Siemens B8762.0GB - Manuals

7 BOILER SPECIFICATION Technical data THERMOcompact 615/2 E (VU GB 152/2-5) Units CH heat output range (80/60 °C) 6.5 - 15 (22300 - 51200) kW (Btu/h) DHW heat output --- kW DHW flow rate ∆ T = 35 °C rise --- l/min DHW flow rate at factory set temperature rise ( ∆ T 42 °C) --- l/min Mains water press...

8 BOILER SPECIFICATION Key: 1 Heating system return (22 mm tail) 2 Cold water connection with shutoff valve (15 mm tail) 3 Gas connection (15 mm tail) 4 Hot water connection (15 mm tail) 5 Heating system flow (22 mm tail) 6 Flue outlet (100 mm flue with turret) 7 Hanging bracket 8 Rear flue outlet B...

11 GENERAL REQUIREMENTS Ensure that ALL regulationsare observed. Fig. R.1 Euro B/S 006/0_GB Related Documents The installation of the boiler must bein accordance with the relevant requirements of Gas Safety(Installation and Use) Regulations1998, Health and Safety DocumentNo. 635 (The Electricity at ...

12 GENERAL REQUIREMENTS Gas Supply The gas supplier should ensure theavailability of an adequate supply ofgas. A gas meter may only be connectedto the service pipe by the supplier ofgas or their contractor. An existing meter should be checkedto ensure that it is capable of passingthe rate of gas sup...

13 GENERAL REQUIREMENTS Top outlet flue system(100 mm outside diameter) The top outlet horizontal flue system(Art. No. 303 807) is suitable forinstallations up to 720 mm measuredfrom the centre of the boiler flue outletto the outside face of the wall. Flue extensions are available toextend this leng...

14 GENERAL REQUIREMENTS A BCD AG H, I F J B F M L L K K G G F F E A A Flue termination The following details refer to bothflue systems. a. The terminal must be positioned such that the products of combustion can disperse freely atall times. b. In certain weather conditions a plume of water vapour ma...

15 GENERAL REQUIREMENTS Cupboard or compartmentventilation The boilers are very high efficiencyappliances. As a consequence theheat loss from the appliance casing during operation isvery low. For cupboard or compartment installations it is therefore not necessary to provideany high or low level perm...

16 GENERAL REQUIREMENTS Guide to system requirements Water circulation system Detailed recommendations for thewater circulation system are given inBS 6798 and BS 5449: Part 1 (forsmall bore and micro bore centralheating systems). Pipework not forming part of the useful heating surface should be insu...

17 GENERAL REQUIREMENTS Expansion vessel The 15 and 20 kW THERMOcompactboilers as well as the 24 kWTURBOmax Plus boiler incorporate a6 litre expansion vessel which is suit-able for a sealed heating system witha maximum water content of 60 litres.A 10 litre expansion vessel kit is available as an opt...

18 GENERAL REQUIREMENTS 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 50 100 150 200 250 300 350 400 450 500 550 600 650 700 Volume flow [l/min] Lift [mbar] Pump switch in position II (pre-deliver y setting) Pump switch in position I Fig. R.7: Pump specifications Euro B/S_VC_010/0GB...

BOILER INSTALLATION SEQUENCE 19 General Preparation of boiler location Clearances required Mount the boiler on a flat and verticalarea of wall of sufficient area for theboiler plus the required clearances forinstallation and servicing. The clearances are as detailed belowand are shown on the install...

20 BOILER INSTALLATION SEQUENCE 5 5 210 124163 03 240/242/280/282/824/828 Pro/Plus 60/100 07/2000 Fig. I.3: Using Boiler template 124163_03 Using boiler template Fix the paper template to the wallensuring that the correct flue exitpoint has been identified, ensure thatthe template is vertical. The t...

3 320 131 22 26,5 27 131 105 105 1 2 Euro B/S 091/0 21 BOILER INSTALLATION SEQUENCE Fig. I.4: Fitting the boiler Fitting the boiler ● Lift the boiler ( 3 ) up to the wall so that it is slightly above the hangingbracket ( 1 ). ● Lower the boiler slowly onto thehanging bracket so that the crossmember ...

22 BOILER INSTALLATION SEQUENCE Removing boiler casing ● Turn both securing fasteners ( 1 ) anti-clockwise by 90° to releasecontrol panel ( 2 ). ● Pull the case ( 3 ) forward at the bottom to disengage from the securing clips. ● Lift the case slightly to clear the toplocations and pull forward to re...

24 BOILER INSTALLATION SEQUENCE Cold water mains inletand hot water outlet(TURBOmax Plus) Flush all foreign matter from the mainssupply before connecting to the boiler. ● Connect the cold water servicevalve ( 1 ) to the cold inlet water connection ( 3 ) of the appliance with the washer ( 2 ) provide...

25 BOILER INSTALLATION SEQUENCE Central heating flow andreturn pipework(TURBOmax Plus) Before connecting the heating circuitto the boiler appliance, all pipeworkand radiators must be thoroughly flushed to remove any installationdebris. ● Connect the central heating flow( 6 ) and return ( 1 ) service...

26 BOILER INSTALLATION SEQUENCE Gas supply(THERMOcompact) ● Connect the 15 mm compressiongas service cock ( 1) and 15 mm copper outlet tail ( 3 ) as supplied with the appliance and tighten. ● Connect a gas supply pipe of notless than 15 mm diameter to thecopper tail. ● Tighten all connections.(Ensur...

30 BOILER INSTALLATION SEQUENCE Electrical installationGeneral requirements All electrical work shall be carried outby a competent person and shall comply with BS7671 (IEE Regulations). The boiler is supplied for connectionto 230 V, ~ 50 Hz supply fused at 3 Arating. Connection to the mains supply s...

31 BOILER INSTALLATION SEQUENCE Caution Mains connection terminals Land N remain live even whenthe boiler on/off control isswitched off. ● Refit the terminal box cover by pushing into place until it clipsback into position. ● Raise the control panel and securein place. Connection to the mainsupply ●...

33 BOILER INSTALLATION SEQUENCE Controls (TURBOmax Plus boiler) External electrical controls The boiler terminals 3, 4 and 5 arefor connecting external electrical controls such as a timeswitch and/or room thermostat. Terminals 3 and 4 are linked togetherwhen the boiler is supplied. If externalcontro...

34 BOILER INSTALLATION SEQUENCE Connection details for external timeswitches and boiler terminal strip. Fig. I.15 shows the connection detailswhere a time switch is used without aroom thermostat to control the boiler. Important: The arrowed numbers indicate connection into the relevantterminal in th...

37 BOILER INSTALLATION SEQUENCE Thermostatic radiator valves The boiler has a built in automaticbypass valve making it ideal for usein systems with thermostatic radiatorvalves (no separate system bypass isrequired). For optimum fuel economy it is recommended that where TRV’s areused they are used in...

38 BOILER INSTALLATION SEQUENCE 4 5 I 0 I 0 90 ° 90 ° 3 2 1 Fit boiler casing ● Carefully push case ( 1 ) onto the boiler such that the locating pointseither side at the top of the boilerengage. Push the casing onto thesecuring clips at the bottom of theboiler. ● Close control panel ( 2 ). ● Secure ...

42 COMMISSIONING PART I THERMOcompact Initial system flush(“cold“) The whole of the heating system mustbe flushed out at least twice: oncecold, and once hot as instructed lateron page 53. Open all radiator and heating valvesand the boiler CH service valves anddrain the heating system and boilercompl...

1 3 2 1a 3a 2a Turbo H und PB Fig. G.2: Connection of U-gauge 45 GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) Main burner pressure ● The burner pressure on this appliance has been factory set anddoes not require adjustment. Tocheck the main burner pressureconnect the U-Gauge as follows depending o...

52 FUNCTIONAL CHECKS(COMMISSIONING PART III) I 0 Functional checks Procedure Once the unit has been installed andthe gas supply has been checked,operate the system to ensure that it isworking correctly. ● Operate the system, following theoperating instructions supplied withthe boiler. ● Check the sy...

53 FUNCTIONAL CHECKS (COMMISSIONING PART III) Functional check of operation (TURBOmax Plus only) This boiler is fitted with indicatorlights to display the operating statusof the boiler. The status of the indicators in normal operation will beas follows. Boiler in stand by mode ● Red lock out indicat...

54 FUNCTIONAL CHECKS(COMMISSIONING PART III) Functional check of operation(THERMOcompact only) This boiler is fitted with indicatorlights to display the operating statusof the boiler. The status of the indicators in normal operation will beas follows. Boiler in stand by mode ● Red lock out indicator...

55 FUNCTIONAL CHECKS (COMMISSIONING PART III) Adjusting pump speed The unit is fitted with a two-speedpump.The pump is delivered with the switch( 1 ) set to position II. Important note: The boiler should only be operated atpump setting II because the heatingcapacity for hot water is reducedwhen oper...

56 FUNCTIONAL CHECKS(COMMISSIONING PART III) Handing over to the user Set the maximum radiator temperaturecontrol to the desired setting. Set the maximum hot water temperature control to the desired setting. Instruct the user in the safe and efficient operation of the boiler, inparticular the functi...

57 SERVICING Before commencing any servicing ormaintenance work, carry out an initialinspection of the system as follows: ● Inspect the flue, pipework and electrical connections for indications of damage or deterioration. ● Inspect the air supply and ventilation arrangements of theinstallation. ● Ch...

59 PARTS REPLACEMENT Ensure that ALL regulationsare observed. Fig. E.1: General Euro B/S 006/0GB Safety instructions The following safety instructions are to be followedwhen installing replacementparts! Important: Before starting any maintenancework: ● Isolate the mains electricity supplyby disconne...

61 PARTS REPLACEMENT 1 2 4 3 8 9 5 7 6 Fig. E.4: Fan Euro B/S 162/0 Fan ● Refer to the important informationand initial preparation on page 59. ● Remove combustion chamber coverby unclipping the three clamps ( 1 ). ● Remove the screw ( 3 ) and push the flue connector ( 4 ) upwards until it clears th...

62 3 1 2 6 5 7 4 Euro B/S 297/0 9 10 8 13 14 11 12 Euro B/S 298/0 PARTS REPLACEMENT Fig. E.5: Gas valve Fig. E.6: Gas valve Gas valve ● Refer to the important informationand initial preparation on page 59. ● Loosen screw and pull electricalplug off the gas valve. ● Pull off the two modulating coilwi...

64 PARTS REPLACEMENT 1 4 2 3 Fig. E.9: Expansion vessel Euro B/S 164/0 Expansion vessel Please note: In the unlikely event of afailure of the CH expansion vessel follow procedure depending upon theinstallation circumstances.Boiler installed with top connectionair/flue duct to left/right hand side,or...

65 PARTS REPLACEMENT Electronic control board ● Refer to the important informationand initial preparation on page 59. ● Lower control box. ● Unclip the terminal box cover byreleasing the cover retaining clipsand lift to remove. ● Unclip the electronic board coverby releasing the clips ( 2 ) and lift...

66 PARTS REPLACEMENT Pump ● Refer to the important informationand initial preparation on page 59. ● Release central heating water pressure. ● Unclip the terminal box cover byreleasing the cover retaining clipsand lift to remove. ● Unplug the pump wire ( 2 ) from the electronic board. ● Undo the thre...

67 PARTS REPLACEMENT Automatic bypass ● Refer to the important informationand initial preparation on page 59. ● Release central heating water pressure. ● Remove spring clip ( 2 ) ● Undo union ( 1 ), remove bypass/connecting pipe. ● Pull apart bypass and connectingpipe. ● Re-assemble in reverse order...

71 FAULT FINDING The TURBOmax Plus andTHERMOcompact boilers have aninbuilt advanced multifunction diagnostic display to assist with faultfinding in the unlikely event of a boiler malfunction.The display features the following fourmodes: Normal Mode Under normal conditions the boilerdisplay will show...

74 FAULT FINDING Status Mode The status mode provides informationabout the current operating status ofthe boiler. To display status mode proceed as follows: ● Press the „i” button below the display, and a status code willappear in the display indicatingthe current operational status of theboiler (se...

79 FAULT FINDING Sheet B Check operation of pump and fan Tu rn off the main ON/OFF control to the "0" position Disconnect the power supply to the boiler Go to sheet A Is there a display on the LCD panel? Check transfor mer 230 V AC primar y (black/red) and approx. 17 VDC secondar y (blue/bro...

81 FAULT FINDING Does fan run after approx. 30 secs.? Check flue and ignition system No Check diagnostic code D.24 (see page 53) equal 1? Check pitot tube (in fan outlet) and air hoses are not obstructed and correctly aligned. Check or replace air pressure switch. Does the fan run now? Is 230 V AC p...

83 FAULT FINDING Does flame indicator glow and flames increase in size to full gas rate after approx. 2 mins? Ye s Does bur ner flame modulate/ go out when radiator temperature control is tur ned left to the horizontal position at flow temperature of approx. 50 C? Ye s Does heating flow pipe tempera...

84 TURBOmax Plus Draw hot water at high rate Does green war mstar t indicator flash? Ye s Check hot water flow rate and temperature. Compare with technical data, if flow is not sufficient check incoming main and cold water filter . Nor mal operation carr y out electrical safety checks No Check cold ...

85 DIAGRAMS POWER SUPPLY F2A L 2 N 1 MAIN SWITCH MAIN TRANSFORMER 230V20V AIR PRESSURE SWITCH FAN PUMP NTC FLOW TEMPERATURE SENSOR FLAME SENSOR GAS VALVE DHW Aqua Sensor F1,25A NTC RETURN TEMPERATURE SENSOR Burner lock out indicator (red) Hot water/warmstart demand indicator Ignition indicator MAIN ...

89 SHORT PARTS LIST Description Part No. Key No. Burner, natural gas Burner chamber group 615E: 031508Burner chamber group 620E: 031509Burner chamber group 624E/824E: 031500Burner chamber group 628E/828E: 031501Distributor tube 615E: 126762Distributor tube 620E: 126751Distributor tube 624E/824E: 126...

83 37 86 GB 10 · 05/ 200 1 Mü · Printed on 100 % recycled paper · Subject to alteration Head OfficeVaillant Ltd., Vaillant House, Medway City Estate, Trident Close,Rochester, Kent ME 2 4 EZ Service Solutions 0870 6060 777 Technical Advice 01634 292392