Vaillant TURBOmax VUW 242 E, Instructions For Installation And Servicing

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

Page 2: ...ecks 27 5 11 Checking flame supervision device 28 5 12 Final system flush hot 28 5 13 Fitting case 28 5 14 Handing over to user 29 Page 6 Servicing 29 6 1 Initial inspection 29 6 2 Routine maintenance 30 6 3 Re commissioning the boiler 31 7 Parts replacement 32 7 1 Initial preparation 32 7 2 Fan 34 7 3 Air pressure switch 34 7 4 Burner 35 7 5 Electrodes 35 7 6 Temperature sensor NTC 36 7 7 Gas val...

Page 3: ...ent The Boiler Effi ciency Regulations 1993 and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels The TURBOmax range consists of models with outputs for domestic hot water of 24 and 28 kW The boiler is easily sited on any internal wall and can be installed with either a horizontal or verti...

Page 4: ...oss C V s t 37 8 37 8 MJ m3 Gas burner pressure max rate 10 0 10 6 mbar Gas burner pressure ignition rate 2 0 2 0 mbar Gas rate max DHW 2 79 3 26 m3 h Main burner jet size 16 x 7 120 18 x 7 120 no x size CH flow temperature range 40 90 40 90 C Minimum CH water flow for 20 C rise 1 032 1 204 l h Pump pressure available 0 25 0 25 bar 8l expansion vessel pre charge pressure 0 75 0 75 bar Maximum CH s...

Page 5: ...t off valve 7 Service valve return of heating system 8 Compression union return of heating system 9 Pressure relief valve 200 124 50 35 70 25 1 2 3 4 5 6 7 8 9 GW 546 1 fig 2 2 2 Dimensions All dimensions in mm 1a Air flue duct to the rear 1b Air flue duct to the side 2 Appliance bracket 3 Heating system return 22 mm 4 Cold water connection 15 mm 5 Gas connection 15 mm 6 Hot water connection 15 mm...

Page 6: ...ghts LED s 11 Maximum radiator temperature control 12 Maximum hot water temperature control 13 Central heating control and lockout reset 14 Main on off control 15 CH flow service valve 16 Gas service valve 17 Flue gas duct 18 Fan 19 High efficiency heat exchanger 20 Flame sensing electrode 21 Differential pressure switch 22 Expansion vessel charging valve 23 Expansion vessel 24 Automatic air vent ...

Page 7: ...chosen for the boiler must permit the provision of a satisfactory flue termination The location must also provide adequate space for servicing and air circulation around the boiler The boiler may be installed in any room although particular attention is drawn to the requirements of BS7671 I E E Regulations and in Scotland the electrical provisions of the Building Standards Scotland Regulations in ...

Page 8: ...installation must be tested for soundness and purged as described in BS 6891 3 4 Flue system The standard horizontal flue system Art No 300 807 is suitable for installations up to 995 mm measured from the centre of the boiler flue outlet to the outside face of the wall A fig 4 Flue extensions Art No 300 802 are available to extend this length up to 2965 mm Both 90 elbows Art No 300 808 and 45 bend...

Page 9: ...ipes or drain pipes 25 C Below eaves 25 D Below balconies 25 below car port roof 200 E From vertical drain pipes and soil pipes 25 F From internal or external corners 25 G Above ground or balcony level 300 H From a surface facing a terminal 600 I From a terminal facing a terminal 1200 J From an opening in a car port e g door window into a dwelling 1200 K Vertically from a terminal on the same wall...

Page 10: ...ble pole switch with a 3mm contact separation on both poles may be used 3 7 Guide to system requirements 3 7 1 Water circulation system Detailed recommendations for the water circulation system are given in BS 6798 and BS 5449 Part 1 for small bore and micro bore central heating systems Pipework not forming part of the useful heating surface should be insulated to help prevent heat loss and possib...

Page 11: ... pump with break tank must be used The heating system will not be filled automatically from the domestic hot water side Alternative methods of filling sealed systems are given in BS 5449 3 7 3 Pressure relief valve A pressure relief valve is provided ready assembled within the boiler 5 fig 7 This safety device is required on all sealed C H systems and is pre set at 3 bar and provided with a 3 4 in...

Page 12: ...ed in the return pipe as close as possible to the boiler in accordance with BS 5449 Part 1 Guidance on the sizing of an additional expansion vessel is given in Table 2 3 7 6 Circulating pump The circulating pump is included in the boiler The pump head available for the heating system is shown in fig 8 3 7 7 System by pass An automatic system by pass is included within the boiler The boiler is suit...

Page 13: ...re installation connecting group Art no 8015 is used This clearance is only required to enable easier access to the boiler for servicing and may be provided by an openable door etc Note If the boiler is to be fitted in a timber framed building it should be fitted in accordance with British Gas publication reference DM2 Guide for gas installations in timber framed housing 4 2 Boiler delivery The TU...

Page 14: ...able for the TURBOmax combination boilers 4 2 2 Unpack the boiler fig 11 Open the boiler carton and remove a protective cardboard sheet b top and bottom decorative panels c polystyrene packaging Note Care should be taken not to scratch the white surface of the boiler casing Packed in the boiler carton are the following boiler installation template boiler hanging bracket gas service valve fixing sc...

Page 15: ...existing connecting group Refer to the instructions supplied separately with these accessories 4 3 2 3 Mark on the wall the positions of the hanging bracket fixing holes 2 Drill two holes Ø10 mm for the hanging bracket Note Use the alternative fixing holes where necessary 4 3 2 4 Rear exit flue Mark the position of the centre of the flue duct and its circumference e g by drilling through the templ...

Page 16: ...n heating and water pipework to above the boiler the purpose provided voids in the left and right sides of the boiler casing may be used see fig 16 Note To allow fitting of the bottom boiler cover the left hand tab 2 fig 16 should be folded upwards where pipes are fitted in the left hand void Where pipes are installed in these voids a method of disconnection e g a compression connector 1 fig 16 mu...

Page 17: ...rizontal flue is more than 1 m in length Vertical flues Where a vertical flue less than 1 m e g 1 m between the top of the boiler and the bottom of the vertical air flue duct assemly is used DO NOT fit the restrictor where the vertical flue is more than 1 m in length 4 6 1 Horizontal Flue Remove two screws 1 fig 18 and take off one half ring 2 fig 18 If necessary fit the flue restrictor ring Note ...

Page 18: ...care not to penetrate the inner flue duct Screw the clamps to the air ducts using the self tapping screws provided 4 6 2 Vertical Flue Remove the two half rings 2 fig 18 and if necessary fit the flue restrictor ring Note It will be necessary to remove both half rings if the flue restrictor ring is to be fitted The flue restrictor ring should be placed on top of flue outlet directly below the two h...

Page 19: ...ow complete electrical isolation of the boiler and its ancillary controls It should be readily accessible and adjacent to the boiler A 3 core flexible cord according to BS6500 tables 6 8 or 16 3x0 75 to 3x1 5 mm2 should be used Warning This appliance must be earthed 4 7 2 Connecting to mains supply Slacken front panel fixing screw 1 fig 25 and lower front panel Remove terminal box cover by undoing...

Page 20: ...d boiler terminal 4 should be broken by the contacts of the room thermostat see Schematic layout fig 30 If a frost thermostat is to be fitted it should be connected in parallel across terminals 3 and 4 4 8 2 3 Vaillant optional Plug in timer Accessories Refer to the instructions supplied with the optional plug in timer accessories for connection details ACL Drayton Lifestyle LP711 ACL Drayton Swit...

Page 21: ...i cycling economiser control The boiler incorporates a built in anti cycling control to ensure that energy wasteful short cycling of the boiler cannot occur This control prevents the boiler from re igniting for a pre set period of 5 minutes after central heating operation The hot water operation is unaffected by this control and hot water can be drawn at any time Note To temporarily override the a...

Page 22: ...there is adequate ventilation extinguish naked flames and do not smoke whilst purging After purging the gas service valve connection must be re tightened and tested for soundness The boiler itself does not require purging as this will be done by the automatic burner sequence control 5 3 Water supply Open all domestic hot water taps supplied by the boiler turn on the mains water supply to the boile...

Page 23: ...r release valve To allow this to vent the boiler the cap on top 2 fig 32 must be slackened by 1 2 turns This cap must be left slackened during boiler operation to ensure any residual air or system gases are released Check the heating system and boiler connections are sound 5 5 Initial system flush cold The whole of the heating system must be flushed out at least twice once cold and once hot as ins...

Page 24: ...he Heating and Hot Water position The boiler will now operate for central heating Allow the boiler to run for a few minutes to clear any air remaining in the primary circuit If the boiler should fail to light after the 2nd ignition attempt the lock out indicator will illuminate see fig 41 This usually means that the gas supply is turned off or is not purged of air Check gas supply and turn the cen...

Page 25: ... the desired level Turn off the hot tap after completion of adjustment 5 7 Gas inlet working pressure Check the gas inlet working pressure by slackening the sealing screw and attaching a U gauge to the test point 3 fig 36 on the inlet to the gas valve Fire the boiler at full rate by opening a hot water tap Check that the U gauge is reading 20 mbar If the pressure is not 20mbar this should be inves...

Page 26: ...6 Remove screw 1 fig 39 and remove terminal box cover to access the range rating potentiometer 1 fig 40 beneath Operate the central heating by turning the central heating control to the Heating and Hot Water position ensuring that the external controls are calling for heat and the maximum radiator temperature control is set to 9 The central heating output can now be altered by inserting an electri...

Page 27: ...ed Set the boiler central heating control to the Hot Water only position Turn on a hot tap and draw water at a high rate The hot water demand indicator will illuminate The appliance will start its lighting sequence Once the fan and flue system has proved itself the fan operation indicator will light The gas valve will open and sparking will commence at the burner The ignition indicator will illumi...

Page 28: ...The minimum pressure should not be less than 1 Bar in any installation If the system is to be treated with an inhibitor it should be applied at this stage Sentinel X 100 is suitable for this purpose and it should be applied in accordance with the manufacturers instructions Further instructions can be obtained from Sentinel Grace Dearborn Ltd Tel 0151 4951861 Disconnect the temporary filling connec...

Page 29: ... is law that all servicing work is carried out by a competent person CORGI registered IMPORTANT Before starting any maintenance work Isolate the mains electricity supply by disconnecting the plug at the socket outlet if there is an isolating switch only remove the fuse from the switch Turn OFF the gas supply at the gas service valve fitted to the boiler Always test for gas soundness and always car...

Page 30: ...Turn off boiler CH service valves 1 and 5 Turn off DHW cold water service valve 4 6 2 3 Remove combustion chamber front cover 5 fig 44 Remove four screws 2 fig 54 securing combustion chamber front cover Lift combustion chamber clear of top retaining lugs and pull forward Remove combustion chamber cover by first bringing the left side forward to clear boiler casing 6 2 4 Inspect main heat exchanger...

Page 31: ...el is between 0 7 0 9 Bar If pressure is lower than this the vessel should be re pressurised using an air pump Refit valve cap 2 fig 49 Open central heating service valves and re pressurised the boiler and heating system if necessary see section 5 4 6 3 Re commissioning the boiler Refit the heat exchanger front panel Refit combustion chamber front cover ensuring that the seal is in good condition ...

Page 32: ...ter any service work and after exchanging any electrical component 7 1 Initial preparation These initial preparation procedures need only be carried out where specifically mentioned in the individual component replacement procedures 7 1 1 Turning off the boiler fig 50 Isolate the electrical supply to the boiler Turn off the gas service valve 1 Turn off boiler CH service valves 2 Turn off DHW cold ...

Page 33: ...mbustion chamber cover fig 54 Remove front casing as in section 7 1 3 Remove four screws 2 securing combustion chamber front cover Lift combustion chamber cover clear of top retaining lugs and pull forward Remove combustion chamber cover by first bringing the left side forward to clear boiler casing Check condition of case seal and if necessary replace before refitting Reassemble in reverse order ...

Page 34: ... casing Carry out electrical checks see section 5 1 7 3 Replacement of air pressure switch fig 56 Isolate the boiler from the electrical supply Remove front casing as in section 7 1 3 Disconnect electrical connections to pressure switch Remove screw 1 and lift out pressure switch Disconnect air tubes 2 from switch Reassemble in reverse order Carry out electrical checks see section 5 1 Note Air tub...

Page 35: ...e 7 5 Replacement of electrodes Isolate the boiler from the electrical supply Remove front casing as in section 7 1 3 and remove combustion chamber cover as in section 7 1 5 Remove heat exchanger front panel as in section 7 1 7 Pull off HT lead ignition electrode or sensing wire flame sensing electrode 1 fig 57 Depress spring retaining clip 1 fig 58 gently pull electrode up and clear of burner To ...

Page 36: ...cal supply Remove the front casing as in section 7 1 3 Lower front control panel as in section 7 1 6 Turn off the gas service valve 1 fig 50 Loosen screw 1 fig 59 and pull off rectifier plug 2 fig 59 from the gas operator Pull off modulating coil wires 3 fig 59 Disconnect air tube from gas operator 4 fig 59 Remove two screws 5 fig 59 at burner inlet connection Remove screw 6 fig 59 from gas valve ...

Page 37: ... Carry out electrical checks see section 5 1 and test all gas joints for soundness 1 4 2 3 fig 61 GW 644 1 7 8 Replacement of main heat exchanger Turn off the boiler as in section 7 1 1 Remove front casing as in section 7 1 3 and remove combustion chamber cover as in section 7 1 5 Remove heat exchanger front panel as in section 7 1 7 Release CH water pressure and drain boiler as in section 7 1 2 R...

Page 38: ...r as in section 7 1 1 Release CH water pressure and drain boiler as in section 7 1 2 Lower front control panel as in section 7 1 6 Disconnect external wiring from boiler wiring terminal box Disconnect flow and return connections at compression connection above boiler CH service valves 1 fig 64 and remove two screws securing retaining lug to appliance chassis 2 fig 64 Disconnect gas connection at c...

Page 39: ... 7 1 6 Pull wires off overheat thermostat 2 fig 66 Unscrew overheat thermostat to remove Reassemble in reverse order Carry out electrical checks see section 5 1 7 12 Replacement of pump Remove front casing as in section 7 1 3 Turn boiler off as in section 7 1 1 Release pressure and drain boiler as in section 7 1 2 Lower front control panel as in section 7 1 6 Disconnect ignition leads 3 fig 65 fro...

Page 40: ...emove bypass connecting pipe Undo union 1 fig 69 to remove bypass Reassemble in reverse order using sealing washers supplied Refill and repressurise the boiler see section 5 4 7 15 Replacement of diverter valve Turn off boiler as in section 7 1 1 Remove front casing as in section 7 1 3 Release CH water pressure and drain boiler as in section 7 1 2 Open hot water taps Lower front control panel as i...

Page 41: ...ion 7 1 6 Undo union 2 fig 71 on diverter valve to release pressure gauge tube Remove temperature gauge phial from pocket on primary flow pipe Press spring clips on side of gauge to remove from front panel Replace in reverse order Refill and repressurise the boiler see section 5 4 7 17 Replacement of differential pressure switch Turn off boiler as in section 7 1 1 Remove front casing as in section...

Page 42: ...ks see section 5 1 7 19 Replacement of DHW heat exchanger Turn off boiler as in section 7 1 1 Remove front casing as in section 7 1 3 Release CH water pressure and drain boiler as in section 7 1 2 Lower front control panel as in section 7 1 6 Unscrew the top two unions 1 fig 74 bottom left hand union and backnut 2 fig 74 Note The connection between the DHW heat exchanger and water section is a pus...

Page 43: ...le from control board 2 fig 75 Unplug all leads from the both boards 1 fig 75 Pull off switchboard board support Pull switchboard carefully out of control box Push four spring retaining clips 5 fig 76 out and gently lift control board out of control box Reassemble in reverse order Note When refitting the control board ensure that the user control spindles 3 fig 75 are aligned with the potentiomete...

Page 44: ...an operation indicator yellow Illuminates to indicate that the fan is operating and has been checked by the fan pressure switch A flashing indicator shows that the air pressure switch has not made Ignition indicator yellow Illuminates when gas valve operator and ignition transformer are energised This indicator remains on during burner operation A flashing indicator shows lack of water or poor wat...

Page 45: ... with appliance If fuse is defective suspect wiring fault on external controls see note 1 Does green power on indicator glow now Go to sheet B Go to sheet C Check continuity of overheat thermostat replace if necessary Does the green indicator flash now Check transformer A fig 67 230 V AC primary black red and approx 17 V secondary blue brown Does the indicator flash now Replace electronic boards R...

Page 46: ...ck replace 1 25 A fuse next to the transformer plug spare fuse provided with the appliance Does green indicator glow now Check main on off control overheat thermostat and anti surge fuse Sheet B Check transformer A fig 67 230 V AC primary black red and approx 17 V secondary blue brown Does the indicator glow now Replace electronic boards Yes Yes Yes No No No No Yes ...

Page 47: ...ntral Heating control and external controls Sheet C If the central heating demand indicator still does not glow replace electronic boards Yes Yes No No Go to sheet D Is 230 V AC present across boiler terminals 4 and 5 External fault Check whether all external controls are calling for heat replace or repair as necessary see also note 1 sheet A No Yes No ...

Page 48: ...after 30s Turn boiler on off control switch off then on again Check maximum radiator temperature control is set high enough e g 9 Does the pump run now Is 230 V present at the pump plug connection X10 on the electronic boards Replace electronic boards Check pump replace as necessary Yes Yes No No Yes No No No No Yes Go to sheet H Go to sheet E Fill and vent system No Go to sheet F Yes Yes Yes ...

Page 49: ...No heat demand Go to sheet C Check replace fan Yes No Yes Yes No No No No Yes Switch main on off control off and on again Yes Check NTC Disconnect NTC lead at plug 3 fig 37 Does fan run now Check connection to NTC temperature sensor clean and tighten Check NTC not shortened to earth If O K replace NTC sensor Replace electronic boards No Yes Does yellow flame indicator glow Defective electronic boa...

Page 50: ...ith water Is solenoid activated Is differential pressure switch activated Check for dirt or damage to the differential switch supply tubes and diaphragm Go to sheet G Yes Yes No Yes No No No Yes Fill and vent system and boiler No Check continuity of microswitch Replace if necessary Check connection of ribbon plug to switch board If burner still fails to light replace electronic boards Yes ...

Page 51: ...ision device defective replace electronic boards Check gas supply Reset lockout turn central heating control to position and release Does sparking commence at burner Go to sheet H No Yes No Yes Go to sheet H Check all electrodes and leads for damage and correct connection Replace if necessary No Does sparking commence at burner now Ignition transformer on electronic board defective replace electro...

Page 52: ...connections to modulating solenoid Replace modulating regulator of gas valve if burner still fails to increase to full rate Yes No No No Replace electronic boards Go to sheet J Yes Is flame extinguished after 2nd ignition attempt and red lockout indicator lit Is flame visible prior to lockout condition Check gas supply is live and purged Check connections operation of both solenoids replace gas va...

Page 53: ...ectrical checks Check D H W operation Sheet J Does actuating lever operate D H W microswitch on diverter valve water section assembly Check cold water inlet pressure is sufficient Check filter in cold water inlet is clean Check cold water isolating valve 3 fig 50 is fully opened turn anticlockwise Does lever move now Yes No Draw hot water at high rate Check replace D H W microswitch Check clean di...

Page 54: ...ATER PUMP SELECTOR OVERHEAT THERMOSTAT FAN CONTROL AIR PRESSURE SWITCH FAN PUMP DHW MICRO SWITCH FLAME SENSOR GAS VALVE GAS BURNER CONTROL LEGEND NOTE ALL UNCODED WIRES ARE BLACK b blue br brown r red t transparent t r r NTC TEMPERATURE SENSOR PRESSSURE DIFFERENTIAL SWITCH IGNITION ELECTRODES b br IGNITION TRANSFORMER L 2 1 F2A F2A N plug in connector plug in connector fig 78 ...

Page 55: ... 0 Combustion chamber Control box Flame sensing electrode Ignition electrode NTC sensor Fan Water switch Pressure differential switch Overheat thermostat Air pressure switch Gas valve Pump Main transformer Ignition transformer Main switchboard Control board ...

Page 56: ...ITION ELECTRODES GAS VALVE PUMP PRESSURE DIFFERENTIAL SWITCH OVERHEAT THERMOSTAT MAIN SWITCHBOARD CONTROL BOARD CONTROL BOX DHW MICRO SWITCH 9 IGNITION TRANSFORMER grey orange green 8 MAIN TRANSFORMER 7 5 4 3 LN NTC TEMPERATURE SENSOR AIR PRESSURE SWITCH LEGEND b blue br brown r red t transparent fig 80 ...

Page 57: ...rode 09 0562 10 Flame sensing electrode 09 0563 11 HT lead ignition electrode 09 1534 12 Expansion vessel 18 1045 13 Pump 16 1111 14 Gas valve natural gas 05 3369 15 Modulating regulator natural gas 17 0376 16 DHW microswitch 12 6255 17 Diaphragm 01 0357 18 Switch and control board 13 0438 19 Main transformer 28 7442 20 NTC temperature sensor 25 2805 21 Temperature and pressure gauge 10 1558 01 fi...

Page 58: ...W 684 1 13 fig 90 GW 686 1 15 fig 92 GW 682 1 09 fig 87 GW 683 1 12 fig 89 GW 693 1 14 fig 91 GW 691 1 16 fig 93 GW 689 1 17 fig 94 GW 690 1 N L 3 4 5 7 8 9 18 19 fig 95 GW 692 1 20 fig 96 GW 685 2 21 fig 97 GW 681 2 ...

Page 59: ... MJ m3 Gas consumption s t 1 09 Propane 1 27 Propane m3 h 0 84 Butane 0 98 Butane m3 h 59 Technical Data L P G Appliances VUW 242 1 EB VUW 282 1 EB The appliance delivered is designed for use with LPG Please read the instructions for installation therefore as follows Related documents to be supplemented by BS 5482 CP for domestic butane and propane gas burning installations Part 1 Installations in...

Page 60: ...ubject to alteration We do not accept liability for damage arising as a result of the non observance of these instructions Head Office Vaillant Ltd Vaillant House Medway City Estate Trident Close Rochester Kent ME2 4EZ Sales 01634 292310 Service Solutions 0870 6060 777 Technical Advice 01634 292392 Training 01634 292370 ...