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- TURBOmax VUW 242 E
- Instructions For Installation And Servicing
Vaillant TURBOmax VUW 242 E Instructions For Installation And Servicing
Summary of TURBOmax VUW 242 E
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..
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2 page 1. Introduction 3 2. Boiler specification 4 2.1 technical data 4 2.2 dimensions 5 2.3 boiler connections 5 2.4 function diagram 6 3. General requirements 7 3.1 related documents 7 3.2 boiler location 7 3.3 gas supply 8 3.4 flue system 8 3.5 air supply 10 3.6 electricity supply 10 3.7 guide to...
Page 3: 1. Introduction
3 3 1. Introduction note: this boiler must be installed and serviced by a competent person in accordance with the gas safety (installation and use) regulations 1994. In the uk 'corgi' registered installers undertake the work to a safe and satisfactory standard. The turbomax is a fully automatic, wal...
Page 4: 2. Boiler Specification
Turbomax vuw 242/1 e vuw 282/1 e units countries of destination gb, ie maximum ch heat input 29.3 34.2 kw (100,000) (116,600) (btu/h) ch heat output range 9.6-24.0 11.2-28.0 kw (32,800-81,900) (38,200-95,500) (btu/h) maximum dhw heat input 29.3 34.2 kw (100,000) (116,600) (btu/h) maximum dhw heat ou...
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5 5 1021 880 95.5 480 120 max. 995* max. 995 * 1a 1a 190 1b 2 7 6 5 4 3 8 35 50 380 120 gw 547/1 fig. 1 2.3 boiler connections 1 compression union (flow of heating system) 2 service valve (flow of heating system) 3 domestic hot water connection 4 compression union (gas) 5 gas service valve (supplied...
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6 6 1 9 2 3 4 5 6 7 8 1 9 2 3 4 5 6 7 8 υ 0 0 60 90 120 4 3 2 1 30 1 2 3 4 5 7 6 8 9 10 11 12 13 14 15 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 gw 573/2gb fig. 3 2.4 function diagram 1 air duct 2 air pressure switch 3 combustion chamber 4 temperature sensor (ntc) 5 ignition electrodes 6...
Page 7: 3. General Requirements
7 3. General requirements 3.1 related documents the installation of the boiler must be in accordance with the relevant requirements of gas safety (installation and use) regulations 1994, health and safety document no. 635 (the electricity at work regulations 1989), bs7671 (iee wiring regulations) an...
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8 3.3 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 gas supply required...
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3.4.1 flue termination 1. The terminal must be positioned such that the combustion products can disperse freely at all times. 2. In certain weather conditions a plume of water vapour may be visible from the flue terminal. Positions where this could be a nuisance should be avoided. 3. If the terminal...
Page 10
10 3.5 air supply detailed recommendations for air supply are given in bs 5440: part 2. It is not necessary to have an air vent in the room or internal space in which the boiler is installed. 3.5.1 cupboard or compartment air supply turbomax room sealed combination boilers are very high efficiency a...
Page 11
11 heating circuit return double check valve assembly hose unions temporary hose test valve stop valve mains water supply fig. 6 gw 400/1 3.7.2 filling and make up the system should be filled with water via a separate filling point fitted at a convenient position on the heating circuit. Where local ...
Page 12
12 safety valve setting (bar) 3.0 initial system pressure (bar) 1.0 1.5 total water content of system vessel volume (l) litres 25 2.7 3.9 50 5.4 7.8 100 10.9 15.6 125 13.6 19.5 150 16.3 23.4 175 19.1 27.3 200 21.8 31.2 225 24.5 35.1 250 27.2 39.0 275 30.0 42.9 300 32.7 46.8 325 35.7 50.7 350 38.1 54...
Page 13: 4. Boiler Installation
4. Boiler installation sequence 4.1 general the boiler should be mounted on a flat and vertical area of wall of sufficient area for the boiler plus the required minimum clearances for installation and servicing (fig. 10). These are shown on the installation template supplied with the boiler and are:...
Page 14
Standard accessories art. No. 1. Air/flue duct and terminal accessory 300 807 optional accessories art. No. 1. Vertical air / flue duct (including terminal) 300 800 2. Pitched roof adjustable roof tile (for use with vertical air/flue duct) 9076 3. Flat roof penetration collar (for use with vertical ...
Page 15
15 4.3.2 using the boiler template (fig. 12) 4.3.2.1 once a suitable location has been chosen, fix the paper installation template on the wall ensuring that the centerline of the template is vertical using a spirit level or plumb line. The template shows the positions of the fixing holes for the boi...
Page 16
4.4 installing the flue system at this stage install the flue system (refer to separate installation instructions supplied). 4.5 mounting the boiler 4.5.1 preparation remove the boiler from the carton. Lay the boiler on the floor and remove the white boiler bottom cover by removing two screws (1, fi...
Page 17
4.5.3.4 gas supply the boiler is supplied with a 20 x 15 mm gas service valve (10, fig. 14). Fit the 20 mm compression fitting to the boiler gas inlet (11, fig. 14) and tighten. Install a gas supply pipe not less than 15 mm diameter and connect to the gas service valve. (ensure the gas supply pipewo...
Page 18
Loosen screws on the 95 mm diameter x 55 mm wide clamp (6, fig. 21) and push over the air duct. Remove screws and sealing washer on the 95 mm diameter x 25 mm wide clamp (3, fig. 21) and push onto the flue elbow on the side to be connected to the appliance. Ensure the clamp is clear of the end of th...
Page 19
Drill two holes 3 mm diameter through the air duct clamp (2. Fig 24) ensuring that the drill does not pene- trate the flue duct. Screw the clamp to the boiler half ring using the self tap- ping screws provided. Note: the air duct clamp must not be screwed to the bottom of the air flue duct and termi...
Page 20
N l 4 3 n l 4 3 3 4 5 20 4 3 n l n l 4 4.8 controls 4.8.1 external electrical controls the boiler terminals 3,4 and 5 are for connecting external 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, t...
Page 21
21 4.8.3 thermostatic radiator valves the boiler has a built-in automatic bypass valve making it ideal for use in systems with thermostatic radiator valves (no separate system bypass is required). For optimum fuel economy it is recommended that where trvs are used they are used in conjunction with a...
Page 22: 5. Commissioning
22 3 1 2 fig. 31 gw 610/1 5. Commissioning 5.1 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. 5.2 gas supply the complete gas installation including the gas meter must be ...
Page 23
23 2 1 fig. 32 gw 634/1 5.4 filling the heating system the boiler primary circuit and the heating system should be filled using a filling method as described in section 3.7.2. Ensure that the boiler ch service valves (3, fig. 31) are open. Partially open the filling valve and allow water to enter th...
Page 24
5.6 initial lighting • check that the boiler combustion chamber (5, fig. 33) is correctly fitted. • ensure the cold water shut-off valve (4, fig. 34) is open by turning anti-clockwise. • open the gas service valve (2, fig. 34) • check that the ch service valves (1 and 5, fig. 34) are open. • check t...
Page 25
Vuw 242/1 vuw 282/1 maximum burner 10.0 mb 10.6 mb pressure (dhw) ( -–+1.0 mb) ( -–+1.0 mb) maximum gas 2.79 m 3 /h 3.26 m 3 /h rate (98.5 ft 3 /h) (115.1 ft 3 /h) 25 1 fig. 35 gw 635/1 1 2 3 fig. 36 gw 1533/0 1 2 3 fig. 37 gw 1532/0 table 4: burner pressure & gas rate tolerance shown, contact vaill...
Page 26
Output to range rating mbar central heating mbar vuw 242/1 vuw 282/1 28.0 (95,560) - 10,6 24.0 (81,900) 10,0 8,0 21.0 (71,700) 8,0 6,3 18.0 (61,500) 6,1 4,8 15.0 (51,200) 4,5 3,4 12.0 (41,000) 3,1 2,2 min. 9,6 (32,800) 2,0 - min. 11,2 (38,240) - 2,0 26 table 5: central heating output (range rating) ...
Page 27
• the gas valve will open and spar- king will commence at the burner. The ignition indicator will illuminate. • as soon as the burner has ignited and the flame has been sensed the flame indicator will illuminate. • by illuminating in this sequence the indicator lights have demonstrated correct opera...
Page 28
28 5.11 checking flame supervision device operate the boiler and turn off the gas supply at the boiler gas service valve. The boiler should attempt to re-light (sparking at ignition electrode visible through viewing window) for approximately 9 seconds, if ignition does not occur the boiler will re-a...
Page 29: 6. Servicing
5.14 hand over to user set the maximum radiator temperature control (3, fig. 44) to the desired setting. The following settings may be used as a guide: spring and autumn 5 – 6 winter (normal) 6 – 7 winter (severe) 7 – 9 note: if the setting is too low the radiators may not reach the desired temperat...
Page 30
30 6.2 routine maintenance 6.2.1 remove front case remove bottom hinge screw (1, fig. 46) and pull lower door panel forward and down to release it from the top hinge pin (2, fig. 46). Slide the top panel up to release retaining clips (1, fig. 47). Lift off top panel. • remove boiler bottom cover by ...
Page 31
31 2 fig. 49 gw 604/1gb 2 1 3 fig. 48 gw 639/1 6.2.5 inspect burner with the combustion chamber front cover and heat exchanger front panel removed it is possible to inspect the burner. Any deposits should be removed with a soft brush. Check the condition of the ignition and monitoring electrodes. 6....
Page 32: 7. Parts Replacement
32 4 3 2 5 4 2 1 fig. 50 gw 619/1 7. Parts replacement 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). • when removing any water carrying co...
Page 33
33 7.1.3 removal of front casing 7.1.3.1 door (fig. 52) • remove bottom hinge screw (1) and pull the bottom door panel forwards and down to release it from top hinge pin (2). 7.1.3.2 top panel (fig. 53) • slide top panel upwards to release retaining clips (1). 7.1.3.3 bottom cover plate (fig. 51) • ...
Page 34
34 7.2 replacement of fan (fig. 55) • 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. • disconnect the electrical connections from the fan. • remove the 2 fan securing screws (4) and remove fan. • reas...
Page 35
35 7.4 replacement of burner • isolate the boiler from the electrical supply. • remove front casing as in section 7.1.3. • remove combustion chamber cover as in section 7.1.5 • disconnect the ignition and flame sensing electrode leads (1, fig. 57). • remove two screws (2, fig 57) and pull burner for...
Page 36
36 1 5 4 3 2 6 fig. 59 gw 643/1 1 1 2 2 fig. 60 gasventil 7.6 replacement of ntc temperature sensor note: the ntc temperature sensor is an extremely reliable component and as such is unlikely to fail. Before changing the ntc please check that it is defective - see section 8 - fault finding. • discon...
Page 37
37 7.7.1 replacement of modulating regulator • isolate the boiler from the electrical supply. • remove 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. 61) and pull off rectifier plug (2, fig. 61...
Page 38
38 7.9 replacement of ch expansion vessel in the unlikely event of a failure of the ch expansion vessel follow procedure 7.9.1 or 7.9.2 depending upon the installation circumstances. 7.9.1. Boiler installed with air/flue duct to left/right hand side, or vertical flue installation (where 300mm vertic...
Page 39
39 7.10 replacement of transformer • isolate boiler from the electricity supply. • remove front casing as in section 7.1.3 • lower front control panel as in section 7.1.6. • disconnect ignition leads (3, fig. 65) from rear of control box. • remove back of control box by undoing the 3 screws (1 and 2...
Page 40
40 2 1 fig. 69 gw 607/1 2 1 fig. 70 gw 646/1 5 1 6 2 3 4 5 fig. 71 gw 647/1 7.13 replacement of automatic air release • 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 ...
Page 41
41 7.15.1 replacement of water section diaphragm (fig. 72). • turn off boiler as in section 7.1.1. • remove bottom cover as in section 7.1.3.3. • open hot water taps. • remove clip (2), undo union (3) • remove 6 screws (4). • pull water section base away from dhw heat exchanger and drop down. • remo...
Page 42
42 1 2 fig. 74 gw 650/2 7.18 replacement of dhw microswitch. • isolate appliance from electricity supply. • remove front casing as in section 7.1.3. • lower front control panel as in section 7.1.6. • lift off microswitch retaining ’bow’ spring, • pull microswitch forward to remove from mounting brac...
Page 43
5 1 i ii fig. 76 gw 774/1 43 7.20 removal of printed circuit boards (pcbs) before commencing work on pcb replacements carry out the following:- diagnose that the boards require changing using the fault finding guide (see section 8: fault finding). • turn off the boiler as in section 7.1.1. • remove ...
Page 44: 8. Fault Finding
Flame indicator (yellow) illuminates when flame is recognised by the flame monitoring system. (a flashing indicator shows that the ntc sensor is broken, not connected or shorted to earth.) burner lockout indicator (red) illuminates if the burner fails to light within 9 seconds of illumination of the...
Page 45
45 does green power `on` indicator ( ) glow or flash? Does green power `on` indicator ( ) flash? Go to sheet c. Ensure boiler main on/off control is set to position ` `. Is 230 v present across ter minals l and n? Reset overheat cut-off device by pressing on the middle of the transparent rubber cove...
Page 46
46 is 230 v present across boiler ter minals 3 and 5? Does green power `on` indicator ( ) glow now? Go to sheet c. Boiler on/off control defective, replace electronic boards. Check, replace 1.25 a fuse next to the transfor mer plug (spare fuse provided with the appliance). Does green indicator glow ...
Page 47
47 does yellow central heating demand indicator ( ) glow? Does bur ner light? Go to sheet h. Check central heating control switch is set to the position ( ). Check central heating control and exter nal controls sheet c if the central heating demand indicator ( ) still does not glow , replace electro...
Page 48
48 does pump run? Does the yellow ignition indicator ( ) flash after 30s? Has system been filled with water? Does bur ner light? Check operation of pump sheet d does the yellow ignition indicator ( ) flash after 30s? Tu rn boiler on/off control switch off, then on again. Check maximum radiator tempe...
Page 49
49 does fan run? Does yellow fan operation indicator ( ) flash? Does yellow flame indicator ( ) flash? Does yellow fan operation indicator flash or glow? Check air/flue gas system is correctly fitted and not obstructed. Check pitot tube (in fan outlet) and air hoses are not obstructed and are correc...
Page 50
50 does sparking star t? Go to sheet .H does yellow ignition indicator ( ) flash after 30s? Replace electronic boards. Check operation of dif ferential pressure switch sheet f has system been filled with water? Is solenoid activated? Is differential pressure switch activated? Check for dir t or dama...
Page 51
51 does bur ner light? Does yellow flame indicator ( ) flash? Check/change ntc and connections does red lockout indicator ( ) glow after 2nd ignition attempt? Check ignition system and gas section sheet g ye s ye s no flame super vision device defective, replace electronic boards. Check gas supply ....
Page 52
52 does yellow flame indicator ( ) glow and flames increase in size to full rate? Does bur ner flame modulate/ go out when maximum radiator temperature control is tur ned down to position 1 at a flow temperature of approx. 50 degree c? Check potentiometer for par tial load setting (see 5.9 c.H. Rang...
Page 53
53 does yellow hot water demand indicator ( ) glow? Check hot water flow rate and temperature. Compare with techncal data. The max. Temperature increase is obtained with d.H.W . Ther mostat on position 9. If flow rate is not sufficient, check imcoming main water supply . Nor mal operation carr y out...
Page 54: 9 Electrical Diagrams
54 9 electrical diagrams 9.1 functional flow diagram: vuw 242/1 e, 282/1 e gw 651/1 main switch control box main switchboard main transformer 230v 20v power supply control board water-pump selector overheat thermostat fan- control air pressure switch fan pump dhw micro switch flame sensor gas valve ...
Page 55
55 9.2 wiring diagram: vuw 242/1 e, 282/1 e fig. 79 gw 1542/0 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 switchboa...
Page 56
56 9.3 schematic appliance circuit diagram: vuw 242/1 e, 282/1 e gw 652/1 fan b br t r r flame-sensor ignition-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 transf...
Page 57: 10. Short Parts List
57 10. Short parts list key no. Description part no. Gc no. 01 fan 19 0162 02 air pressure switch 05 0557 03 main heat exchanger vuw 242/1 06 4951 04 main heat exchanger vuw 282/1 06 4952 05 burner vuw 242/1 04 1960 06 burner vuw 282/1 04 1961 07 diverter valve 01 1269 08 dhw heat exchanger 06 4950 ...
Page 58
58 10 fig. 88 gw 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: Technical Data
Type vuw vuw 242/1 e b 282/1 e b countries of gb, ie gb, ie destination main burner jet size 16 x 7/075 18 x 7/075 number x mark. Burner setting pressure 25.1 (9.9) propane 26.6 (10.5) propane mbar (in w.G.) 19.3 (7.6) butane 20.6 (8.1) butane mbar (in w.G.) restrictor 2 * 350 2 * 375 marking delive...
Page 60
83 30 50 gb/ie heating, controls, hot water 0698 v printed in germany - imprim é en allemagne printed on 100 % recycled paper subject 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 ...