Turbomax VUW 242E 282E
Turbomax VUW 242E 282E
3
2. Boiler specification
2.1 Technical data
Connections
Heating flow / return 22 22 mm
Cold water inlet 15 15 mm
DHW outlet 15 15 mm
Gas inlet 15 15 mm
Pressure relief discharge pipework (min) 15 15 mm
Weight 47 48 kg
Primary water content 0.7 0.7 litres
Electrical supply
Voltage 230/50 230/50 V~/Hz
2 x internal fuses 2 2 A
1 x internal fuse 1,25 1,25 A
external fuse 3 3 A
Power input 130 130 W
4
2.2 Dimensions
(All dimensions in mm)
GW 547/0
fig. 1
shut-off valve
7 Service valve (return of heating
fig. 2
system)
8 Compression union (return of
heating system)
9 Pressure relief valve
5
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
10 Indicator lights (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
25 Circulating pump
26 Diverter valve
27 Water switch (DHW)
28 Water section
29 Temperature and Pressure gauge
30 Automatic bypass valve
31 Pressure relief valve
32 CH return service valve
33 Cold water shut off valve
GW 573/1
fig. 3
6
3. General requirements 3.1 Related documents 3.2 Boiler location
The installation of the boiler must be The location chosen for the boiler must
in accordance with the relevant permit the provision of a satisfactory
requirements of Gas Safety (Installation flue termination. The location must
and Use) Regulations 1994, Health also provide adequate space for
and Safety Document No. 635 (The servicing and air circulation around
Electricity at Work Regulations 1989), the boiler. The boiler may be installed
BS7671 (IEE Wiring Regulations) and in any room, although particular
the byelaws of the local Water attention is drawn to the requirements
Undertaking. It should also be in of BS7671 (I.E.E. Regulations) and, in
accordance with the relevant Scotland, the electrical provisions of
requirements of the Local Authority, the Building Standards (Scotland)
Building Regulations, Building Regulations, in respect of the installation
Standards (Scotland) Regulations and of a boiler in a room containing a
the relevant recommendations of the bath or shower.
following British Standards:-
(Note: Where a room sealed boiler
is installed in a room containing a
BS 5440: Flues and ventilation of gas
bath or shower, any electrical switch
fired boilers not exceeding 60 kW:
or boiler control utilising mains
- Part 1: Flues
electricity should be so situated that it
- Part 2: Ventilation
cannot be touched by a person using
BS 5449: Specification for forced the bath or shower).
circulation hot water for domestic
Where the installation of the boiler
premises.
will be in an unusual location, special
BS 5546: Specification for gas hot procedures may be necessary and BS
water supplies for domestic premises. 5546 and BS 6798 give detailed
guidance on this aspect.
BS 6700: Services supplying water
for domestic use within buildings and The boiler must be mounted on a flat,
their curtilages. vertical wall, which must be sufficiently
robust to take the weight of the boiler.
BS 6798: Specification for installation
The boiler may be installed on a
of gas fired boilers not exceeding 60
combustible wall, subject to the
kW input.
requirements of the Local Authorities
BS 6891: Specification for installation and Building Regulations.
of low pressure gas pipework up to
A compartment used to enclose the
28 mm (R1) in domestic premises (2nd
boiler must be designed and
family gas). constructed specifically for this
BS 7593: Treatment of water in purpose. (An existing cupboard or
domestic hot water central heating compartment may be used provided
systems. that it is modified for the purpose).
Details of essential features of
BRITISH GAS PUBLICATION DM2: cupboard/compartment design
Guide for Installation in Timber including airing cupboard installations
Framed Housing are given in BS 6798.
If the boiler is to be fitted in a timber
Important framed building, it should be fitted in
accordance with British Gas Publication
The appliance must be installed and DM2 'Guide for Gas Installations in
serviced by a competent person as Timber Framed Housing'.
stated in the Gas Safety (Installation
and Use) Regulations 1994
7
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.
Installation pipes should be fitted in
accordance with BS 6891.
Pipework from the meter to the boiler
must be of an adequate size. Do not
use pipes of a smaller size than the
boiler gas connection (15mm).
The complete installation must be
tested for soundness and purged as
described in BS 6891.
8
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 is fitted less than 2m
above a balcony, above ground or
above a flat roof to which people
have access, then a suitable guard
must be provided and fitted (available
from Tower Flue Components,
Tonbridge, TN9 1TB: reference TFC
type K3).
Table 1:
Terminal position for fan-assisted flue
(minimum distance - see fig. 5)
GW 595/0
A- Directly below an openable mm fig. 5
window or other opening
(e.g. air brick) 300 Where a terminal is fitted less than
B- Below gutters, soil pipes 1m below a plastic gutter or less than
or drain pipes 25 0.5m below painted eaves or any
C- Below eaves 25
other painted surface then a suitable
D- Below balconies 25
shield at least 1m long should be
(below car port roof 200)
fitted to protect the surface.
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 1500
L- Horizontally from a
terminal on the same wall 300
M-Distance from adjacent
wall for Vertical Flue 500
9
3.5 Air supply 3.6 Electricity supply 3.7 Guide to system
Detailed recommendations for air A 230 V~ 50Hz single phase requirements
supply are given in BS 5440: Part 2. electricity supply fused to 3 amps must 3.7.1 Water circulation system
be provided in accordance with the
It is not necessary to have an air vent Detailed recommendations for the
latest edition of BS7671 (I.E.E. Wiring
in the room or internal space in which water circulation system are given in
Regulations) and any other local
the boiler is installed. BS 6798 and BS 5449: Part 1 (for
regulations that may apply.
small bore and micro bore central
3.5.1 Cupboard or compartment air THIS APPLIANCE MUST BE EARTHED. heating systems).
supply The method of connection to the mains
Pipework not forming part of the useful
TURBOmax Room Sealed Combination electricity supply must provide a
heating surface should be insulated to
Boilers are very high efficiency means of completely isolating the
help prevent heat loss and possible
appliances. boiler and its ancillary controls.
freezing, particularly where pipes are
As a consequence the heat loss from Isolation is preferably by the use of a
run through roof spaces and ventilated
the appliance casing during operation fused three pin plug and unswitched
underfloor spaces.
is very low. For cupboard and shuttered socket outlet, both complying
compartment installations it is therefore with the requirements of BS 1363. Draining taps must be located in
not necessary to provide any high or Alternatively, a 3 Amp fused accessible positions which permit the
low level permanent air vents for double-pole switch with a 3mm draining of the whole system including
cooling purposes. contact separation on both poles may the boiler and the hot water system.
be used. Draining taps should be at least 1/2
in. BSP nominal size and be in
accordance with BS 2879.
The boiler is suitable for use with
minibore or microbore systems.
Copper tubing to BS 2871: Part 1
should be used for water carrying
pipework. All capillary joints in the
DHW pipework must be made with
lead free solder.
Particularly where a new boiler is to
be fitted to an existing system, it is
good practice that the system is
thoroughly cleansed. This cleasing
should take place prior to the fitting of
the new boiler and be in accordance
with BS 7593.
For advice on the application of
system cleansers contact Sentinel,
Grace Dearborn Ltd, Widnes,
Cheshire, WA8 8UD.
Tel: 0151 4951861.
10
3.7.2 Filling and make up
The system should be filled with water Heating
via a separate filling point fitted at a circuit
convenient position on the heating return Double check Hose Mains
valve assembly unions water
circuit. Where local Water Authority supply
Regulation allows, a temporary
connection to the mains may be used Stop
(fig. 6). The connection must be valve
removed when filling is completed. Test
valve
Where local Water Authority
Temporary
Regulation does not allow temporary
GW 400/0
Hose
connection, a sealed system filler
pump with break tank must be used. fig. 6
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).
GW 609/0
fig. 7
11
3.7.5 Expansion vessel Table 2: Sizing of Additional Expansion Vessel
An expansion vessel is incorporated
into the boiler suitable for a sealed Safety valve setting (bar) 3.0
heating system with a maximum water Initial system pressure (bar) 1.0 1.5
content of 100 litres.
Total water content of system VESSEL VOLUME (L)
If the nominal capacity of the built in
litres
expansion vessel is not sufficient for
25 2.7 3.9
the heating system (for instance in 50 5.4 7.8
case of modernisation of old open 100 10.9 15.6
systems) an additional expansion 125 13.6 19.5
vessel can be installed external to the 150 16.3 23.4
boiler. It should be fitted in the return 175 19.1 27.3
pipe as close as possible to the boiler 200 21.8 31.2
in accordance with BS 5449: Part 1. 225 24.5 35.1
250 27.2 39.0
Guidance on the sizing of an
275 30.0 42.9
additional expansion vessel is given in 300 32.7 46.8
Table 2. 325 35.7 50.7
3.7.6 Circulating pump 350 38.1 54.6
375 40.9 58.5
The circulating pump is included in the 400 43.6 62.4
boiler. The pump head available for 425 46.3 66.3
the heating system is shown in fig. 8. 450 49.0 70.2
475 51.8 74.1
3.7.7 System by-pass 500 54.5 78.0
An automatic system by-pass is For system volumes other than
included within the boiler. The boiler those given above, multiply 0.109 0.156
is suitable for use in systems with the system volume by the factor
thermostatic radiator valves and no across
additional by-pass is required.
3.7.8 Venting
The boiler is fitted with an automatic
air vent. Additional provision should
be made to enable the heating system
to be vented during filling and
commissioning either by automatic air
vents or manually.
fig. 9
12
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:
5 mm either side of the boiler
100 mm below the boiler*
165 mm on top of the boiler
500 mm in front of the boiler **
* 150 mm where optional pre-
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.
GW 403/1
Note: If the boiler is to be fitted in a
fig. 11
timber framed building, it should be
fitted in accordance with British Gas
publication reference DM2 'Guide
for gas installations in timber framed
housing.'
13
4.2.1 Installation accessories Table 3: Installation Accessories
Table 3 lists the standard and optional Standard Accessories Art. No.
accessories which are available for
the TURBOmax combination boilers. 1. Air/flue duct and terminal accessory 300 807
fig. 11
14
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 boiler hanging
bracket (2) and the optional
pre-installation connection group (3).
The template also shows the position
of the flue exit hole, for use where the
air flue duct is to be installed directly
to the rear of the boiler, e.g. where
the boiler is installed on an outside
wall and the flue terminates directly
behind.
4.3.2.2 A Pre - installation connection
group (Art. No. 8015) is available as
an optional accessory. It is used to
allow the installation of the central
heating and domestic hot water
pipework without the need to have the
boiler in position. Where an old
existing Vaillant boiler is to be
GW 426/0
replaced, the boiler replacement
accessory (Art. No. 300 813) can be fig. 12
used to allow easy connection on the
new boiler to the existing connecting 4.3.3 Fitting the boiler hanging
group. Refer to the instructions bracket.
supplied separately with these Secure the hanging bracket to the
accessories. wall using the screws supplied. (If the
4.3.2.3 Mark on the wall the positions condition of the wall is poor it may
of the hanging bracket fixing holes (2). be necessary to use additional or
Drill two holes Ø 10 mm for the alternative fixings to ensure adequate
hanging bracket. (Note: Use the support).
alternative fixing holes where
necessary). NOTE: If the boiler is to be fitted in a
timber framed building ensure that the
4.3.2.4 Rear exit flue.
brackets are secured to a substantial
Mark the position of the centre of the part of the timber frame capable of
flue duct and its circumference, e.g. taking the weight of the boiler.
by drilling through the template
(1, fig. 12).
4.3.2.5 Other flue options.
Refer to the installation instructions
supplied with the flue accessory for
detailed instructions on other flue
options such as vertical RSF flues, flue
runs to the side of the boiler and the
use of additional flue elbows and
bends etc.
4.3.2.6 Remove the template from the
wall and plug the drilled holes using
the wallplugs supplied.
15
4.4 Installing the flue system Note: To allow fitting of the bottom
At this stage install the flue system boiler cover, the left hand tab (2, fig.
(refer to separate installation 16) should be folded upwards where
instructions supplied). pipes are fitted in the left hand void.
Where pipes are installed in these
4.5 Mounting the boiler voids, a method of disconnection e.g.
4.5.1 Preparation a compression connector (1, fig. 16)
Remove the boiler from the carton. must be provided to allow easy
removal of the boiler from the wall, if
Lay the boiler on the floor and
required.
remove the white boiler bottom cover
GW 608/0
by removing two screws (l, fig. 51) 4.5.3.2 Cold mains water inlet and
and slackening two screws (2, fig. hot water outlet (fig. 14)
51). Do not remove boiler side fig. 13
Flush out all foreign matter from the
panels. Remove the two plastic sea- mains supply pipe before connecting
ling caps from the domestic water to the boiler.
connections. Connect the mains water supply (3)
Fit the pre-assembled cold water inlet and hot water outlet pipes (4) to the
and hot water outlet pipes with 15 mm compression connections.
straddle bracket (1,2,3, fig. 15) to Note: The boiler has a maximum
water connections on boiler (4, fig. domestic water working pressure of
15) using washers provided. 10 Bar. If the cold mains supply
4.5.2 Fitting the boiler (fig. 13) pressure exceeds 10 Bar, a pressure
reducing valve must be fitted to the
Lift the boiler up to the wall so that it is cold water inlet.
slightly above the hanging bracket.
GW 609/0
Note: Lift the boiler from under the 4.5.3.3 Pressure relief valve discharge
front edge of the side panels. The appliance contains the pressure fig. 14
Do not lift the boiler by the control relief valve required for a sealed
box. Do not attempt to lift the boiler system (5). Connect a discharge pipe
without the side panels or side not less than 15 mm diameter to the
casing fitted. outlet of this valve.
Lower the boiler slowly onto the This discharge pipework should be as
hanging bracket so that the cross short as possible and installed with a
member at the top rear of the boiler continuous fall away from the boiler.
fully engages into the hanging The pipe should terminate in a position
bracket. which ensures that any discharge of
4.5.3 Pipework connections (fig. 14) water or steam from the valve cannot
Figure 14 shows the central heating, create a hazard to persons in or
domestic hot water, mains cold water, about the premises, or cause damage
GW 706/0
16
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 the gas service valve. (Ensure the
gas supply pipework is adequately
sized such that a 20 mbar - (8" w.g.) -
gas pressure is available at the boiler
inlet at full flow rate). Tighten all union
GW 553/0
connections.
fig. 17
4.6 Connecting the flue
assembly to the boiler
Note : A flue restrictor ring is sup-
plied packed with the users and
installation instructions.
The restrictor should be used under
the following circumstances : -
Horizontal flues
Where a horizontal flue less than 1 m
in length is used.
(DO NOT fit the restrictor where the
horizontal flue is more than 1 m in
GW 592/0
length).
fig. 18
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).
fig. 19
17
Loosen screws on the 95 mm diameter Lower the flue assembly until a gap of
x 55mm wide clamp (6, fig. 21) and about 25 mm exists between the air
push over the air duct. duct of the air/flue duct and terminal
Remove screws and sealing washer assembly and the half rings on the
on the 95 mm diameter x 25 mm appliance. The two ducts must not butt
wide clamp (3, fig. 21) and push onto together.
the flue elbow on the side to be Pull the sleeve (2, fig. 22) down over
connected to the appliance. Ensure the flue connection of the appliance
the clamp is clear of the end of the against the stop. Align the holes in the
elbow. sleeve and boiler flue gas connector
Push the flue elbow into the clamp (2, and secure with a self tapping screw
(1, fig.23).
fig. 20) connected to the appliance
flue gas duct and tighten the securing Note : The sleeve must not be screwed
GW 616/0
screws lightly. to the bottom of the flue gas duct of
Ensure that the elbow and air/flue the air/flue duct assembly. This duct
duct line up and are closely butted must be able to slide in order to fig. 20
together. Pull the clamp (4, fig. 20) absorb small movements of the roof
over the joint between the flue gas structure.
duct and flue elbow. Ensure that the Refit the two half rings. Pull the 95mm
air/flue duct and terminal are correctly diameter x 55 mm wide clamp down
positioned. Tighten the securing screws over the joint between the air/flue duct
on both clamps. assembly and the half rings. Tighten
Note : Excessive tightening of these the clamp screws (1, fig.24).
screws is not necessary. Ensure that
the air / flue duct and terminal
assembly is not displaced though the
wall. Check that the air duct of the
terminal still projects by 90 mm
through the wall.
Refit the half ring 2, fig. 21. Pull the
GW 594/0
95 mm diameter x 25 mm wide
clamp (3, fig. 21) over the joint
between the flue elbow and half rings. fig. 21
Refit the screws and sealing washer
and tighten lightly.
Pull the 95 mm diameter x 55 mm
wide clamp (6, fig. 21) over the joint
between the flue elbow and air/flue
duct. Tighten the securing screws on
both clamps.
Drill two holes, 3 mm diameter
through both air duct clamps into the
air ducts at the most convenient
positions (5, fig. 21). Take care not to
penetrate the inner flue duct. Screw
the clamps to the air ducts using the
self tapping screws provided.
GW 558/0
GW 603/0
movements in the roof structure.
fig. 25
4.7 Electrical installation
4.7.1 General electrical 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 a 230V~ 50Hz supply fused at 3A
rating. Connection to the mains supply
should be made via a fused 3 pin
plug to an unswitched, shuttered
socket, both complying with the
GW 614/0
requirements of BS1363. (Alternatively,
connection may be made via a 3
Amp fused double pole isolator fig. 26
having a contact separation of at least
3mm in all poles and supplying the
boiler and controls only).
The point of connection to the mains
must allow 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
GW 638/0-B
earthed
4.7.2 Connecting to mains supply
fig. 27
Slacken front panel fixing screw (1,
fig. 25) and lower front panel. Remove
terminal box cover by undoing screw
(1, fig. 26)
Connect the power supply cord as
follows (see fig. 28):-
green / yellow (earth) wire....
boiler terminal
Blue (neutral) wire..... boiler terminal N
Brown (live) wire..... boiler terminal L
Note: Do not use boiler terminal
connections 7-8-9
GW 679/0
fig. 28
19
4.8 Controls Connection details for programmable thermostats
N L 3 4
4.8.1 External electrical controls
→
Vaillant Calotrol
1 2 3 4
(VRT 9083 and VRT 9084)
The boiler terminals 3,4 and 5 are for
3 4
connecting external controls such as a
→
ACL Drayton 1 2 3
Digistat 2 and 3
time switch and/or room thermostat.
N L 4 3
Terminals 3 and 4 are linked together
→
ACL Drayton N L 1 2 3 4
PT110, PT170
when the boiler is supplied. If external
controls are used, this link must be ACL Drayton N L 3
→
Lifestyle
removed, and the controls connected CT171, CT172, N L 1 2
OFF
3
ON
4
PT271, PT371
across terminals 3 and 4. 3 4
→
Danfoss Randall
Terminal 5 is an additional neutral TP2, TP3, TP4, TP5
1 2 3
→
Honeywell
A B C
CM51, CM41
thermostat.
3 4
Refer to Section 4.8.2 for full
→
Landis & Gyr
Q1 Q2
REV 10 and 21
connection details.
3 4 5
→
4.8.2 Connection of external electrical Potterton Myson 2 L 1 N C
Pot 1
controls OFF ON
f i g
4.8.2.1 Connection details for
programmable thermostat and boiler Connection details for time switch
terminal strip (refer to fig. 29). ACL Drayton N L 3 4
→
Lifestyle
Fig. 29 shows the connection details LP711
N L 1 2
OFF
3
ON
4
→
Switchmaster 300 N L 1 2 3 4
(time switch with built-in room (Please note: Remove Link N-2 and L-4) ON
N L 3 4
thermostat) is used to control the
→
→
Grässlin Towerchron
N L 1 2 3 4
Dt71, T200l
boiler. (Important: The arrowed ON
N L 3 4
numbers indicate connection into the
→
→
Honeywell
N L 1 2 3 4
ST6100
relevant terminal in the boiler terminal
Honeywell 3 4
strip).
→
→
ST7000B L 2 3 4
(Battery operated) OFF ON
4.8.2.2 Connection details for Horstmann N L 4
→
→
Landis & Gyr
N L 1 2 3 4
Fig. 29a shows the connection details RWB100, 152, 170
N L 4 3
where a time switch is used without a
→
Potterton Myson
N L 1 2 3 4 5 E
EP400l, EP500l
room thermostat to control the boiler. OFF ON
4 3 N L
(Important: The arrowed numbers
→
Danfoss Randall
1 2 3 E 5 6
103, 103E, 103E7
indicate connection into the relevant N L
ON
4 3
terminal in the boiler terminal strip).
→
Danfoss Randall E N L 1 2 3 4 5 6
Set 1E, TS975
ON OFF
If a room thermostat is to be connected
f i g .
in addition to a time switch the wire
between the time switch 'ON' terminal Connection detail for room thermostat and time switch
and boiler terminal 4 should be broken
by the contacts of the room thermostat Boiler Terminal Strip
(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.
GW 409/0
f i g
20
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 programmable roomstat or separate
timer and room thermostat to ensure
complete boiler shutdown when the
heating demand is satisfied. (The
radiator in the room containing the
room thermostat should not be fitted
with a TRV).
21
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.
GW 610/0
boiler to the hot taps. Starting with the
lowest tap supplied, turn the hot taps fig. 31
off one at a time until the hot water
pipework is purged of air.
Check all hot and cold pipework for
leaks.
22
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 the system.
Starting with the lowest radiator, open
the radiator air release until water
GW 634/0
(clear of bubbles) is emitted.
Repeat this at all radiators until the fig. 32
23
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 that all external heating
controls are calling for heat.
• Switch on the electricity supply to
the boiler.
• Set both the maximum hot water
temperature control (4, fig. 33) and
maximum radiator temperature
control (3, fig. 33) to '9'.
• Turn the boiler on/off control (1,
fig. 33) to the ”on” position ( ).
• Set the boiler central heating
control (2, fig. 33) to the 'Heating
and Hot Water' position ( ).
GW 612/0
The boiler will now operate for central
heating. Allow the boiler to run for a fig. 33
24
At this point the preset maximum tolerance shown, contact Vaillant fig. 35
domestic hot water flow rate can be Ltd. Technical Department).
adjusted if required. • Turn off the hot tap.
Note: The water flow limiter built • Remove U gauge. Tighten the sea-
ling screw (1, fig. 36)and test for
into the boiler ensures that the soundness. Reconnect NTC sensor
maximum domestic hot water flow (3, fig. 37). Refit plastic plug in
rate does not exceed the nominal chamber sensing tube.
setting (equivalent to a hot water • Reset the maximum hot water
temperature rise of 35°C). temperature selector to the required
Adjustment is only required if the user setting (see Section 5.14).
requires a higher temperature rise • Raise control box and secure in
GW 635/0
than this setting. position using screw (1, fig. 25).
Turn the water flow adjusting screw
(1, fig. 35) clockwise to decrease the
flow from the tap until the temperature
rise is at the desired level. Turn off the
hot tap after completion of adjustment.
GW 636/0
(If the pressure is not 20mbar this
should be investigated before fig. 36
continuing with the commissioning
procedure. Lower pressures than
20mbar are indicative of an incorrectly
sized or partially blocked gas supply).
Turn off the hot tap. Remove U gauge.
Tighten the test point screw and test
for soundness.
GW 603/0
lower control panel.
GW 614/0
• Slacken the sealing screw and fig. 38 fig. 39
attach one arm of a U gauge to
the burner pressure test point (1,
fig.37). Remove plastic sealing
plug and connect the other arm to
the combustion chamber sensing
tube (2, fig.37).
• Remove screw (1, fig. 39) and
remove terminal box cover to
access the range rating
potentiometer (2, fig. 40) beneath.
• Operate the central heating by
turning the central heating control
GW 638/0-B
to the 'Heating and Hot Water'
position ( ) ensuring that the
external controls are calling for fig. 40
heat and the maximum radiator
temperature control is set to 9.
• The central heating output can now
be altered by inserting an
electricians screwdriver into the
potentiometer (2, fig. 40)
• Turn the potentiometer fully
anticlockwise to the stop.
• Slowly turn the potentiometer T a b l e 5 : C e n t r a l H e a
clockwise, whilst observing the U
Output to Range rating mbar
gauge.
central Heating
• Stop turning the potentiometer when mbar VUW 242 VUW 282
the burner pressure is at the correct
setting for the output required (see 28.0 (95,560) - 10,6
table 5).
• Turn the boiler off. 24.0 (81,900) 10,0 8,0
• Remove U gauge. Tighten the
sealing screw, (1, fig. 36) and test 21.0 (71,700) 8,0 6,3
for soundness.
18.0 (61,500) 6,1 4,8
• Refit plastic plug in chamber
sensing tube.
15.0 (51,200) 4,5 3,4
• After setting, refit cover screw (1,
fig. 39) and re-secure control panel 12.0 (41,000) 3,1 2,2
(1, fig. 38).
min. 9,6 (32,800) 2,0 -
26
5.10 Functional Checks
5.10.1 Introduction
The Vaillant TURBOmax 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 (fig. 41).
GW 618/0
sparking will commence at the Power on indicator
burner. The ignition indicator will
fig. 41
illuminate.
• As soon as the burner has ignited • The gas valve will open and spar-
and the flame has been sensed the king will commence at the burner.
flame indicator will illuminate. The ignition indicator will
• By illuminating in this sequence the illuminate.
indicator lights have demonstrated
correct operation of the boiler for
• As soon as the burner has ignited
and the flame has been sensed the
DHW. flame indicator will illuminate.
5.10.3 Functional check of central • By illuminating in this sequence the
heating indicator lights have demonstrated
correct operation of the boiler for
• Ensure that the power on indicator CH.
is illuminated.
• Set the boiler central heating Note : Should the boiler fail to light
control to the 'Central Heating and the burner lock out indicator will
Hot Water' position ( ). illuminate. This usually means that the
• Ensure external controls are calling gas supply is turned off or has not
for heat. been purged of air. Check the gas
supply, turn the central heating
• The central heating demand control to the reset position ( ) and
indicator will illuminate.
repeat the lighting procedure.
• Providing the boiler has not
achieved its set temperature, and
the anti cycling control is not
activated, the boiler will start its
lighting sequence. Once the fan
and flue system have proved their
satisfactory operation the fan
operation indicator will light.
27
5.11 Checking flame 5.13 Fitting case
supervision device Attach top door panel by slotting side
Operate the boiler and turn off the clips (1, fig. 42) into holes in side
gas supply at the boiler gas service panel and sliding panel down to
valve. The boiler should attempt to secure. Attach bottom door panel by
re-light (sparking at ignition electrode locating onto top hinge pin (2, fig.
visible through viewing window) for 43) and inserting bottom hinge screw
approximately 10 seconds before (1, fig. 43) so that it also locates into
shutting down. The lock out indicator the door.
light will illuminate. Open the gas
service valve and turn the central 5.13.1 Door hinged at left hand side
GW 605/0
heating control (2, fig. 33) to the reset If required the appliance lower door
position ( ). The boiler should now can be altered to hinge on the fig. 42
re-light. lefthand side.
Remove screws from bottom hinge pin
5.12 Final system flush ('hot') (1, fig. 43) and transfer to left hand
Allow the boiler and system to reach side panel.
maximum temperature and check that Lift bottom of top hinge pin (2, fig.
the heating system is watertight. Turn 43)away from casing to release
the boiler off and rapidly drain both retaining lug. Rotate top hinge
boiler and system while still hot. through 90° to remove. Refit to left
Refill the system and release all air as hand side casing.
described in Section 5.4. Release Attach bottom door panel by locating
water from the system until the system onto top hinge pin (2, fig. 43) and
design pressure of 1.2 bar is attained. inserting bottom hinge screw (1, fig.
GW 606/0
(The actual reading on the pressure 43) so that it also locates into the
gauge - (6, fig. 33) - should ideally be door.
fig. 43
0.5 Bar plus an additional pressure
corresponding to the highest point of 5.13.2 Fit bottom cover
the system above the base of the Attach bottom cover to boiler by
boiler - 10 m head equals an locating over front screws (2, fig. 51)
additional 1 Bar reading on the and secure with rear screws
pressure gauge. The minimum pressure (1, fig. 51).
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
connection.
28
5.14 Hand over to user 6. Servicing 6.1 Initial Inspection
Set the maximum radiator temperature Before commencing any servicing or
control (3, fig. 44) to the desired To ensure the continued safe and maintenance work, carry out an initial
setting. efficient operation of the boiler it is inspection of the system as follows:-
The following settings may be used as recommended that it is checked and Inspect the flue, pipework and electrical
a guide: serviced as necessary at regular connections for indications of damage
intervals. The frequency of servicing or deterioration.
Spring and Autumn 5–6 will depend upon the particular
Winter (normal) 6–7 Inspect the air supply and ventilation
installation conditions and usage, but
Winter (severe) 7–9 arrangements of the installation,
in general once per year should be
ensuring that the requirements of
Note: if the setting is too low the adequate. It is law that all servicing
Section 3.5 are met.
radiators may not reach the desired work is carried out by a competent
person (CORGI registered). Operate the boiler by turning the
temperature.
maximum hot water temperature
Set the maximum hot water temperature IMPORTANT: control (4, fig. 44) to '9' and fully
control (4, fig. 44) to the desired Before starting any maintenance opening a hot water tap. Inspect the
setting. For normal circumstances the work: burner operation through the viewing
maximum hot water temperature window. Check that the flames are
should be set to 6.
• Isolate the mains electricity supply burning evenly over the full surface of
by disconnecting the plug at the
socket outlet (if there is an isolating the burner. Inspect for signs of excessive
Instruct the user in the safe and lifting or sooting.
efficient operation of the boiler, in switch only remove the fuse from
particular the function of:- the switch). Check the heating and hot water
system, in particular the condition of
• the boiler on / off control • Turn OFF the gas supply at the gas the radiator valves, evidence of leakage
service valve fitted to the boiler.
• the maximum radiator temperature from the heating system and dripping
control • Always test for gas soundness and hot water taps.
always carry out functional checks
• the maximum hot water temperature
after any service work and after
control
exchanging any gas carrying
• the pressure gauge. component.
Show the user how to operate any • Always check earth continuity,
external controls. polarity and resistance to earth with
a multi-meter after any service work
Explain to the user the importance of
and after exchanging any electrical
having the boiler regularly serviced by
component.
a competent servicing company. To
ensure regular servicing, it is strongly Note: The boiler is fitted with a
recommended that arrangements are combustion analysis test point (7, fig.
made for a Maintenance Agreement. 44). A suitable combustion analyser
Please contact Vaillant Service can be connected to this point to
Department (FREEPHONE 0800 establish the combustion performance
318076) for further details. of the boiler.
Leave the user instructions in the
purpose provided pocket on the front
of the control panel (2, fig 38).
Leave the installation and service
instructions with the user.
GW 612/0
fig. 44
29
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
GW 553/0
undoing two screws (1, fig. 51)
and slackening two screws (2, Fig.
fig. 45
51).
GW 606/0
front cover (5, fig. 44)
Remove four screws (2, fig. 54) fig. 46
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.
30
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.
GW 639/0
Note : It is not necessary to carry out
this check every year - a check every fig. 48
three years should be sufficient.
Release the pressure from the boiler as
described in section 7.1.2.
Remove valve cap from expansion
vessel charge point (2, fig. 49).
Check that internal charge pressure of
expansion vessel 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
GW 604/0
and re-pressurised the boiler and
heating system if necessary (see fig. 49
section 5.4).
31
7. Parts replacement 7.1.2 Releasing CH water pressure
and draining the boiler (fig. 50)
IMPORTANT: • Isolate electrical supply to boiler.
Before starting any maintenance • Remove combustion chamber cover
work: as in section 7.1.5.
• Isolate the mains electricity supply • Turn off boiler CH service valves
by disconnecting the plug at the (2).
socket outlet (if there is an isolating • Attach a length of rubber tube to
switch only, remove the fuse from draining points (4), and drain the
the switch). water from the boiler into a
• When removing any water carrying suitable container by undoing the
GW 619/0
components ensure that the control drain points one turn.
box cover and terminal box cover • When pressure gauge reads zero, fig. 50
are in position and water is kept open main heat exchanger air vent
away from all electrical (5, fig. 57) to allow complete
components. draining of the boiler. Close air
• Turn OFF the gas supply at the gas vent before refilling the boiler.
service valve fitted to the boiler.
• Always test for gas soundness and
always carry out functional checks
after any service work and after
exchanging any gas carrying
component.
• Always check earth continuity,
polarity and resistance to earth with
a multimeter after any service work
and after exchanging any electrical
component.
32
7.1.3 Removal of front casing 7.1.7 Removal of heat exchanger
7.1.3.1 Door (fig. 52) front panel.
• Remove bottom hinge screw (1) • Remove the five screws (1 and 3,
and pull the bottom door panel fig. 47) securing the heat exchanger
forwards and down to release it and remove the panel by gently
from top hinge pin (2). pulling down and forward.
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)
• Remove two screws (1) and slacken
GW 611/0
two screws (2).
• Slide cover forwards and drop fig. 51
down to remove
7.1.3.4 Reassembly
• Reassemble in reverse order.
7.1.4 Removal of side casings
• Remove front casing as in section
7.1.3.
• Remove screws (3, fig. 53)
• Remove screws (4, fig. 53) and
retaining brackets.
• Slide side case panel upwards to
release retaining clips (2, fig. 53)
GW 606/0
and lift off.
• Reassemble in reverse order
fig. 52
fig. 54
33
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.
GW 639/0-a
• Reassemble in reverse order.
• Re-fit combustion chamber and front fig. 55
casing.
• Carry out electrical checks (see
section 5.1).
GW 640/0
pressure switch
• Remove screw (1) and lift out
fig. 56
pressure switch.
• Disconnect air tubes (2) from switch.
• Reassemble in reverse order.
• Carry out electrical checks (see
section 5.1).
34
7.4 Replacement of burner fig. 57
GW 641/0
pull burner forwards to remove.
• Reassemble in reverse order.
• Carry out electrical checks (see
section 5.1) and check burner
pressure (see section 5.8) and gas
rate.
fig. 58
35
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.
• Disconnect boiler from electricity
supply.
GW 643/0
• Remove front casing as in section
7.1.3 and remove combustion
fig. 59
chamber cover as in section 7.1.5
• Pull off connecting wire to sensor.
• Unscrew NTC sensor. (4, fig 62)
• Reassemble in reverse order.
• Carry out electrical checks (see
section 5.1).
36
7.7.1 Replacement of main solenoid 7.7.3 Replacement of gas operator
valve. • Isolate boiler from the electrical
• Isolate the boiler from the electrical supply.
supply. • Remove front casing as in section
• Remove front casing as in section 7.1.3.
7.1.3 • Lower front control panel as in
• Lower front control panel as in section 7.1.6.
section 7.1.6 • Turn off gas service valve (1, fig.
• Turn off the gas service valve 50).
(1, fig. 50). • Remove screw (5, fig. 59) and lift
GW 643/0
• Disconnect ignition leads (3, fig. 65) cover off gas valve.
from rear of control box. • Disconnect two wires from gas fig. 60
• Remove three screws (1 + 2, fig. 65) operator.
and control box covers. • Remove screws (1 and 3, fig. 60)
• Disconnect solenoid wires from and pull operator forward to
main switchboard and appliance remove.
earth strip. • Reassemble in reverse order using
• Remove two screws (2, fig. 61) new cork gasket supplied with
and pull solenoid forward to spare part.
remove from gas valve • Set burner pressure in accordance
• Reassemble in reverse order. with instructions supplied with
spare part.
• Carry out electrical checks (see
section 5.1).and test all gas joints • Carry out electrical checks (see
for soundness section 5.1) and test all gas joints
GW 644/0
for soundness.
7.7.2 Replacement of modulating fig. 61
valve 7.8 Replacement of main heat
• Isolate the boiler from the electrical exchanger fig. 62
supply.
• Turn off the boiler as in section
• Remove front casing as in section 7.1.1.
7.1.3 .
• Remove front casing as in section
• Lower front control panel as in 7.1.3 and remove combustion
section 7.1.6 chamber cover as in section 7.1.5
• Turn off the gas service valve • Remove heat exchanger front panel
(1, fig. 50). as in section 7.1.7
• Remove screw (5, fig. 59) and lift • Release CH water pressure and
cover off gas valve. drain boiler as in section 7.1.2.
GW 641/0
37
7.9 Replacement of CH 7.9.2 Boiler installed with air flue duct
expansion vessel to the rear, or vertical flue
installation (where less than
In the unlikely event of a failure of the 300mm vertical clearance exists
CH expansion vessel follow procedure above the boiler)
7.9.1 or 7.9.2 depending upon the
installation circumstances. EITHER
Remove the boiler from the wall as
7.9.1. Boiler installed with air/flue follows:
duct to left/right hand side, or • Remove front casing as in section
vertical flue installation (where 7.1.3
300mm vertical clearance exists • Turn off the boiler as in section
GW 639/0
above the boiler). 7.1.1.
• Remove front casing as in section • Release CH water pressure and fig. 63
7.1.3 drain boiler as in section 7.1.2.
• Turn off the boiler as in section • Lower front control panel as in
7.1.1. section 7.1.6
• Release CH water pressure and • Disconnect external wiring from
drain boiler as in section 7.1.2. boiler wiring terminal box.
• Remove combustion chamber cover • Disconnect flow and return
as in section 7.1.5 connections at compression
• Remove 2 screws (2, fig 63). connection above boiler CH service
valves (1, fig. 64).and remove two
• Remove screw (1, fig. 56) to screws securing retaining lug to
release air pressure switch.
appliance chassis
• Slide expansion vessel upwards
GW 620/0
(2, fig. 64)
and out of boiler casing.
• Replace in reverse order. • Disconnect gas connection at
fig. 64
compression joint on top of gas
• Refill and repressurise the boiler service valve (3, fig. 64).
(see section 5.4).
• Disconnect domestic hot and cold
water connections (4, fig. 64)
• Disconnect the flue from the top of
boiler as described in section 4.6.
• Remove boiler from wall.
• Remove screw (3, fig. 56) to
release air pressure switch.
• Remove two screws (2, fig. 63) and
slide expansion vessel upwards
and out of boiler casing.
• Reassemble in reverse order.
• Re-mount the boiler (see section 4.5
and 4.6).
• Re-commission the boiler (see
section 5).
OR
A suitable replacement expansion
vessel can be fitted externally to the
boiler as described in Section 3.7.5
(if possible on the central heating
return in an accessible position). In
these circumstances, the replacement
expansion vessel must be correctly
sized ignoring the original expansion
vessel which can be left in position on
the boiler.
38
7.10 Replacement of • Pull pump forward to remove.
transformer • Fit new '0' rings (supplied with
pump) to pump connections.
• Isolate boiler from the electricity • Re-assemble in reverse order.
supply.
• Carry out electrical checks
• Remove front casing as in section (see section 5.1).
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
GW 614/0
undoing the 3 screws (1 and 2, fig.
65). fig. 65
• Unplug transformer (A, fig 67)
connecting lead from main switch
board.
Move clips (3, fig. 67) to the left
and remove transformer from
control box.
• Reassemble in reverse order.
• Carry out electrical checks (see
section 5.1).
GW 645/0
• Isolate the boiler from the electricity
supply.
fig. 66
• Remove front casing as in section
7.1.3.
• Lower front panel as in section
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).
39
7.13 Replacement of automatic 7.15 Replacement of diverter
air release valve
• Turn off boiler as in section 7.1.1. • Turn off boiler as in section 7.1.1.
• Remove front casing as in section • Remove front casing as in section
7.1.3. 7.1.3.
• Release CH water pressure and • Release CH water pressure and
drain boiler as in section 7.1.2. drain boiler as in section 7.1.2.
Open hot water taps.
• Lower front control panel as in
section 7.1.6. • Lower front control panel as in
section 7.1.6.
• Unscrew cap (2, fig. 68) of auto air
GW 607/0
release and remove inner • Remove pump as in 7.12
components. • Remove three screws (1, fig. 70) fig. 69
• Replace with new inner and pump support bracket (2, fig.
components and reassemble in 70).
reverse order. • Remove clip and disconnect pressure
• Refill and repressurise the boiler tube (1, fig. 71) from diverter valve.
(see section 5.4). • Undo nut (2, fig. 71) and
disconnect pressure guage tube.
7.14 Replacement of automatic • Disconnect union (6, fig. 71).
bypass
• Disconnect electrical connections
• Turn off boiler as in section 7.1.1. from DHW microswitch (3, fig 71).
• Remove front casing as in section • Remove clip (4, fig. 71) by pulling
7.1.3. down.
GW 646/0
• Release CH water pressure and • Undo two unions (5, fig. 71).
drain boiler as in section 7.1.2.
• Undo union (3, fig. 72). fig. 70
• Lower front control panel as in
• Carefully pull diverter valve and
section 7.1.6. cold water inlet pipe away from
• Remove spring clip (1, fig. 66). DHW heat exchanger Lift valve and
• Disconnect wires from overheat cold water inlet pipe (1, fig. 72)
thermostat (2, fig. 66). out of boiler.
• Remove temperature gauge phial • Reassemble in reverse order.
from primary flow pipe. • Carry out electrical checks (see
• Undo unions (3, fig. 66). Remove section 5.1).
bypass/connecting pipe. • Refill and repressurise the boiler
• Undo union (1, fig. 69) to remove (see section 5.4).
bypass.
GW 647/0
40
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.
GW 635/0-a
• Remove diaphragm.
• Replace in reverse order. fig. 72
• Carry out electrical checks (see
section 5.1).
• Refill and repressurise the boiler
(see section 5.4).
GW 649/0
section 7.1.6.
• Undo union (2, fig 71) on diverter fig. 73
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).
GW 650/1
drain boiler as in section 7.1.2.
• Lower front control panel as in fig. 74
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 push fit joint.
42
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 off the boiler as in section
7.1.1.
• Remove front casing as in section
7.1.3.
• Lower from control panel as in
section 7.1.6.
• Remove back of control box by
undoing the 3 screws (1 and 2,
fig. 65).
GW 615/0
switchboard.(1, fig. 75) and lift
switchboard carefully out of control fig. 75
box.
• Reassemble in reverse order.
Note: When refitting the main
switchboard ensure that the on/off
control knob spindle (3, fig. 75)
engages correctly into the on/off
switch (5, fig. 75) mounted on the
board.
• Carry out electrical checks (see
section 5.1)
44
Sheet A Check electrical supply and appliance fuses
No
No
Repair external Is 230 V present across terminals L and N
wiring fault
Yes
NOTE 1
For test purposes, disconnect Check and if necessary replace 2A fuses
external controls from terminals situated below boiler terminal strip (spare
3 - 4 and replace with a bridge fuse supplied with the appliance).
between these terminals. If If fuse defective, suspect wiring fault on
appliance then operates, the external controls (see note 1)
fault is with the external controls.
No
Go to sheet B
45
46
Sheet B Check main on/off control, overheat Thermostat and anti-surge fuse
Is 230 V present across boiler Does green power ’on’ indicator ( ) Go to sheet C
terminals 3 and 5 Yes glow now ? Yes
No No
No
Does yellow central heating demand indicator ( ) glow ? Does burner light ? Go to Sheet H
Yes Yes
No No
No
External fault. Check whether all external controls are If the yellow central heating demand indicator ( )
calling for heat, replace or repair as necessary still does not glow, replace main switchboard
(see also note 1, sheet A)
47
48
Sheet D Check operation of pump
Yes Yes
Does pump run? Does burner light ? Go to Sheet H
No
No
No No
No
NOTE 2
Yes Check pump is not jammed. Yes Is 230 V~ present at the pump Plug Before removing any water bearing
Check/replace pump. connection(x10) on the main switchboard components, replace covers on electronic
See note 2
control box.
No
No No Go to Sheet F
Check air/flue gas system is correctly
No
fitted and not obstructed. Check Pitot
tube ( in fan outlet) and air hoses are not
obstructed and are correctly aligned. Defective switch
Check or replace air pressure switch. board.
Is 230 V~present
Yes
across fan terminals ?
No
No
Check NTC. Disconnect NTC
Switch main on/off control off and No lead at plug (3, fig. 37), does
No heat demand, go to sheet C on again. Does fan now operate ? fan now run ?
Yes No
Yes
Check connection to Replace
NTC temperature main
sensor clean and switchboard
tight. If o.k, replace
NTC sensor
49
50
Sheet F Check operation of differential pressure switch
No
Yes
Yes
Is gas solenoid Go to sheet G
activated?
No
Check continuity of
microswitch. Replace Yes Is differential pressure
if necessary. Check
switch activated ?
connection of plug X11
to main switchboard.
If burner still fails No
to light, replace main
switchboard
Has system been filled
No with water ?
Fill and vent
system and boiler
Yes
Yes
Does burner light ? Go to Sheet H
No
Yes Go to Sheet H
Reset lockout (turn central heating
control to position ( ) and release)
Does sparking commence at burner ?
No
No
51
52
Sheet H Check operation of burner and modulation
Yes Yes
Is flame extinguished No Does yellow flame indicator ( ) Does burner flame modulate / Go Sheet J
after 10s, and red glow and flames increase in go out when maximum radiator
lockout indicator ( ) lit size to full rate ? temperature control is turned
down to position 1 at a flow
Yes temperature of approx. 50 °C ?
No
No
No
53
9 Electrical diagrams
9.1 Functional Flow diagram: VUW 242 E / 282 E
GW 651/0
fig. 78
54
9.2 Wiring diagram: VUW 242 E / 282 E
electrode
Ignition
electrode
sensing
Flame
fig. 79
55
9.3 Schematic appliance circuit diagram: VUW 242 E / 282 E
GW 652/0
fig. 80
56
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 valve 01 1269
08 DHW heat exchanger 06 4950
09 Ignition electrode 09 0562
10 Flame sensing electrode 09 0563
11 HT lead (ignition electrode) 09 1534
12 Expansion vessel 18 1045
13 Pump 16 1083
14 Gas valve (natural gas) 05 3210
15 Gas operator (natural gas) 05 0222
16 Main gas solenoid 17 0365
17 DHW microswitch 12 6255
18 Diaphragm 01 0357
19 Main switchboard 13 0391
20 Control board 13 0390
21 Main transformer 28 7442
22 NTC temperature sensor 25 2805
23 Temperature and pressure gauge 10 1558
GW 688/0
GW 680/0
GW 695/0
GW 694/0
GW 687/0
57
58
fig. 96
fig. 93
fig. 90
fig. 87
GW 685/0 GW 689/0 GW 686/0 GW 683/0
fig. 97
fig. 94
fig. 91
fig. 88
fig. 92
fig. 89
fig. 95
GW 692/0 GW 682/1 GW 693/0
11. Supplementary L.P.G. Appliances:
information for VUW 242 EB
TURBOmax VUW 282 EB
Burner setting pressure 25.1 (9.9) Propane 26.6 (10.5) Propane mbar (in W.G.)
Delivered gas
Propane G 31 MJ/m2
Gross C.V. (s.t.) 95.65
59
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