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Vaillant thermoCOMPACT/2 manual

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Table of contents for the manual

  • Page 1

    F or the installer 82 4/2 E 828 /2 E 83 7 E 615/2 E 620 / 2 E 62 4/ 2 E 62 8/ 2 E 63 7 E GB Instructions f or Installation and S ervicing t urboMAX plus and thermoC OMP A CT W all hung r oom sealed f an assis ted c ombination and s y stem boiler s[...]

  • Page 2

    T able o f C ontents Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 2 P age 1 List of C onten ts . . . . . . . . . . . . . . . . . . . . . . . . . 4 1. 1 Cont ents included with boiler (t urboMAX plus) 4 1.2 C ontents included with boiler ( thermoCOMP ACT) 4 2 Introduction . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 3

    T able o f C ontents Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 3 P age 10 F ault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7 10. 1 Intr oduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 10.2 Indicator lights ( turboMAX plus only ) . . . . . . . 37 10.3 Indicat or lights[...]

  • Page 4

    1 List o f cont ents Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 4 1.2 Cont ents included with boiler (thermoC OMP ACT) Ensure that all c ontents ar e included befor e co mmencing installation. Not e! DO NO T remov e the boiler from the polys trene ba se at this st age. Fig. 1.2: Items supplied with unit ( ther[...]

  • Page 5

    Intr oduction 2 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 5 2 Introduction 2. 1 General In formation Not e! T his boiler must be ins talled and serviced b y a c ompet ent person in ac cordance with the Gas Sa fe ty (Installation and U se ) Regulations 1998. In the UK "CORGI“ r egister ed installer s un[...]

  • Page 6

    3 Boiler Specific ation Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 6 t urboMAX plus turboMAX plus turboMAX plus 82 4/ 2 E 8 28 / 2 E 83 7 E Units (VUW GB 2 42/ 2 -5) (VUW GB 28 2/ 2-5) (VUW GB 36 2/ 2-5) Maximum CH heat input ( net) 2 6. 7 (9 1,200) 31. 1 (106,200) 31. 1 (106,200) kW (Btu/h ) CH heat output r [...]

  • Page 7

    B oiler Specific ation 3 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 7 thermoCOMP ACT thermoC OMP AC T thermoCOMP A CT thermoCOMP ACT thermoCOMP A CT 61 5/ 2 E 62 0 /2 E 62 4 /2 E 62 8 /2 E 63 7 E Units (VU GB 152 /2 -5) (VU GB 2 02/ 2-5) (VU GB 2 42/ 2 -5) (VU GB 28 2/ 2-5) (VU GB 362 -5) Maximum CH heat input[...]

  • Page 8

    3 Boiler Specific ation Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 8 Key : 1H e ating s ystem r eturn (22 mm t ail) 2 Gas connection (15 mm t ail) 3H e ating sy stem flo w (22 mm tail, 22 mm f or 637) 4 Flue outlet (100 mm flue with turret ) 5 Hanging brack et 6R e ar flue outlet 3. 4 F unctional Diagr am (tur[...]

  • Page 9

    B oiler Specific ation 3 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 9 22 P res sure gauge 23 D isplay 24 Expansion ve ssel 25 Expansion ve ssel charging v alve 26 Circulating pump 27 Aut omatic air v ent 28 Ignition electrode 29 T emperat ure sensor (NT C II) 30 A ir pre ssure s witch 31 Flue gas duct 3 .5 F u[...]

  • Page 10

    4 Gener al R equirement s 4 .2 Boiler loc ation T he loc ation chosen for the boiler mus t permit the pro vision of a satisf actory flue t ermination. The location must also pr ovide adequat e space f or servicing and air circ ulation around the boiler . The boiler ma y be installed in any r oom, although particular att ention is dra wn to the requ[...]

  • Page 11

    Gener al R equirement s 4 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 11 4.4 .2 Re ar outlet flue sy stem (100 mm outside diamet er) T he r ear outlet horizont al flue sy stem ( Ar t. No. 3 03 817) is suitable f or installations up t o 600 mm wall thicknes s. Fig. 4.3: Art.-No. 30 3 817 4.4. 3 Extended t op out[...]

  • Page 12

    4 Gener al R equirement s 1) In addition, the terminal should not be near er than 150mm to an opening in the building f abric formed for the purpos e of acc ommodating a built-in element such as a window . * BS 5440-1 It is r ecommended that a f anned flue terminal should be positioned as f ollows: a) at le ast 2m from an opening in a building dire[...]

  • Page 13

    Gener al R equirement s 4 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 13 ( Alt ernative methods of f illing sealed sy stems ar e given in BS 544 9). 4 .8.3 Pres sure relief v alve A pre ssure r elief valv e is pro vided with the boiler . This safe ty devic e is requir ed on all sealed C.H. sy stems and is pre s[...]

  • Page 14

    4 Gener al R equirement s Fig. 4.6: Pump specifications 3 7 kW 4 .8. 7 Sy stem b y-pass An automatic s yst em by-p ass is included within the boiler . The boiler is suitable f or use in s yst ems with thermost atic radiat or valv es and no additional by-p ass is r equir ed. 4 .8.8 V enting T he boiler is fit ted with an automatic air v ent. Additio[...]

  • Page 15

    B oiler Ins tallation Sequenc e 5 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 15 Se lecting position of boiler Ref er to "Boiler loc ation“ for inf ormation regar ding siting the appliance . In general the boiler mus t be positioned such that. •T here is adequat e space ar ound the boiler for servic e [...]

  • Page 16

    5 Boiler Ins tallation Sequenc e Not e! Us e alternativ e fixing holes where nec essary . Identify corr ect flue exit Mark the centr e of the select ed air /flue duct and its circ umfer ence , e.g. b y drilling through the t emplate. F or installation o f a rear e xit outlet please r efer t o the installation ins tructions of the re ar exit outlet [...]

  • Page 17

    B oiler Ins tallation Sequenc e 5 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 17 5. 7 Gas supply (turboMAX plus ) •C onnect the 15 mm compr ession gas servic e cock (1) and 15 mm copper outlet t ail (22mm copper t ail with 83 7) (3) as supplied with the appliance (2) and tight en. •C onnect a gas supply pip[...]

  • Page 18

    5 Boiler Ins tallation Sequenc e 5. 9 C entral he ating flow and re turn pipew ork (t urboMAX plus) Be fo re c onnecting the heating circuit t o the boiler appliance , all pipew ork and radiat ors must be thor oughly flushed to r emov e any installation debris . •C onnect the centr al heating flo w (6) and return (1) s ervic e valve s to the appl[...]

  • Page 19

    B oiler Ins tallation Sequenc e 5 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 19 5. 11 Centr al heating flow and re turn pipew ork ( thermoC OMP A CT) Be fo re c onnecting the heating circuit t o the boiler appliance , all pipew ork and radiat ors must be thor oughly f lushed to r emov e any inst allation debri[...]

  • Page 20

    5 Boiler Ins tallation Sequenc e Fig. 5. 11: Wiring s yst em Fig. 5. 12: Exposed r ear view of s witchgear cabinet (pictur e show s turboMAX appliance ) •C onnect the pow er supply cor d as follow s (Fig. 5. 13). Green/ y ellow ( earth) wir e: boiler terminal E ar th sign B lue ( neutral) wir e: boiler terminal N Bro wn (live ) wire: boiler t erm[...]

  • Page 21

    B oiler Ins tallation Sequenc e 5 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 21 Abb. 0 .0 Bildunter schrift Fig. 5. 13: Connection wiring N L 9 8 7 F3 5 4 3 24V 230V F1 5. 16 Electr onic board la yout Socket X2 for internal unit components Socket X4 for diver ter valve Socket X7 for accessor y box connection S[...]

  • Page 22

    5 Boiler Ins tallation Sequenc e C onnection de tails for e xternal time s witches and boiler terminal s trip. Fig. 5. 15 sho ws the connection det ails where a time s wit ch is used without a r oom thermostat t o control the boiler . At te n tion! T he arr owed number s indicate connection in to the rele vant t erminal in the boiler terminal strip[...]

  • Page 23

    B oiler Ins tallation Sequenc e 5 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 23 Fig. 5. 16 5. 18 C ontrols ( thermoCOMP ACT boiler ) External electrical c ontrols T he boiler t erminals 3, 4 and 5 ar e for connecting ext ernal electrical c ontrols such as a pr ogrammer , room thermost at, etc. Te rminals 3 and[...]

  • Page 24

    5 Boiler Ins tallation Sequenc e Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 24 5. 19 T hermostatic r adiator v alves T he boiler has a built in aut omatic bypass v alve making it ideal f or use in sy stems with thermos tatic r adiator v alves ( no separ ate sy stem b ypass is r equired). F or optimum fuel econ[...]

  • Page 25

    C ommissioning P art I 6 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 25 6 Commisioning P ar t I 6. 1 Preliminary electrical checks Check the electrical ins tallation by c arrying out shor t circ uit, earth continuity and r esist ance to e ar th tes ts and a check for c orrect polarit y . 6.2 Gas supply T he c o[...]

  • Page 26

    6 C ommissioning P art I Gas supply adjustment s ( Com. P art II) 7 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 26 7 Gas supply adjustment s 7. 1 Gas inlet working pre ssure To check the gas inle t working pre ssure: •L ow er the front p anel of the boiler . •L ow er the contr ol panel. • Slacken the seal[...]

  • Page 27

    Gas supply adjustment s ( Commis sioning P ar t II) 7 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 27 7 .2 Main burner pressur e T he burner pr essur e on this appliance has been f actory se t and does not r equire adjustment . T o check the main burner pre ssure c onnect the U-Gauge as follow s depending on the[...]

  • Page 28

    7 Gas supply adjustments ( Commis sioning P ar t II) Not e! F ollowing adjustment o f the central he ating output, the ne w output can be checked using the gas rat e table as det ailed. Fig. 7 . 3: Using burner pres sure to check and adjust the he ating sy st em partial load (picture sho ws a turboMAX plus boiler ) Not e! T his illustr ation show s[...]

  • Page 29

    Gas supply adjustment s ( Commis sioning P ar t II) 7 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 29 7. 4 Adjusting to the maximum he at load ( nominal lo ad) • Undo scre w and remo ve the cap (1) tu rboMAX only: •S et the DHW temper ature c ontrol to maximum and fi re the boiler at full rat e by fully open[...]

  • Page 30

    7 Gas supply adjustments ( Commis sioning P ar t II) Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 30 7 .6 Checking the gas valve mid s etting point (t urboMAX plus 83 7 and thermoCOMP ACT 63 7 only ) To ensur e the most ef ficient operation o f the boiler a gas v alve mid set ting point is necessary . T his mid [...]

  • Page 31

    Gas supply adjustment s ( Commis sioning P ar t II) 7 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 31 Bu rner Pres sure and gas rat e Bu rner Pres sure thermoCOMP AC T 615 /2 E Output[kW] Gas type Ignition rat e 6.5 8.0 10. 0 12.0 14. 0 15. 0 Natur al gas 2H Burner pressur e 1) [mb a r] Main burner jet mark 2) f[...]

  • Page 32

    7 Gas supply adjustments ( Commis sioning P ar t II) Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 32 Gas R ate thermoCOMP A CT 615 / 2 E Output[kW] Gas type 6.5 8.0 10. 0 12. 0 14.0 15 .0 Natur al gas 2H Gas Rate 1) [m 3 /h] Main burner jet mark 2) for G 20 0.8 1.0 1. 3 1 .4 1. 7 1. 7 7 / 120 Gas R ate thermoCOM[...]

  • Page 33

    Gas supply adjustment s ( Com. P art II) 7 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 33 7. 8 Fit c ombustion chamber co ver Ca re fully re-fit the c ombustion chamber co ver to the boiler ensuring it is corr ectly sealed. Secur e cov er with ret aining clamps. 7. 9 Fit boiler casing •C arefully push c ase ([...]

  • Page 34

    8 F unctional Checks ( C ommissioning P art III) Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 34 •Y ellow flame indicat or (2) ON. •G r een warms tart indicator (3) FLA SHING (hot wat er is being dr awn from the s ys tem). Ce nt r al He ating operation • Operat e the heating sy stem. If boiler is oper atin[...]

  • Page 35

    F unctional Checks ( Commissioning P ar t III) 8 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 35 Fig. 8.4: Pump speed 8.5 Handing ov er to the user •S et the maximum radiat or temper ature c ontrol t o the desir ed setting. •S et the maximum hot wat er temper ature c ontrol t o the desir ed setting. • Inst[...]

  • Page 36

    9 Servicing •T urn off the boiler CH s ervice valv es. •T urn off the c old wat er inlet service v alve . •R elease the thr ee clamps (1), remo ve the combus tion chamber co ver (2). 9 .2. 1 F or thermoCOMP AC T 615, 63 7 and turboMAX plus 83 7 •R emov e the flue gas connect or (2a) on the f an. •R emov e the ret aining spring (3). • 1 [...]

  • Page 37

    S ervicing 9 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 37 10.3 Indicat or lights (thermoC OMP A CT only ) T he boiler c ontrol panel als o contains thr ee indicator lights whos e function is as follow s: •R ed lock out indicat or (1), when illuminated boiler is at lock out. •Y ellow flame indicat or (2), [...]

  • Page 38

    To ac ces s the various modes pr ess the butt ons on the co ntrol panel as f ollows: Not e! If no ke y is pres sed for appr ox. 4 minute s the display will aut omatically change back t o Normal mode. 10 F ault Finding Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 38 10.5 S tatus Modes T he st atus mode pro vides [...]

  • Page 39

    F ault Finding 10 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 39 Display Indication Display ed values / adjustment v alues d.00 Part load set ting 0 - 15 (0 - 30 , 837 / 637 only ) d.01 W ater pump ov er run 1, 2, 3, …60 min ( fact ory adjusted set ting: 5 min) d.0 2 Maximum burner anti cy cling period at 20 [...]

  • Page 40

    10 F ault Finding Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 40 10. 7 F ault codes F ault codes t ake priorit y over all other displa y functions in the ev ent of a s yst em fault oc curring. If multiple f aults occur , the corre sponding fault c odes are displa yed alternat ely for about t wo seconds e ach. 1[...]

  • Page 41

    F ault Finding 10 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 41 Ensure boiler main ON/OFF control is set to position "1" Is there a display on the LCD Panel? Ye s Go to sheet C Check electrical supply , appliance fuses and on/off control No Is 230V AC present across terminals L and N? Ye s Is 230V AC[...]

  • Page 42

    10 F ault Finding Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 42 Sheet B Check operation of pump and fan Tu rn off the main ON/OFF control to the "0" position Disconnect the power supply to the boiler Go to sheet A Is there a display on the LCD panel? Check transformer 230 V AC primary (black/red) and[...]

  • Page 43

    F ault Finding 10 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 43 Check central heating and controls Ensure that radiator temperature control knob is set to vertical position and that any internal timer (if fitted) is calling for heat Check diagnostic code D.08 (see page 53). Is heating demand present? No Is 230[...]

  • Page 44

    10 F ault Finding Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 44 Does fan run after approx. 30 secs.? Check flue and ignition system No Check diagnostic code D.24 (see page 53) equal 1? Check pitot tube (in fan outlet) and air hoses are not obstructed and correctly aligned. Check or replace air pressure switch.[...]

  • Page 45

    F ault Finding 10 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 45 Check gas valve and central heating system pressure Does burner light 1st attempt? Does burner light within 3 ignition attempts? No Ye s Check gas supply Does burner light? Ye s Check burner pressure settings are correct Ye s No Reset boiler No Ch[...]

  • Page 46

    10 F ault Finding Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 46 Does flame indicator glow and flames increase in size to full gas rate after approx. 2 mins? Ye s Does burner flame modulate/ go out when radiator temperature control is turned left to the horizontal position at flow temperature of approx. 50 C? Y[...]

  • Page 47

    F ault Finding 10 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 47 Draw hot water at high rate Does green warmstart indicator flash? Ye s Check hot water flow rate and temperature. Compare with technical data, if flow is not sufficient check incoming main and cold water filter . Normal operation carr y out electr[...]

  • Page 48

    11 Diagr ams Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 48 11. 1 F unctional Flo w diagram: turboMAX plus 8 2 4 /2 E, 8 2 8 /2 E, 8 37 E Fig. 11. 1: F unctional Flow diagr am VUW POWER SUPPL Y F2A L 2 N 1 MAIN SWITCH MAIN TRANSFORMER 230V 20V AIR PRESSURE SWITCH PUMP NTC FLOW TEMPERA TURE SENSOR FLAME SENSOR G[...]

  • Page 49

    Diagr ams 11 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 49 F unctional Flo w diagram: thermoC OMP AC T 615 / 2 E, 620 / 2 E, 62 4 /2 E, 6 2 8/ 2 E, 63 7 E Fig. 11.2: F unctional Flow diagr am VU POWER SUPPL Y F2A L 2 N 1 MAIN SWITCH MAIN TRANSFORMER 230V 20V AIR PRESSURE SWITCH FA N PUMP NTC FLOW TEMPERA TURE [...]

  • Page 50

    11 Diagr ams Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 50 W iring diagr am: turboMAX plus 8 2 4/ 2 E, 8 2 8/ 2 E, 83 7 E Fig. 11.3: Wiring diagram VUW Switchgear cabinet U100 X3 T 2 = F1 T 1,25 = F3 X2 X2 X1 24 23 1 12 13 14 15 16 17 18 19 20 21 22 2 3 4 5 6 7 8 9 10 11 4 3 2 1 X2 NTC NTC Wa r mstart earth Io[...]

  • Page 51

    Diagr ams 11 Instructions for Ins tallation and Servicing turboMAX plus and thermoCOMP AC T R1 51 W iring diagr am: thermoCOMP ACT 6 15/ 2 E, 6 20 / 2 E, 6 2 4/ 2 E, 6 28 / 2 E, 637 E Fig. 11.4: Wiring diagr am VU Switchgear cabinet U100 X3 T 2 = F1 T 1,25 = F3 X2 X2 X1 24 23 1 12 13 14 15 16 17 18 19 20 21 22 2 3 4 5 6 7 8 9 10 11 X2 Pressure sens[...]

  • Page 52

    83 37 86_30 GB R2 04 /2 00 3 Mü Printed on 100 % rec ycled paper · Subject to alt eration Head Office: Vaillant Ltd. Service Solutions 0870 6060 777 Vaillant House Trident Close Medway City Estate Rochester Kent ME2 4EZ Technical Advice 01634 292392[...]