Page 4 - Item
4 LIST OF CONTENTS Contents included withboiler (TURBOmax Plus) Ensure that all contents are includedbefore commencing installation. DO NOT remove the boiler from thepolystrene base at this stage. TURBOmax Plus 4 B E D I E N U N G S A N L E I T U N G B E D I E N U N G S A N L E I T U N G B E D I E N...
Page 5 - LIST OF CONTENTS; THERMOcompact
5 LIST OF CONTENTS Contents included withboiler (THERMOcompact) Ensure that all contents are includedbefore commencing installation. B E D I E N U N G S A N L E I T U N G B E D I E N U N G S A N L E I T U N G B E D I E N U N G S A N L E I T U N G B E D I E N U N G S A N L E I T U N G 9 10 10 10 B E ...
Page 6 - INTRODUCTION; THERMOcompact boiler; General Notes; This boiler must be installed; General Information; TURBOmax Plus boiler; EC designation
6 INTRODUCTION THERMOcompact boiler The THERMOcompact is a fully automatic, wall mounted, room sealedsystem boiler for central heating anddomestic hot water (where a separateindirect hot water storage cylinder isalso incorporated in the system). The THERMOcompact range consistsof models with outputs...
Page 7 - Units
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...
Page 8 - BOILER SPECIFICATION; Hanging bracket; TURBOmax Plus
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...
Page 11 - The appliance must be; Preliminar y remarks
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 ...
Page 12 - Where a room sealed boiler
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...
Page 13 - The boilers are delivered
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...
Page 14 - GENERAL REQUIREMENTS; BCD; Flue termination; Terminal position; mm
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...
Page 15 - This appliance must be earthed.
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...
Page 16 - Water circulation system
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...
Page 17 - Expansion vessel; Total water content of system
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...
Page 18 - Pump specifications
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...
Page 19 - Preparation of boiler location; Clearances required; * Clearance is only required to; Selecting position of boiler; If the boiler is to be fitted in a; Should it be necessary to run
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...
Page 20 - - The position of the fixing holes for; Identify correct flue exit.; Use alternative fixing holes; TURBOmax only
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...
Page 21 - Lift the boiler from either side; Install the flue system; Fix the hanging bracket (
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 ...
Page 22 - Turn both securing fasteners (
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...
Page 24 - BOILER INSTALLATION SEQUENCE; ) to the cold inlet water
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...
Page 25 - Pressure Relief Valve
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...
Page 26 - with the appliance and tighten.
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...
Page 30 - Ensure that all cords pass
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...
Page 31 - Caution
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 ●...
Page 33 - External electrical controls; The arrowed numbers; Connection details for programmable thermostats
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...
Page 34 - Connection details for time switch; MAINS
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...
Page 37 - Thermostatic radiator valves; To temporarily override the
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...
Page 38 - Carefully push case (
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 ...
Page 42 - Refill the heating system.
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...
Page 45 - GAS SUPPLY ADJUSTMENTS; For natural gas appliances:; U-Gauge connection points for Natural gas
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...
Page 52 - Functional checks; Procedure; Check the
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...
Page 53 - FUNCTIONAL CHECKS; Boiler in stand by mode
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...
Page 54 - Red lock out indicator (
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...
Page 55 - Refit the boiler casing.
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...
Page 56 - Handing over to the user; The boiler on/off control
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...
Page 57 - SERVICING; Functional check of boiler operation; Initial Inspection; The boiler is fitted with a
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...
Page 59 - Turn off the gas service valve.
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...
Page 61 - ) towards the rear of the boiler
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...
Page 62 - Disconnect air tube from gas valve.
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...
Page 64 - OR
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...
Page 65 - Unplug all leads from the board.; Main transformer
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...
Page 66 - Unplug the pump wire (; Air pressure switch; Disconnect air tubes (; Note: Air tubes should be
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...
Page 67 - picture shows a TURBOmax Plus boiler
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...
Page 71 - FAULT FINDING; Normal Mode
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...
Page 74 - Display
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...
Page 79 - Sheet B
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...
Page 81 - Check flue and ignition system
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...
Page 83 - Check operation of bur
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...
Page 84 - Sheet G; TURBOmax Plus only
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 ...
Page 85 - DIAGRAMS; Legend
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 ...
Page 89 - SHORT PARTS LIST; Description
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...
Page 92 - Mü · Printed on 100 % recycled paper · Subject to alteration
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
