will shw a fault cde indicating what the prblem may be. 0. Indicatr lights (turbmax plus nly) The biler cntrl panel als cntains three indicatr lights whse functin is as fllws: Red lck ut indicatr (), when illuminated biler is at lck ut. Yellw flame indicatr (), when illuminated main burner is ignited. Green warmstart indicatr (3): Illuminated = Warmstart switched ON Nt illuminated = Warmstart is switched OFF and there is n demand fr ht water Flashing = There is either a demand fr ht water r warmstart 0.3 Indicatr lights (thermompat nly) The biler cntrl panel als cntains three indicatr lights whse functin is as fllws: Red lck ut indicatr (), when illuminated biler is at lck ut. Yellw flame indicatr (), when illuminated main burner is ignited. Green indicatr (3) is illuminated but has n functin. 0.4 Lgical fault finding prcedure These checks must be carried ut befre attempting t use the fault finding guide.. arry ut electrical safety checks (See Sectin Preliminary Electrical hecks )..heck that the external electricity supply t the biler is n, and a supply f 30 V~ is present between biler terminals L and N. 3.heck that the gas supply t the biler is n, that it has been crrectly purged and that an inlet pressure f 0 mbar is available at the gas valve. (See Sectin Gas Supply ). 4.Ensure the heating system is full f water and charged t between and.5 bar. If nt, refill and vent the system. (See Sectin Filling the heating system ). Ensure biler flw and return service valves are pen. 5.heck that the main ON/OFF cntrl is set t the ON psitin. 6.Set the central heating temperature t maximum. 7. Set the dmestic ht water temperature t maximum (turbmax nly). 8.heck that all external cntrls are n and calling fr heat (if, n external cntrls are fitted, biler terminals 3 and 4 must be linked). heck that the biler anti-cycling ecnmiser is nt engaged. Prcedure Nte! Always check the peratin f the biler fr central heating first befre checking ht water peratin. D nt pen a ht water tap unless instructed t d s by the fault finding guide (turbmax nly). Fig. 0. LED indicatrs 3. If a fault cde is shwing in the biler display fllw the fault finding charts referring als t the fault cde and diagnstic mde tables..if the biler is nt functining crrectly and a fault cde is nt shwing in the biler display fllw the fault finding charts referring als t the status mde table. Nte! If the biler display is cmpletely blank initially check the tw fuses (Islate the electrical supply befre checking the fuses, spare fuses are lcated n the inside f the cntrl bx rear cver). Instructins fr Installatin and Servicing turbmax plus and thermompat R 37

38 0 Fault Finding T access the varius mdes press the buttns n the cntrl panel as fllws: Mde Status mde Diagnstic mde T display Press i buttn Press the i and the reqiured mde + buttn simultaneusly T return t Press i buttn Press the i and Nrmal mde + buttn simultaneusly 0.5 Status Mdes The status mde prvides infrmatin abut the current perating status f the biler. T display status mde prceed as fllws: Press the i buttn belw the display, and a status cde will appear in the display indicating the current peratinal status f the biler (see table belw). T cancel the status cde mde prceed as fllws: Press the i buttn belw the display r D nt press any key fr apprximately fur minutes. The display will nw revert back t shwing the current flw temperature. Nte! If n key is pressed fr apprx. 4 minutes the display will autmatically change back t Nrmal mde. Display Indicatin turbmax plus thermompat S.00 N heat demand (heating peratin) x x S.0 Fan running (heating peratin) x x S.0 Pump running pre ignitin (heating peratin) x x S.03 Ignitin sequence (heating peratin) x x S.04 Burner ignited (heating peratin) x x S.05 Fan and pump ver run (837/637 nly) x x S.07 Pump ver run (heating peratin) x x S.08 Anti cycling mde (heating peratin) x x S.0 Ht water demand (ht water peratin) x S. Fan running (ht water peratin) x S.3 Ignitin sequence (ht water peratin) x S.4 Burner ignited (ht water peratin) x S.6 Fan ver run (ht water peratin) x S.7 Pump ver run (ht water peratin) x S.0 Warmstart demand (warm start) x S. Fan running (warm start) x S.3 Ignitin sequence (warm start) x S.4 Burner ignited (warm start) x S.7 Pump ver run (warm start) x S.8 Anti cycling mde (warm start) x S.30 N heating demand frm external cntrls x x S.3 Summer mde (heating cntrl knb in ff psitin) x x S.3 Main heat exchanger anti freeze prtectin due t fan speed deviatin x t great (837/637 nly) S.33 heck air/flue system x x S.34 Frst prtectin mde x x S.36 N heating demand frm lw vltage cntrls x x S.39 ntact thermstat has been activated (under flr systems) x x S.53 Delay mde due t lack f water in system (~,5 mins.) x x S.54 Delay mde due t flw temperature gradient t steep (apprx 0 mins.) x x Table 0.: Status mdes 38 Instructins fr Installatin and Servicing turbmax plus and thermompat R

39 Fault Finding Diagnstic Mdes In rder t assist with the pinpinting f a particular fault it is pssible t use the biler display in a diagnstic mde t interrgate the biler abut the status f certain cmpnents. Press the i and + buttns belw the display simultaneusly. The display will nw shw d.00. Use + r - buttns t scrll up r dwn t the desired diagnsic number. Press i buttn t display the crrespnding diagnsic infrmatin. If necessary, yu can nw alter the value by pressing + r - buttns. (When altering values display will flash). Press and hld the "i buttn t save the value t memry, when the value is saved the display will stp flashing. Diagnsic mde is cancelled as fllws: Press the i and + buttns simultaneusly r D nt press any key fr apprximately fur minutes. The display will nw revert back t shwing the current flw temperature. Display Indicatin Displayed values/adjustment values d.00 Part lad setting 0-5 (0-30, 837/637 nly) d.0 Water pump ver run,, 3, 60 min (factry adjusted setting: 5 min) d.0 Maximum burner anti cycling perid at 0 flw temperature 8-60 min (predelivery setting: 5 min) d.05 Flw temperature setting d.07*. Vantage ht water temperature (nt applicable) Warmstart temperature setting (applies t turbmax plus nly) d.08 External cntrls heat demand 0 = pen, n demand; = clsed, demand d.0 Pump status = ON; 0 = OFF d. External pump status = ON; 0 = OFF d. Flame rectificatin = ON; 0 = OFF d.* Dmestic ht water demand = ON; 0 = OFF d.3 Summer/winter functin (cntrl knb) = winter; 0 = summer d.4 Air pressure switch = ON; 0 = OFF d.5* Warmstart status (turbmax plus) = ON; 0 = OFF d.30 Gas valve status = ON; 0 = OFF d.33 Required value f the rtary speed f the fan r.p.m. (837/637 nly) d.34 Actual value f the rtary speed f the fan r.p.m. (837/637 nly) d.35* Diverter valve psitin = ht water; 0 = heating system d.37 Mdulatr current ma d.40 Actual flw temperature d.4 urrent return temperature (837/637 nly) in d.50 Maximum flw temperature d.60 Number ver heat cut ff peratins d.6 Number f lck uts s d.64 Average ignitin time s d.65 Maximum ignitin time s d.67 Remaining anti cycling perid min d.68 Number f unsuccessful attempted st ignitins d.69 Number f unsuccessful attempted st ignitins d.7 Maximum target value fr heating system flw temperature 0 = 8 ; = 87 (factry setting: 8 ) d.7* Pump ver run (fr lading warmstart) 0,,, 50 s (factry-adjusted t: 80 s) d.73* Offset warmstart temperature value -5, K (factry-adjusted - 5 K) d.75 Maximum ht water pririty peratin time (Vantage nly) 0,, 90 min (factry-adjusted t: 30 min) d.76 Gas type set (837/637 nly) H36 (nat gas) P36 (LPG) E36 (E+ gas). Factry setting H36 d.80** Number f heating system perating hurs (Ttal) h d.8* Number f ht water system perating hurs (Ttal) h d.8 Number f heating system cycles (Ttal) d.83* Number f ht water system cycles (Ttal) Table 0.: Diagnstic Mdes * turbmax plus nly Instructins fr Installatin and Servicing turbmax plus and thermompat R 39

40 0 Fault Finding 0.7 Fault cdes Fault cdes take pririty ver all ther display functins in the event f a system fault ccurring. If multiple faults ccur, the crrespnding fault cdes are displayed alternately fr abut tw secnds each. 0.8 Fault memry The fault memry stres details f the ten mst recent faults. Press the i and - buttns simultaneusly. Use the + buttn t scrll back thrugh the list f memrised errrs. T cancel fault errr memry display mde, prceed as fllws: Press the i buttn belw the display. r D nt tuch any key fr abut fur minutes. The display will nw revert back t shwing the current flw temperature. Display Indicatin Displayed values/adjustment values F.00 Flw-NT: NT brken; NT cable brken; Defective cnnectin at NT Defective cnnectin at electrnics Flw-NT cable defective/ brken NT faulty F.0 Return NT: NT brken; NT cable brken; Defective cnnectin at NT Defective cnnectin at electrnics Return-NT cable defective/brken NT faulty F.0 Shrt circuit - flw-nt (<30 ) NT-plug shrted t casing, NT defective F. Shrt circuit - return-nt (<30 ) NT-plug shrted t casing, NT defective F.0 Over heat cut ff activated Maximun temperature exeeded F. Dry fire prtectin N water in appliance, pump cable defective, pump blcked r defective, pump utput t lw F.3 Dry fire prtectin (difference between flw and N water in appliance, pump cable defective, pump return NT's t large) blcked r defective, pump utput t lw F.4 Dry fire prtectin (temperature gradient f flw NT t steep). Air in biler/system, pump blcked r defective, pump utput t lw F.7 N demand t gas valve Electrnic bard defective; Gas valve defective F.8 Biler ges t lck ut N gas; Isufficient gas; Incrrect gas valve adjustment; Electrde defective; Ignitin lead defect; Electrnic igniter defective F.9 Flame extinguished re-ignitin unsuccesful Gas supply absent r insufficient F.3 Main heat exchanger anti freeze prtectin mde heck fan cntrl cables/cnnectins; Defective fan (837/637 nly) due t fan speed deviatin t great cntrl cable; F.33 Main heat exchanger anti freeze prtectin mde heck air pressure switch, fan, fan supply r flue (837/637 nly) due t n switching signal frm the air pressure switch system F.37 The rtary speed f the fan is t high r t lw Air pressure switch defect; fan defect; electrnics defect (837/637 nly) F.4 N setting fr the type f gas is stred Set gas type in PB (see page 30) (837/637 nly) F.4 Faulty cable lm Faulty r incrrect lm fitted F.43 Faulty cable lm Faulty r incrrect lm fitted F.60 Electrnic fault Electrnics defect F.6 Electrnic fault Electrnics defect F.6 Flame rectificatin present 4 secs. after gas valve turns ff heck gas valve, burner tubes and injectrs r electrnics defect F.63 EM fault EM r electrnics defect F.64 Sensr r electrnics fault heck NT's/cnnectins r electrnics defect F.65 PB prcessr temperature t high heck earth cnnectin r electrnics defect F.66 Display fault Display defect; fault in the cnnectin t the display; electrnics defect F.67 Electrnic fault Electrnics defect Table St.: Fault cdes 40 Instructins fr Installatin and Servicing turbmax plus and thermompat R

41 Fault Finding 0 heck electrical supply, appliance fuses and n/ff cntrl Sheet A Ensure biler main ON/OFF cntrl is set t psitin "" Is there a display n the LD Panel? Yes G t sheet N Biler ON/OFF cntrl defective, change electrnic bard Repair external fault N Is 30VA present acrss terminals L and N? Yes Yes Replace switch mechanism N Des ON/OFF knb perate switch n electrnic bard Yes Is the cntinuity acrss fuse F? N Is 30VA present acrss terminals 3 and 5? N Yes G t sheet B Is vltage between 6-6 VD present acrss terminals 8 and 9? N Is there cntinuity acrss fuse F3? Yes heck transfrmer Replace if necessary Yes N Nte : Fr test purpses, discnnect external cntrls frm terminal 3-4 and replace with a bridge between these terminals. It appliance then perates, the fault is with the external cntrls. Is 5 VD present between 5V and GND test pints n electrnic bard? Yes Replace LD display N Replace electrnic bard Instructins fr Installatin and Servicing turbmax plus and thermompat R 4

42 0 Fault Finding Turn ff the main ON/OFF cntrl t the "0" psitin Discnnect the pwer supply t the biler Replace fuse F Turn the main ON/OFF cntrl t the "" psitin Is t here a display n the LD panel? Yes Prduce central heating demand. Des fuse blw immediately? N After apprx. 0 secs. Des fuse F blw? N If fan cmmences peratin, exchange gas valve Yes Yes heck peratin f pump and fan N heck transfrmer 30 VA primary (black/red) and apprx. 7 VD secndary (blue/brwn) heck/replace pump Is there a display n the LD panel? N heck/replace fan Replace electrnic bard Yes G t sheet A Sheet B 4 Instructins fr Installatin and Servicing turbmax plus and thermompat R

43 Fault Finding 0 Ensure that radiatr temperature cntrl knb is set t vertical psitin and that any internal timer (if fitted) is calling fr heat heck diagnstic cde D.08 (see page 53). Is heating demand present? N Is 30 VA present acrss terminals 4 and 5 N External fault: heck all external cntrls are calling fr heat, replace r repair as necessary (see als nte sheet A) heck central heating and cntrls Yes Des failure cde shw n LD display? Yes Discnnect built in timer (if fitted) N G t sheet D N Des ignitin cmmence? Yes Replace defective timer Sheet Instructins fr Installatin and Servicing turbmax plus and thermompat R 43

44 0 Fault Finding Yes N Des fan run after apprx. 30 secs.? N heck diagnstic cde D.4 (see page 53) equal? Yes heck pitt tube (in fan utlet) and air hses are nt bstructed and crrectly aligned. heck r replace air pressure switch. 837/637 heck 4 pin cnnectr fr fan speed cntrl. Des the fan run nw? N Is 30 VA present acrss fan terminals? N Replace electrnic bard heck flue and ignitin system Yes Des the biler cmmence ignitin N heck status cde (see page 5) is S.33? Yes heck air/flue gas system is crrectly fitted and nt bstructed heck flue restrictr crrespnd t flue length Yes heck/replace fan Yes N Replace electrnic bard Are electrdes sparking at the burner? N heck electrdes and electrde leads. Replace as necessary. Sheet D Yes G t sheet E 44 Instructins fr Installatin and Servicing turbmax plus and thermompat R

45 Fault Finding 0 Yes Des burner light st attempt? N Des burner light within 3 ignitin attempts? Yes heck gas supply Des burner light? Yes heck burner pressure settings are crrect heck gas valve and central heating system pressure Yes Is burner indicatr illuminated? Yes N N Reset biler heck flame rectificatin lead and electrde Yes N heck/replace gas valve as necessary Is burner indicatr illuminated Des burner light? N N Replace electrnic bard Des burner shut dwn after apprx. 5 secs. Yes Des status cde (see page 5) shw S. 53? heck water pressure in central heating system, refill and vent. as necessary heck pump is running? N Is 30 VA present at the pump plug cnnectin? N Replace electrnic bard Sheet E N G t sheet F Yes Replace pump Instructins fr Installatin and Servicing turbmax plus and thermompat R 45

46 0 Fault Finding heck partial lad setting N G t sheet G Yes heck peratin f burner and mdulatin Des flame indicatr glw and flames increase in size t full gas rate after apprx. mins? Yes Des burner flame mdulate/ g ut when radiatr temperature cntrl is turned left t the hrizntal psitin at flw temperature f apprx. 50? Yes Des heating flw pipe temperature rise? N N N N heck peratin f biler in DHW mde, des flame increase in size t full rate? (TURBOmax Plus nly) Replace electrnic bard Ensure flw and return service valves are pen Yes N Turn main ON/OFF cntrl t the "0" psitin (TURBOmax Plus nly) heck diagnstic cde D. (see page 53) equals (TURBOmax Plus nly) Yes Insert a small screwdriver thrugh the hle in the frnt f the diverter valve and hld blade lightly against spindle heck cnnectins and mdulatr, replace gas valve if burner still fails t increase t full rate Turn "ON" the main ON/OFF cntrl Des spindle mve? Yes Replace diverter valve Yes N Sheet F G t sheet G Replace electrnic bard 46 Instructins fr Installatin and Servicing turbmax plus and thermompat R

47 Fault Finding 0 Sheet G Nte! turbmax plus nly Draw ht water at high rate heck/replace hall sensr Des ht water indicatr glw/flash nw? N N heck D.H.W peratin (turbmax plus nly) Des green warmstart indicatr flash? Yes heck ht water flw rate and temperature. mpare with technical data, if flw is nt sufficient check incming main and cld water filter. N heck cld water inlet pressure is sufficient and that cld water inlet filter is clear Nrmal peratin carry ut electrical safety checks heck cld water inlet is fully pen and adjustment is at maximum flw rate Des green warmstart indicatr flash nw? Yes N heck/lear impeller in Aquasensr, replace if necessary Des green warmstart indicatr flash nw? N Replace electrnic bard Yes Instructins fr Installatin and Servicing turbmax plus and thermompat R 47

48 Diagrams. Functinal Flw diagram: turbmax plus 84/ E, 88/ E, 837 E ONTROL BOX MAIN SWITH L FA N Burner lck ut indicatr (red) Ignitin indicatr Ht water/warmstart demand indicatr MAIN TRANSFORMER display POWER SUPPLY MAIN SWITHBOARD F,5A 30V 0V plug in cnnectr r gr gr AIR PRESSURE SWITH 837 nly bl b gr b br FAN plus / minus buttns y/g reset buttn inf buttn DHW Aqua Sensr DIVERTER VALVE p p p bl bl bl bl b br y/g t w br PUMP NT FLOW TEMPERATURE SENSOR NT RETURN TEMPERATURE SENSOR Legend b blue br brwn y/g yellw/green r red p pink r range t transparent bl black gr grey w white r r GAS VALVE br y/g b t r FLAME SENSOR br br NT WARMSTART TEMPERATURE SENSOR IGNITION ELETRODES Fig..: Functinal Flw diagram VUW 48 Instructins fr Installatin and Servicing turbmax plus and thermompat R

49 Diagrams Functinal Flw diagram: thermompat 65/ E, 60/ E, 64/ E, 68/ E, 637 E MAIN SWITH ONTROL BOX L FA N Burner lck ut indicatr (red) Ignitin indicatr MAIN TRANSFORMER display POWER SUPPLY MAIN SWITHBOARD F,5A 30V 0V plug in cnnectr r gr gr AIR PRESSURE SWITH 637 nly bl b gr b br FAN plus / minus buttns y/g reset buttn inf buttn b br y/g PUMP t w NT FLOW TEMPERATURE SENSOR br NT RETURN TEMPERATURE SENSOR Legend b br y/g r p r t bl gr w blue brwn yellw/green red pink range transparent black grey white r r GAS VALVE br y/g b t FLAME SENSOR br br IGNITION ELETRODES Fig..: Functinal Flw diagram VU Instructins fr Installatin and Servicing turbmax plus and thermompat R 49

50 Diagrams Wiring diagram: turbmax plus 84/ E, 88/ E, 837 E Pump Gas valve T,5 = F3 X X3 X4 X3 U00 T = F X Diverter valve EV EV 3 4 ding resistr NT return Lifting magnet NT flw Inisatin electrde Aqua sensr Pressure sensr NT earth NT Warmstart Air pressure switch NT Warmstart X8 X0 Fan unit Inisatin Ignitin electrde electrdes Aqua sensr L N X NT flw NT return Switchgear cabinet (837 E nly) X4 (VUV) X7 Accessries X X Fig..3: Wiring diagram VUW 50 Instructins fr Installatin and Servicing turbmax plus and thermompat R

51 Diagrams Wiring diagram: thermompat 65/ E, 60/ E, 64/ E, 68/ E, 637 E Pump Gas valve EV EV 3 4 Switchgear cabinet X X T,5 = F3 X X3 X4 X3 U00 T = F ding resistr NT flw Lifting magnet NT return Inisatin electrde X Pressure sensr NT earth Inisatin electrde Ignitin electrdes X7 Accessries X8 Air pressure switch NT return NT flw X4 (VUV) X L N Bridge X 3 4 Fan unit (637 E nly) Fig..4: Wiring diagram VU Instructins fr Installatin and Servicing turbmax plus and thermompat R 5

52 _30 GB R 04/003 Mü Printed n 00 % recycled paper Subject t alteratin Head Office: Vaillant Ltd. Vaillant Huse Medway ity Estate Trident lse Rchester Kent ME 4EZ Service Slutins Technical Advice

53 Instructins fr use turbmax plus, thermompat 84 E, 88 E, 837 E 65 E, 60 E 64 E, 68 E 637 E GB