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- TURBOmax Pro 2 E
- Instructions For Installation And Servicing
Vaillant TURBOmax Pro 2 E Instructions For Installation And Servicing
Summary of TURBOmax Pro 2 E
Page 1
Instructions for installation and servicing turbomax pro 28/2 e wall hung room sealed fan assisted combination boilers the code of practice for the installation, commissioning & servicing of central heating systems i 0
Page 2: Table Of Contents
2 table of contents introduction boiler specification general requirements boiler installation sequence general information . . . . . . . . . . . . . . . . . . . . . . . . . .5 ec designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 list of contents contents included with boiler ...
Page 3: Table Of Contents
3 table of contents gas supply adjustments (commissioning part ii) servicing fault finding introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 logical fault finding procedure . . . . . . . . . . . . . . . . . .57 fault finding charts . . . . . . . . . . . . . . . . . . . . ....
Page 4: List of Contents
4 list of contents contents included with boiler ensure that all contents are included before commencing installation. Do not remove the boiler from the polystrene base at this stage. Bedienungsanleitung bedienungsanleitung bedienungsanleitung bedienungsanleitung 8 9 9 9 bedienungsanleitung instruct...
Page 5: Introduction
5 introduction the turbomax pro is a fully automatic, wall mounted, room sealed combination boiler for central heating and domestic hot water. Domestic hot water is supplied directly from the boiler, without requiring a copper cylinder, cold water tank, feed and expansion tank and associated pipewor...
Page 6: Boiler Specification
6 boiler specification technical data turbomax pro 28/2 e ( vuw gb 282/2-3) units ch heat output range (80/60 °c) 10.4 - 28 (35 500 - 95 500) kw (btu/h) dhw heat output 28 (95 500) kw (btu/h) dhw flow rate ∆ t =35 °c rise 11.5 l/min dhw flow rate at factory set temperature rise ( ∆ t 42 °c) 9.5 l/mi...
Page 7: Boiler Specification
7 boiler specification boiler connections 0 7 6 310 592 145 6 5 100 100 35 35 4 3 2 130 180 1 148 8 5 4 3 2 1 fig. B.1: connection diameters euro b/s 024/2 key: 1 heating system return (22 mm compression) 2 cold water connection with shut off valve (15 mm compression) 3 gas connection (15 mm compres...
Page 8: Boiler Specification
8 boiler specification c c 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 16 18 19 21 22 23 24 25 26 27 28 29 30 31 functional diagram 1 air duct 2 fan 3 main heat exchanger 4 temperature sensor (ntc i) 5 flame sensing electrodes 6 modulating burner 7 fully modulating automatic gas value 8 maximum hot water...
Page 9: General Requirements
9 general requirements ensure that all regulations are observed. Fig. R.1 euro b/s 006/0_gb related documents the installation of the boiler must be in accordance with the relevant requirements of gas safety (installation and use) regulations 1998, health and safety document no. 635 (the electricity...
Page 10: General Requirements
10 general requirements gas supply the gas supplier should ensure the availability of an adequate supply of gas. A gas meter may only be connected to the service pipe by the supplier of gas or their contractor. An existing meter should be checked to ensure that it is capable of passing the rate of g...
Page 11: General Requirements
11 general requirements top outlet flue system (100 mm outside diameter) the top outlet horizontal flue system (art. No. 303 807) is suitable for installations up to 720 mm measured from the centre of the boiler flue outlet to the outside face of the wall. Flue extensions are available to extend thi...
Page 12: General Requirements
12 general requirements flue termination the following details refer to both flue systems. A. The terminal must be positioned such that the products of combustion can disperse freely at all times. B. In certain weather conditions a plume of water vapour may be visible from the flue terminal. Positio...
Page 13: General Requirements
13 general requirements cupboard or compartment ventilation turbomax pro combination boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during operation is very low. For cupboard or compartment installations it is therefore not necessary to provide ...
Page 14: General Requirements
14 general requirements guide to system requirements 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 ...
Page 15: General Requirements
15 general requirements expansion vessel the 28 kw boiler incorporates a 10 litre expansion vessel which is suitable for a sealed heating system with a maximum water content of 100 litres. If the nominal capacity of the built in expansion vessel is not sufficient for the heating system (for instance...
Page 16: General Requirements
16 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] setting ii setting i fig. R.7: pump specifications euro b/s_vc_011/0gb pump specifications circulating pump the circulating pu...
Page 17: General Requirements
17 general requirements 150 5 200 500 5 i 0 0 120 60 90 30 ° c bar 4 3 2 1 0 euro b/s 022/1 440 800 338 i 0 0 120 60 90 30 ° c bar 4 3 2 1 0 euro b/s 023/1 general preparation of boiler location clearances required mount the boiler on a flat and vertical area of wall of sufficient area for the boile...
Page 18: Boiler Installation Sequence
5 5 210 124163 03 240/242/280/282/824/828 pro/plus 60/100 07/2000 124163_03 1 3 2 18 boiler installation sequence using boiler template fix the paper template to the wall ensuring that the correct flue exit point has been identified, ensure that the template is vertical. The template shows - the pos...
Page 19: Boiler Installation Sequence
I 0 3 320 131 22 26,5 27 131 105 105 1 2 0 120 60 90 30 ° c bar4 3 2 1 0 euro b/s 043/1 19 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 hanging bracket (1). ● lower the boiler slowly onto the hangin...
Page 20: Boiler Installation Sequence
3 i 0 2 i 0 90 ° 90 ° 1 euro b/s 041/1 fig. I.5: remove of boiler casing 20 boiler installation sequence removing boiler casing ● turn both securing fasteners (1) anti-clockwise by 90° to release control panel. ● lower control panel (2). ● pull the case (3) forward at the bottom to disengage from th...
Page 21: Boiler Installation Sequence
21 boiler installation sequence gas supply ● connect the 15 mm compression gas service cock (1) supplied with appliance and tighten. ● connect a gas supply pipe of not less than 15 mm diameter to the inlet of the gas service cock. ● tighten all connections. (ensure the gas supply pipework is adequat...
Page 22: Boiler Installation Sequence
22 boiler installation sequence cold water mains inlet and hot water outlet flush all foreign matter from the mains supply before connecting to the boiler. ● connect the cold water service valve (1) to the cold inlet water connection of the appliance with the washer (2) provided and tigh- ten. ● con...
Page 23: Boiler Installation Sequence
23 boiler installation sequence central heating flow and return pipework before connecting the heating circuit to the boiler appliance, all pipework and radiators must be thoroughly flushed to remove any installation debris. ● connect the central heating flow (4) and return (1) service valves to the...
Page 24: Boiler Installation Sequence
24 boiler installation sequence electrical installation general requirements all electrical work shall be carried out by a competent person and shall comply with bs7671 (iee regulations). The boiler is supplied for connection to 230 v, ~ 50 hz supply fused at 3 a rating. Connection to the mains supp...
Page 25: Boiler Installation Sequence
25 boiler installation sequence caution mains connection terminals l and n remain live even when the boiler on/off control is switched off. ● refit the terminal box cover by pushing into place until it clips back into position. ● raise the control panel and secure in place. Connection to the main su...
Page 26: Boiler Installation Sequence
26 boiler installation sequence euro b/s 048/1 socket x2 for internal unit components socket x4 for minority reversing valve socket x7 for accessory box connection socket x8 for vrc-vc connection room thermostat, 230 v: connections 3, 4 and 5 socket x12: pump connection socket x14: gas valve connect...
Page 27: Boiler Installation Sequence
27 boiler installation sequence controls external electrical controls the boiler terminals 3, 4 and 5 are for connecting external electrical controls such as a time switch and/or room thermostat. Terminals 3 and 4 are linked together when the boiler is supplied. If external controls are used, this l...
Page 28: Boiler Installation Sequence
28 boiler installation sequence for optimum fuel economy it is recommended that where trv’s are used they are used in conjunction with a programmable room thermostat or separate timer and room thermostat to ensure complete boiler shut down when the heating demand is satisfied. (the radiator in the r...
Page 29: Boiler Installation Sequence
29 boiler installation sequence fit boiler casing ● carefully push case (1) onto the boiler such that the locating points either side at the top of the boiler engage. Push the casing onto the securing clips at the bottom of the boiler. ● close control panel (2). ● secure control panel by turning bot...
Page 30: Commissioning Part I
30 commissioning part i preliminary electrical checks check the electrical installation by carrying out short circuit, earth continuity and resistance to earth tests and a check for correct polarity. Gas supply the complete gas installation including the gas meter must be inspected, tested for sound...
Page 31: Commissioning Part I
31 commissioning part i.
Page 32: Commissioning Part I
32 commissioning part i 2 5 3 4 fig. Com. 1: draining the heating system eor b/s 207/0gb_pro.
Page 33: Commissioning Part I
33 commissioning part i initial system flush („cold“) the whole of the heating system must be flushed out at least twice: once cold, and once hot as instructed later on page 41. Open all radiator or heating valves and the boiler ch service valves and drain the heating system and boiler completely fr...
Page 34: Gas Supply Adjustments
34 gas supply adjustments (commissioning part ii) 1 2 euro b/s 034/0 gas inlet working pressure to check the gas inlet working pressu- re: ● lower the front panel of the boiler. ● lower the control panel. ● slacken the sealing screw (1) located at measuring point „min”. ● attach u-gauge to the inlet...
Page 35: Gas Supply Adjustments
35 gas supply adjustments (commissioning part ii) 1a 1 3 2 3a 2a euro b/s 035/0 main burner pressure ● the burner pressure on this appliance has been factory set and does not require adjustment. To check the main burner pressure connect the u-gauge as follows depending on the gas type. For natural g...
Page 36: Gas Supply Adjustments
36 gas supply adjustments (commissioning part ii) adjusting the central heating output (range rating) the turbomax pro is fully modulating for central heating, and it is therefore not necessary to range rate the boiler. However, if desired, it is possible to range rate the boiler, as follows: ● conn...
Page 37: Gas Supply Adjustments
37 gas supply adjustments (commissioning part ii) 1) 15 °c, 1013 mbar, dry 2) the nozzles are stamped with the values shown in this table. The marking corresponds to the nozzle hole diameter multiplied by 100. 3) 1ignition rate 1) 15 °c, 1013 mbar, dry 2) the nozzles are stamped with the values show...
Page 38: Functional Checks
38 functional checks (commissioning part iii) i 0 functional checks procedure once the unit has been installed and the gas supply has been checked, operate the system to ensure that it is working correctly. ● operate the system, following the operating instructions supplied with the boiler. ● check ...
Page 39: Functional Checks
39 functional checks (commissioning part iii) operation the vaillant turbomax pro is equipped with a set of diagnostic indicator lights to show the operational status of the boiler. A functional check of dhw and ch operation can be made using these indicator lights. Hot water system ● ensure that th...
Page 40: Functional Checks
40 functional checks (commissioning part iii) heating system ● ensure that the power on indicator is illuminated (1). ● ensure that the maximum radiator temperature control is turned to the high position. ● ensure external controls are calling for heat. ● the central heating demand indicator will il...
Page 41: Functional Checks
41 functional checks (commissioning part iii) adjusting pump speed the unit is fitted with a two-speed pump. The pump is delivered with the switch (1) set to position ii. Important note: the boiler should only be operated at pump setting ii because the heating capacity for hot water is reduced when ...
Page 42: Functional Checks
42 functional checks (commissioning part iii) set the maximum radiator temperature control 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, in particular the function of ● the boiler on/...
Page 43: Servicing
Servicing 43 before commencing any servicing or maintenance work, carry out an initial inspection 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 the installation. ●...
Page 44: Servicing
44 servicing cleaning the burner and primary heat exchanger ● turn off the boiler. ● isolate the electrical supply to the boiler. ● remove the boiler case as described on page 20. ● turn off the gas service valve. ● turn off the boiler ch service valves. ● turn off the cold water inlet service valve...
Page 45: Parts Replacement
45 parts replacement ensure that all regulations are observed. Fig. E.1: general euro b/s 006/0gb safety instructions the following safety instructions are to be followed when installing replacement parts! Important: before starting any maintenance work: ● isolate the mains electricity supply by dis...
Page 46: Electrodes
46 1 3 4 5 2 euro b/s 158/1 electrodes ● refer to the important information and initial preparation on page 45. ● remove combustion chamber cover by unclipping the three clamps. ● unclip the terminal box cover. ● disconnect both ht leads (3, 4) from the electronic board. ● pull off flame sensor ht l...
Page 47: Parts Replacement
47 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 information and initial preparation on page 45. ● remove combustion chamber cover by unclipping the three clamps (1). ● remove the screw (3) and push the flue connector (4) upwards until it clears the fa...
Page 48: Parts Replacement
48 3 1 2 6 5 7 4 eur o b/s 29 7/0 9 10 8 13 14 11 12 eur o b/s 298/0 parts replacement fig. E.5a: gas valve fig. E.5b: gas valve gas valve ● refer to the important information and initial preparation on page 45. ● loosen screw and pull electrical plug off the gas valve. ● pull off the two modulating...
Page 49: Parts Replacement
49 parts replacement temperature sensors (ntc’s) ● refer to the important information and initial preparation on page 45. ● identify which sensor(s) is to be replaced. ● if required remove combustion chamber cover by unclipping the three clamps. ● pull off connecting wire from sen- sor. ● unscrew nt...
Page 50: Parts Replacement
50 parts replacement 1 4 2 3 fig. E.8: expansion vessel euro b/s 164/0 expansion vessel please note: in the unlikely event of a failure of the ch expansion vessel follow procedure depending upon the installation circumstances. Boiler installed with top connection air/flue duct to left/right hand sid...
Page 51: Parts Replacement
51 parts replacement electronic control board ● refer to the important information and initial preparation on page 45. ● lower control box. ● unclip the terminal box cover by releasing the cover retaining clips and lift to remove. ● unclip the electronic board cover by releasing the clips (2) and li...
Page 52: Air Pressure Switch
52 air pressure switch ● refer to the important information and initial preparation on page 45. ● remove clips (6) and lift out pressure switch (7). ● disconnect electrical connections (4). ● disconnect air tubes (5). ● re-assemble in reverse order. Note: air tubes should be reconnected: p1 (marked ...
Page 53: System Bypass
53 system bypass ● refer to the important information and initial preparation on page 45. ● release central heating water pressure. ● remove spring clip (2) ● undo union (1), remove bypass/connecting pipe. ● pull apart bypass and connecting pipe. ● re-assemble in reverse order. Diverter valve ● refe...
Page 54: Parts Replacement
54 parts replacement 2 2 1 fig. E.15: pressure gauge euro b/s171/0 1 4 6 3 5 fig. E.16: aqua sensor euro b/s 172/0gb_pro pressure gauge ● refer to the important information and initial preparation on page 45. ● release central heating water pressure. ● pull out the four retaining clips and remove th...
Page 55: Parts Replacement
55 parts replacement dhw heat exchanger ● refer to the important information and initial preparation on page 45. ● release central heating water pressure. ● remove the diverter valve and pump as previously described. ● disconnect wire from the ntc. ● remove the spring clips (3 and 4). ● undo the bot...
Page 56: Checking Functions
56 i 0 fig. E.19: functional check euro b/s 058/0 checking functions procedure on completion operate the system run to ensure that the boiler is working correctly. ● operate the system, following the operating instructions supplied with the boiler. ● check the system for water leaks and escaping gas...
Page 57: Fault Finding
57 fault finding flame indicator (yellow) illuminates when flame is recognised by the flame monitoring system. (a flashing indicator shows that an ntc sensor is broken, not connected or shorted to earth.) burner lockout indicator (red) illuminates if the burner fails to light within 10 seconds of il...
Page 58: Fault Finding
58 fault finding ensure boiler main on/off control is set to position "1" ye s go to sheet c check electrical supply , appliance fuses and on/of f control no is 230v ac present across ter minals l and n? Ye s is 230v ac present across ter minals 3 and 5? Ye s is voltage between 16-26 vdc present acr...
Page 59: Fault Finding
59 fault finding sheet b check operation of pump and fan tu rn off the main on/off control to the "0" position diconnect the power supply to the boiler go to sheet a check transfor mer 230 v ac primar y (black/red) and approx. 17 vdc secondar y (blue/brown) check/replace pump replace fuse f1 if fan ...
Page 60: Fault Finding
60 fault finding check central heating and controls ensure that radiator temperature control knob is set to ver tical position and that any inter nal timer (if fitted) is calling for heat no is 230 v ac present across ter minals 4 and 5 no exter nal fault: check all exter nal controls are calling fo...
Page 61: Fault Finding
61 fault finding does fan run after approx. 30 secs.? Check flue and ignition system no 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 present across fan ter minals? Replace electronic b...
Page 62: Fault Finding
62 fault finding check gas valve and central heating system pressure does bur ner light 1st attempt? Does bur ner light within 3 ignition attempts? No ye s check gas supply does bur ner light? Ye s check bur ner pressure settings are correct ye s no reset boiler no check/replace gas valve as necessa...
Page 63: Fault Finding
63 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 64: Fault Finding
64 fault finding draw hot water at high rate 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 water inlet pressure is sufficient and t...
Page 65: Fault Finding
65 fault finding.
Page 66: Diagrams
66 diagrams power supply f2a l 2 n 1 main switch main transformer 230v 20v air pressure switch fan pump ntc flow temperature sensor flame sensor gas valve aqua sensor f1,25a ntc return temperature sensor burner lock out indicator (red) hot water demand indicator central heating demand indicator fan ...
Page 67: Diagrams
67 diagrams switchgear cabinet u100 x3 t 2 = f2 t 1,25 = f3 x2 x2 x1 24 23 1 12 13 14 15 16 17 18 19 20 21 22 2 3 4 5 6 7 8 9 10 11 x6 diagnosis x2 aqua sensor pressure sensor ntc retur n ntc ear th ionisation electrode bridge ntc flow ntc flow lifting magnet 24 23 1 12 13 14 15 16 17 18 19 20 21 22...
Page 68: Short Parts List
68 short parts list description part no. Key no. Burner, natural gas burner chamber group: 031501 distributor tube: 126753 er.1 ignition electrode flame sensing electrode 090724 er.2 fan 190215 er.3 gas valve lpg: 053463 natural gas: 053462 er.4 flow-ntc return-ntc 252805 er.5 main heat exchanger 06...
Page 69: Short Parts List
69 short parts list er.1 er.3 er.4 er.6 er.7 er.8 er.9 er.10 er.11 er.12 euro b/s 143/0 euro b/s 148/0 euro b/s 147/0 euro b/s 146/0 euro b/s 156/0 euro b/s 152/0 euro b/s 154/0 euro b/s 144/0 euro b/s 151/0 eur o b/s 1 53/0 er.2 er.5 euro b/s 142/1 euro b/s 177/1.
Page 70: Short Parts List
70 short parts list er.13 er.14 er.17 er.15 euro b/s 149/0 euro b/s 145/0 euro b/s 178/0 euro b/s 150/0 er.16 euro b/s 155/1.
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83 41 11 gb 11 · 02/2002 mü · printed on 100 % recycled paper · subject to alteration head office vaillant ltd., vaillant house, medway city estate, trident close, rochester, kent me 2 4 ez service solutions 0870 6060 777 technical advice 01634 292392.