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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
Supplied by www.Heating spares.Co tel. 0161 620 6677 turbomax vuw 242 e g.C. No 47-044-25 turbomax vuw 282 e g.C. No 47-044-26 wall hung room sealed fan assisted combination boilers instructions for installation and servicing heating, controls, hot water..
Page 2
Supplied by www.Heating spares.Co tel. 0161 620 6677 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...
Page 3: 1. Introduction
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 satisfac...
Page 4: 2. Boiler Specification
Supplied by www.Heating spares.Co tel. 0161 620 6677 turbomax vuw 242 e vuw 282 e units 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) ma...
Page 5
Supplied by www.Heating spares.Co tel. 0161 620 6677 5 5 gw 547/0 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 with the boiler) 6 cold water ...
Page 6
Supplied by www.Heating spares.Co tel. 0161 620 6677 6 6 gw 573/1 fig. 3 2.4 function diagram 1 air duct 2 air pressure switch 3 combustion chamber 4 temperature sensor (ntc) 5 ignition electrodes 6 modulating burner 7 overheat thermostat 8 fully modulating automatic gas valve 9 dhw heat exchanger 1...
Page 7: 3. General Requirements
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 ...
Page 8
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 ...
Page 9
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 coul...
Page 10
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 ...
Page 11
Supplied by www.Heating spares.Co tel. 0161 620 6677 11 fig. 6 gw 400/0 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 water authority regulation allows, a temporary connection to the m...
Page 12
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 ...
Page 13: 4. Boiler Installation
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 in...
Page 14
Supplied by www.Heating spares.Co tel. 0161 620 6677 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....
Page 15
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 templat...
Page 16
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 wh...
Page 17
Supplied by www.Heating spares.Co tel. 0161 620 6677 4.5.3.4 gas supply the boiler is supplied with a 20 x 15 mm gas service valve (10, fig. 14). Fit the 20mm compression fitting to the boiler gas inlet (11, fig. 14) and tighten. Install a gas supply pipe not less than 15mm diameter and connect to t...
Page 18
Supplied by www.Heating spares.Co tel. 0161 620 6677 loosen screws on the 95 mm diameter x 55mm 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 a...
Page 19
Supplied by www.Heating spares.Co tel. 0161 620 6677 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...
Page 20
Supplied by www.Heating spares.Co tel. 0161 620 6677 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. I...
Page 21
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 wh...
Page 22: 5. Commissioning
Supplied by www.Heating spares.Co tel. 0161 620 6677 22 fig. 31 gw 610/0 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 ga...
Page 23
Supplied by www.Heating spares.Co tel. 0161 620 6677 23 fig. 32 gw 634/0 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 o...
Page 24
Supplied by www.Heating spares.Co tel. 0161 620 6677 24 fig. 33 gw 612/0 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) ...
Page 25
Supplied by www.Heating spares.Co tel. 0161 620 6677 vuw 242 vuw 282 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 fig. 35 gw 635/0 fig. 36 gw 636/0 fig. 37 gw 637/0 table 4: burner pressure & gas ra...
Page 26
Supplied by www.Heating spares.Co tel. 0161 620 6677 output to range rating mbar central heating mbar vuw 242 vuw 282 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 2...
Page 27
Supplied by www.Heating spares.Co tel. 0161 620 6677 • 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...
Page 28
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 10 se...
Page 29: 6. Servicing
Supplied by www.Heating spares.Co tel. 0161 620 6677 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...
Page 30
Supplied by www.Heating spares.Co tel. 0161 620 6677 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)....
Page 31
Supplied by www.Heating spares.Co tel. 0161 620 6677 31 fig. 49 gw 604/0 fig. 48 gw 639/0 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...
Page 32: 7. Parts Replacement
Supplied by www.Heating spares.Co tel. 0161 620 6677 32 fig. 50 gw 619/0 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)...
Page 33
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 retaini...
Page 34
Supplied by www.Heating spares.Co tel. 0161 620 6677 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...
Page 35
Supplied by www.Heating spares.Co tel. 0161 620 6677 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)...
Page 36
Supplied by www.Heating spares.Co tel. 0161 620 6677 36 fig. 59 gw 643/0 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 fi...
Page 37
Supplied by www.Heating spares.Co tel. 0161 620 6677 37 7.7.1 replacement of main solenoid valve. • 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). • disconnect ign...
Page 38
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 si...
Page 39
Supplied by www.Heating spares.Co tel. 0161 620 6677 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...
Page 40
Supplied by www.Heating spares.Co tel. 0161 620 6677 40 fig. 69 gw 607/0 fig. 70 gw 646/0 fig. 71 gw 647/0 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. • l...
Page 41
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 ba...
Page 42
Supplied by www.Heating spares.Co tel. 0161 620 6677 42 fig. 74 gw 650/1 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...
Page 43
Supplied by www.Heating spares.Co tel. 0161 620 6677 fig. 76 gw 617/0 43 7.20 removal of printed circuit boards (pcbs) before commencing work on pcb replacements carry out the following:- • diagnose which board requires changing using the fault finding guide (see section 8: fault finding). • turn of...
Page 44: 8. Fault Finding
Supplied by www.Heating spares.Co tel. 0161 620 6677 44 8. Fault finding 8.1 introduction the turbomax has built in diagnostic indicator lights (fig. 77) to assist you with fault finding in the unlikely event of a boiler malfunction. The lights will illuminate in sequence, indicating the operational...
Page 45
Supplied by www.Heating spares.Co tel. 0161 620 6677 45 sheet a check electrical supply and appliance fuses ensure boiler main on/off control is set to position ’ ’ does green power ’on’ indicator ( ) glow is 230 v present across terminals l and n check and if necessary replace 2a fuses situated bel...
Page 46
Supplied by www.Heating spares.Co tel. 0161 620 6677 46 sheet b check main on/off control, overheat thermostat and anti-surge fuse does green power ’on’ indicator ( ) glow now ? Go to sheet c check, replace 1,25 a fuse next to the boiler terminal strip (spare fuse provided with the appliance). Reset...
Page 47
Supplied by www.Heating spares.Co tel. 0161 620 6677 47 sheet c check central heating control and external controls does yellow central heating demand indicator ( ) glow ? Does burner light ? Go to sheet d if the yellow central heating demand indicator ( ) still does not glow, replace main switchboa...
Page 48
Supplied by www.Heating spares.Co tel. 0161 620 6677 48 sheet d check operation of pump does pump run? Is red burner lockout indicator ( ) glowing ? Turn boiler on/off control switch off, then on again. Check maximum radiator temperature control is set high enough (e.G. 9) does pump now run ? Is 230...
Page 49
Supplied by www.Heating spares.Co tel. 0161 620 6677 49 sheet e check fan/flue gas system does yellow fan operation indicator ( ) glow ? Does yellow ignition indicator ( ) glow ? Defective switch board. Does burner light ? Go to sheet h go to sheet f check air/flue gas system is correctly fitted and...
Page 50
Supplied by www.Heating spares.Co tel. 0161 620 6677 50 sheet f check operation of differential pressure switch does sparking start at burner ? Does red lockout indicator ( ) glow after 10 seconds ? Replace main switchboard is gas solenoid activated? Is differential pressure switch activated ? Has s...
Page 51
Supplied by www.Heating spares.Co tel. 0161 620 6677 51 sheet g check ignition system and gas section does burner light ? Does red lockout indicator ( ) glow after 10 seconds? Reset lockout (turn central heating control to position ( ) and release) does sparking commence at burner ? Check all electr...
Page 52
Supplied by www.Heating spares.Co tel. 0161 620 6677 52 sheet h check operation of burner and modulation is flame extinguished after 10s, and red lockout indicator ( ) lit does yellow flame indicator ( ) glow and flames increase in size to full rate ? Check potentiometer for partial load setting (se...
Page 53
Supplied by www.Heating spares.Co tel. 0161 620 6677 53 sheet j check d.H.W. Operation draw hot water at high rate does yellow hot water demand indicator ( ) glow ? Does actuating lever operate dhw microswitch on diverter valve/water section assembly ? Check cold water inlet pressure is sufficient. ...
Page 54: 9 Electrical Diagrams
Supplied by www.Heating spares.Co tel. 0161 620 6677 54 9 electrical diagrams 9.1 functional flow diagram: vuw 242 e / 282 e gw 651/0 fig. 78 s.
Page 55
Supplied by www.Heating spares.Co tel. 0161 620 6677 55 9.2 wiring diagram: vuw 242 e / 282 e fig. 79 flame sensing electrode ignition electrode.
Page 56
Supplied by www.Heating spares.Co tel. 0161 620 6677 56 9.3 schematic appliance circuit diagram: vuw 242 e / 282 e gw 652/0 fig. 80
Page 57: 10. Short Parts List
Supplied by www.Heating spares.Co tel. 0161 620 6677 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 06 4951 04 main heat exchanger vuw 282 06 4952 05 burner vuw 242 04 1960 06 burner vuw 282 04 1961 07 diverter...
Page 58
Supplied by www.Heating spares.Co tel. 0161 620 6677 58 fig. 88 gw 684/0 fig. 90 gw 686/0 fig. 92 gw 682/1 fig. 87 gw 683/0 fig. 89 gw 693/0 fig. 91 gw 691/0 fig. 93 gw 689/0 fig. 94 gw 690/0 fig. 95 gw 692/0 fig. 96 gw 685/0 fig. 97 gw 681/0
Page 59: Technical Data
Supplied by www.Heating spares.Co tel. 0161 620 6677 59 technical data l.P.G. Appliances: vuw 242 eb vuw 282 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 ...
Page 60
Supplied by www.Heating spares.Co tel. 0161 620 6677 83 20 16 gb 01 heating, controls, hot water 0796 v printed in germany - imprimé 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 instruction...