turbomax plus and thermocompact

Transcription

1 For the installer Instructions for Installation and Servicing turbomax plus and thermocompact Wall hung room sealed fan assisted combination and system boilers 84/ E 88/ E 87 E 65/ E 60/ E 64/ E 68/ E 67 E GB

2 Table of Contents Page List of Contents Contents included with boiler (turbomax plus) 4. Contents included with boiler (thermocompact) 4 Introduction General Information General notes EC designation Boiler Specification Technical data Boiler connections (turbomax plus) Boiler connections (thermocompact) Functional diagram (turbomax plus) Functional diagram (thermocompact) General Requirements Related documents Boiler location Gas supply Flue system Top outlet flue system Rear outlet flue system Extended top outlet flue system Flue termination Air supply Cupboard or compartment ventilation Electrical supply Guide to system requirements Water circulation system Filling and make up Pressure relief valve Pressure gauge Expansion vessel Circulating pump System by-pass Venting Boiler Installation Sequence General Using boiler template Fitting the boiler hanging bracket Install the flue system Fitting the boiler Removing boiler casing Gas supply (turbomax plus) Cold water mains inlet and hot water outlet (turbomax plus) Central heating flow and return pipework (turbomax plus) Gas supply (thermocompact) Central heating flow and return pipework (thermocompact) Connection to a Vantage unvented cylinder. (thermocompact) Page 5. Connect the flue system to the boiler Electrical installation Connection to the main supply Electronic board layout Controls (turbomax plus boiler) Controls (thermocompact boiler) Thermostatic radiator valves Frost protection Circulating pump Anti-cycling economiser control Commissioning Part I Preliminary electrical checks Gas supply Cold water supply (turbomax plus only) Filling the heating system (turbomax plus) Filling the heating system (thermocompact) Initial system flush ("cold ) Gas supply adjustments (Commissioning Part II) 6 7. Gas inlet working pressure Main burner pressure Adjusting the central heating output (range rating) Adjusting to the maximum heat load (nominal load) Adjusting the ignition rate Checking and adjusting to the operating point (turbomax plus 87E and thermocompact 67E only) Setting or adjusting the mid-setting point Fit combustion chamber cover Fit boiler casing Functional checks (Commissioning Part III) 8. Functional checks Functional check of operation (turbomax plus only) Functional check of operation (thermocompact only) Adjusting pump speed Handing over to the user Servicing Initial inspection Cleaning the burner and primary heat exchanger Instructions for Installation and Servicing turbomax plus and thermocompact R

3 Table of Contents Page 0 Fault Finding Introduction Indicator lights (turbomax plus only) Indicator lights (thermocompact only) Logical fault finding procedure Status Modes Diagnostic Mode Fault codes Fault memory Fault finding charts Diagrams Functional flow diagrams Wiring diagrams Instructions for Installation and Servicing turbomax plus and thermocompact R

4 C o C o 0 I VRC-VC C o C o 0 I VRC-VC List of contents List of contents. Contents included with boiler (turbomax plus) Ensure that all contents are included before commencing installation. te! DO NOT remove the boiler from the polystrene base at this stage.. Contents included with boiler (thermocompact) Ensure that all contents are included before commencing installation. te! DO NOT remove the boiler from the polystrene base at this stage Fig..: Items supplied with unit (turbomax plus) Fig..: Items supplied with unit (thermocompact) Item Quantity Description Item Quantity Description Boiler Flue restriction ring Controls cover door 4 Lower cover plate (packed in bottom packaging) 5 Cold water inlet valve 6 Flow and return service value, gas service valve 7 5 Copper tails for gas and water pipework 8 Template 9 Guarantee Card and Benchmark log book 0 Installation and connection accessories and PRV packages incl. DHW outlet union nut Installation and Servicing, Users and Flue Installation Instructions Hanging bracket Boiler Flue restriction ring Controls cover door 4 Lower cover plate (packed in bottom packaging) 5 Flow and return service value, gas service valve 6 Copper tails for gas and water pipework 7 Template 8 Guarantee Card and Benchmark log book 9 Installation and connection accessories and PRV packages 0 Installation and Servicing, Users and Flue Installation Instructions Hanging bracket 4 Instructions for Installation and Servicing turbomax plus and thermocompact R

5 Introduction Introduction. General Information te! This boiler must be installed and serviced by a competent person in accordance with the Gas Safety (Installation and Use) Regulations 998. In the UK "CORGI registered installers undertake the work to a safe and satisfactory standard. turbomax plus boiler The turbomax plus is a fully automatic, wall mounted, room sealed combination boiler for central heating and domestic hot water. Domestic hot water is supplied directly from the boiler, without requiring a copper cylinder, cold water tank, feed and expansion tank and associated pipework. Domestic hot water has priority over central heating. The turbomax plus range consists of models with outputs for domestic hot water of 4 kw, 8 kw and 7 kw. All turbomax plus boilers are available in Natural Gas. The 4 and 8 kw versions are also available in LPG. turbomax plus combination boilers incorporate a warmstart facility that keeps the domestic hot water heat exchanger hot, providing an instantaneous delivery of domestic hot water. The temperature in the domestic hot water heat exchanger is limited by the boiler control system and it is not necessary to install a scale reducer on the cold mains to the boiler. However, in exceptionally hard water areas to prevent scale formation in the property hot water system pipework, a scale reducer may be fitted. The heating system can be filled using the built-in filling loop contained within the boiler. thermocompact boiler The thermocompact is a fully automatic, wall mounted, room sealed system boiler for central heating and domestic hot water (where a separate indirect hot water storage cylinder is also incorporated in the system). The thermocompact range consists of models with outputs of 5, 0, 4, 8 kw and 7 kw. All thermocompact boilers are available in Natural Gas. The 0 and 8 kw versions are also available in LPG. systems are available, the standard concentric flue system (00 mm outside diameter) and a larger diameter concentric flue system (5 mm outside diameter) which allows longer flue lengths to be achieved. Flue extensions and additional bends and elbows are available for both flue systems to increase the siting flexibility. There is also a 00 mm diameter concentric flue accessory which connects to the alternative rear flue outlet on the boiler for direct through the wall installations. The boilers are not suitable for external installation. If desired, an inhibitor may be used in the system. Guidance on the use of inhibitors is contained in these instructions. All boilers have a built in diagnostic system which indicates the operational status of the boiler. This feature provides key information to aid commissioning and fault finding. The data badge is fitted on the rear of the control panel. See text of General Requirements for installation requirements or notes. Vaillant Ltd. support the Benchmark initiative. Within the information pack, you will find a Benchmark Log Book. It is very important that this is completed correctly at the time of installation, commissioning and handover to the user.. EC designation turbomax plus (84/88/87) and thermocompact boilers (65/60/64/68/67) carry the "CE" Mark. This demonstrates that the boilers fulfil the essential requirements of the Gas Appliance Directive(90/96/EEC) and the Gas Appliance (Safety) Regulations 99. The "CE" Mark also demonstrates that the boilers comply with the requirements of the Electromagnetic Compatibility Directive (89/6/EEC), the Low Voltage Directive (7//EEC), the Boiler Efficiency Directive (9/4/EEC) and the Boiler (Efficiency) Regulations 99.. General tes The boilers have been designed for use with a sealed central heating system, and come fully tested and assembled with a built in circulating pump, expansion vessel and diverter valve (turbomax plus only). The boilers are not suitable for use on open vented systems. The boilers are easily sited on any internal wall and can be installed with either a horizontal or vertical RSF (room sealed fan assisted) flue. Two types of flue Instructions for Installation and Servicing turbomax plus and thermocompact R 5

6 Boiler Specification Boiler Specification. Technical Data turbomax plus turbomax plus turbomax plus 84/ E 88/ E 87 E Units (VUW GB 4/-5) (VUW GB 8/-5) (VUW GB 6/-5) Maximum CH heat input (net) 6.7 (9,00). (06,00). (06,00) kw (Btu/h) CH heat output range (80/60 C) * (6,.9) (0,400-8,900) (5,500-95,500) (7,00-95,500) kw (Btu/h) Maximum DHW heat input (net) 6.7 (9,00). (06,00) 40.5 (8,00) kw (Btu/h) SEDBUK Band D D D SAP Seasonal Efficiency % DHW heat output kw DHW flow rate T = 5 C rise l/min DHW flow rate at factory set temperature rise ( T 4 C) l/min Mains water pressure required for max. flow rate bar Minimum water flow rate l/min Mains water pressure required for min. flow rate bar Maximum inlet water pressure bar Inlet gas working pressure required (natural gas) mbar Gas supply (G0) Gross CV (s.t.) MJ/m Gas burner pressure max. rate mbar Gas burner pressure ignition rate.9.8. mbar Gas rate max. (DHW) m /h CH temperature flow range C Minimum CH water flow (for 0 C rise) ** l/h Pump pressure available 0.5 (5) 0.5 (5) 0.5 (5) bar (KPa) Expansion vessel pre-charge pressure bar Maximum CH system pressure bar Weight kg Primary water content.0.0. l Electrical supply 0/50 0/50 0/50 V~/Hz External fuse A Power input W Case height mm Case width mm Case depth mm * factory setting; ** at factory setting 6 Instructions for Installation and Servicing turbomax plus and thermocompact R

7 Boiler Specification thermocompact thermocompact thermocompact thermocompact thermocompact 65/ E 60/ E 64/ E 68/ E 67 E Units (VU GB 5/-5) (VU GB 0/-5) (VU GB 4/-5) (VU GB 8/-5) (VU GB 6-5) Maximum CH heat input kw (net) (56,00) (74,800) (9,00) (06,00) (8,00) (Btu/h) CH heat output range kw (80/60 C) (,00-5,00) (6,00-68,00) (0,400-8,900) (5,500-95,500) (5,800-6,000) (Btu/h) SEDBUK Band D D D D D SAP Seasonal Efficiency % Inlet gas working pressure required (natural gas) mbar Gas supply (G0) MJ/m Gross CV (s.t.) Gas burner pressure mbar max. rate Gas burner pressure mbar ignition rate CH temperature C flow range Minimum CH water flow (for 0 C rise) l/h Pump pressure available 0.5 (5) 0.5 (5) 0.5 (5) 0.5 (5) 0.7 (7) bar (KPa) Expansion vessel pre-charge pressure bar Maximum CH bar system pressure Weight kg Primary water content l Electrical supply 0/50 0/50 0/50 0/50 0/50 V~/Hz External fuse A Power input W Case height mm Case width mm Case depth mm Instructions for Installation and Servicing turbomax plus and thermocompact R 7

8 C C Boiler Specification. Boiler connections (turbomax plus) Key: Heating system return ( mm tail) Gas connection (5 mm tail) Heating system flow ( mm tail, mm for 67) 4 Flue outlet (00 mm flue with turret) 5 Hanging bracket 6 Rear flue outlet.4 Functional Diagram (turbomax plus) u 8 Fig..: Connection diameters turbomax plus Key: Heating system return ( mm tail) Cold water connection with shut off valve (5 mm tail) Gas connection (5 mm tail, mm for 87) 4 Hot water connection (5 mm tail) 5 Heating system flow ( mm tail) 6 Flue outlet (00 mm flue with turret) 7 Hanging bracket 8 Rear flue outlet. Boiler connections (thermocompact) i Fig..: Connection diameters thermocompact Fig..: Functional Diagram turbomax plus Key: Air duct Fan Main heat exchanger 4 Temperature sensor (NTC I) 5 Flame sensing electrodes 6 Modulating burner 7 Fully modulating automatic gas value 8 Maximum hot water temperature control 9 Maximum radiator temperature control 0 Diverter valve DHW heat exchanger Automatic bypass valve CH flow service valve 4 Hot water outlet 5 Gas service valve 6 Cold water service valve 7 CH return service valve 8 Pressure relief valve 9 Aqua sensor (DHW flow switch) 0 Temperature sensor (NTC III) Main on/off control 8 Instructions for Installation and Servicing turbomax plus and thermocompact R

9 Boiler Specification Pressure gauge Display 4 Expansion vessel 5 Expansion vessel charging valve 6 Circulating pump 7 Automatic air vent 8 Ignition electrode 9 Temperature sensor (NTC II) 0 Air pressure switch Flue gas duct 9 Expansion vessel charging valve 0 Circulating pump Automatic air vent Ignition electrode Temperature sensor (NTC II) 4 Air pressure switch 5 Flue gas duct.5 Functional Diagram (thermocompact) Fig..4: Functional Diagram thermocompact Key: Air duct Fan Main heat exchanger 4 Temperature sensor (NTC I) 5 Flame sensing electrodes 6 Modulating burner 7 Fully modulating automatic gas value 8 This control has no function on this boiler 9 Maximum radiator temperature control 0 Automatic bypass valve CH flow service valve Gas service valve CH return service valve 4 Pressure relief valve 5 Main on/off control 6 Pressure gauge 7 Display 8 Expansion vessel Instructions for Installation and Servicing turbomax plus and thermocompact R 9

10 4 General Requirements 4 General Requirements 4. Related Documents The installation of the boiler must be in accordance with the relevant requirements of Gas Safety (Installation and Use) Regulations 998, Health and Safety Document. 65 (The Electricity at Work Regulations 989), BS767 (IEE Wiring Regulations) and the Water Supply (Water Fittings) Regulations 999, or the Water Bylaws 000 (Scotland). It should also be in accordance with the relevant requirements of the Local Authority, Building Regulations, Building Regulations (Scotland), Building Regulations (rthern Ireland) and the relevant recommendations of the following British Standard; Including current amendments to Approved Documents Part L and J.: BS 5440: Flues and ventilation of gas fired boilers not exceeding 70 kw net: - Part : Flues - Part : Ventilation BS 5449: Specification for forced circulation hot water for domestic premises. BS 5546: Specification for gas hot water supplies for domestic premises. BS 6700: Services supplying water for domestic use within buildings and their curtilages. BS 6798: Specification for installation of gas fired boilers not exceeding 70 kw input net. BS 689: Specification for installation of low pressure gas pipework up to 8 mm (R) in domestic premises ( nd family gas). BS 759: Treatment of water in domestic hot water central heating systems.institute of Gas Engineers Publication IGE/UP/7/998: Guide for Installation in Timber Framed Housing. Benchmark Code of Practice. Building Regulations Approved Documents Part L 00 Part J 00. Important! The appliance must be installed and serviced by a competent person as stated in the Gas Safety (Installation and Use) Regulations 998. In IE, the installation must be in accordance with the current edition of IS 8 'Domestic Gas Installations', the current Building Regulations and reference should be made to the current ETCI rules for electrical installation. Preliminary remarks This appliance should only be installed in conjunction with a Vaillant flue system. Install the flue system as detailed in the separate flue installation instructions supplied with this boiler. 4. Boiler location The location chosen for the boiler must permit the provision of a satisfactory flue termination. The location must also provide adequate space for servicing and air circulation around the boiler. The boiler may be installed in any room, although particular attention is drawn to the requirements of BS767 (IEE Regulations), the electrical provisions of the Building Regulations (Scotland) and in IE the current edition of IS 8 and the current ETCI rules, in respect of the installation of a boiler in a room containing a bath or shower. te! Where a room sealed boiler is installed in a room containing a bath or shower, any electrical switch or boiler control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower. Where the installation of the boiler will be in an unusual location, special procedures may be necessary and BS 5546 and BS 6798 give detailed guidance on this aspect. The boiler must be mounted on a flat, vertical wall, which must be sufficiently robust to take the weight of the boiler. The boiler may be installed on a combustible wall, subject to the requirements of the Local Authorities and Building Regulations. A compartment used to enclose the boiler must be designed and constructed specifically for this purpose. (An existing cupboard or compartment may be used provided that it is modified for the purpose). Details of essential features of cupboard/compartment design including airing cupboard installations are given in BS 689. In IE the current edition of IS 8. If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with Institute of Gas Engineers Publication IGE/UP/7/998 "Guide for Gas Installation in Timber Framed Housing. 4. 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 689. 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 (5 mm, mm for 87/67). The complete installation must be tested for soundness and purged as described in BS Instructions for Installation and Servicing turbomax plus and thermocompact R

11 General Requirements Flue system te! The boilers are delivered ready for installation utilising a top outlet flue assembly. For installation with a rear outlet flue assembly refer to the boiler flue outlet adaptation in the flue instructions Top outlet flue system (00 mm outside diameter) The top outlet horizontal flue system (Art ) is suitable for installations up to 70 mm measured from the centre of the boiler flue outlet to the outside face of the wall. Flue extensions are available to extend this length up to 5. m for 5/0 kw; 4.5 m for 4 kw and. m for 8/7 kw. Both 90 bends and 45 elbows are also available to increase siting flexibility. A vertical flue system is also available (Art ). Refer to flue system installation instructions for full details Rear outlet flue system (00 mm outside diameter) The rear outlet horizontal flue system (Art ) is suitable for installations up to 600 mm wall thickness. Fig. 4.: Art Extended top outlet flue system (5 mm outside diameter) A top outlet horizontal flue system of 5 mm outside diameter is also available (Art ) and can be used to achieve flue lengths of up to.9 m for 5/0/4 kw; 0 m for 8/7 kw. Both 45 and 90 bends and elbows are also available to increase siting flexibility. A vertical 5 mm concentric flue system is also available (Art ). Refer to flue system installation instructions for full details. Fig. 4.: Art A vertical flue system is also available (Art ). Refer to flue system installation instructions for full details Fig. 4.4: Art Fig. 4.: Art Instructions for Installation and Servicing turbomax plus and thermocompact R

12 4 General Requirements Flue termination The following details refer to both flue systems. a. The terminal must be positioned such that the products of combustion can disperse freely at all times. b. In certain weather conditions a plume of water vapour may be visible from the flue terminal. Positions where this could be a nuisance should be avoided. c. If the terminal is fitted less than m above a balcony, above ground or above a flat roof to which people have access then a suitable terminal guard; must be provided and fitted (Model K - made by Tower Flue Components, Tonbridge, TN9 TB). te! Vertical flues must not terminate within 600 mm of an openable window, air vent or any other ventilation opening. The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of the building. A ) Terminal position for fan-assisted flue (minimum distance) Directly below an openable, above an opening or horizontal to an opening i.e. air brick, opening mm window or other, etc 00 B Below gutters, soil pipes or drain pipes 5 C Below eaves 5 D Below balconies (below car port roof) 5 E From vertical drain pipes and soil pipes 5 F From internal or external corners 5 G Above ground or balcony level 00 H From a surface or boundary facing a terminal 600* H From a terminal facing a terminal 00 J From an opening in a car port (e.g. door, window) into a dweling 00 K Vertically from a terminal on the same wall 500 L Horizontally from a terminal on the same wall 00 M Distance from adjacent wall for vertical Flue 500 H, I A G F J E Fig. 4.5: Flue termination A A G A BCD F F B F M G L K L K ) In addition, the terminal should not be nearer than 50mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window. * BS It is recommended that a fanned flue terminal should be positioned as follows: a) at least m from an opening in a building directly opposite, and b) so that the products of combustion are not directed to discharge across a boundary. 4.5 Air supply Detailed recommendations for air supply are given in BS 5440: Part. It is not necessary to have an air vent in the room or internal space in which the boiler is installed. 4.6 Cupboard or compartment ventilation The boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during operation is very low. For cupboard or compartment installations it is therefore not necessary to provide any high or low level permanent air vents for cooling purposes. 4.7 Electrical supply A 0 V, ~ 50 Hz single phase electricity supply fused to Amp. must be provided in accordance with the latest edition of BS767 (IEE Wiring Regulations) and any other local regulations that may apply. In IE, reference should be made to the current edition of the ETCI rules. The method of connection to the mains electricity supply must provide a means of completely isolating the boiler and its ancillary controls. Isolation is preferably by the use of a fused three pin plug and unswitched shuttered socket outlet, both complying with the Instructions for Installation and Servicing turbomax plus and thermocompact R

13 General Requirements 4 requirements of BS 6. Alternatively, a Amp. fused doublepole switch with a mm contact separation on both poles may be used. Important! This appliance must be earthed. 4.8 Guide to system requirements 4.8. Water circulation system Detailed recommendations for the water circulation system are given in BS 6798 and BS 5449: Part (for small bore and micro bore central heating systems). Pipework not forming part of the useful heating surface should be insulated to help prevent heat loss and possible freezing, particularly where pipes are run through roof spaces and ventilated underfloor spaces. Draining taps must be located in accessible positions which permit the draining of the whole system including the boiler and the hot water system. Draining taps should be at least / in. BSP nominal size and be in accordance with BS 879. The boiler is suitable for use with minibore or microbore systems. Copper tubing to BS 87: Part should be used for water carrying pipework. All capillary joints in all 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 cleansing should take place prior to the fitting of the new boiler and be in accordance with BS 759. For advice on the application of system cleansers contact either Sentinel, GE Betz. Widnes, Cheshire, WA8 8UD. Tel: or: Fernox Alpha-Fry Technologies Tandem House Marlow Way, Beddington Farm Road Croydon CRO 4xS Tel Fernox technical help line (Alternative methods of filling sealed systems are given in BS 5449) Pressure relief valve A pressure relief valve is provided with the boiler. This safety device is required on all sealed C.H. systems and is preset at bar and provided with a 5 mm compression connection for a discharge pipe, which must be of no less than 5 mm in diameter. The Pressure Relief Valve must not be used for draining purposes Pressure gauge This is factory fitted to the boiler and indicates the primary circuit pressure to facilitate filling and testing Expansion vessel The 5 and 0 kw thermocompact boilers as well as the 4 kw turbomax plus boiler incorporate a 6 litre expansion vessel which is suitable for a sealed heating system with a maximum water content of 60 litres. A 0 litre expansion vessel kit is available as an optional accessory for for the turbomax plus 4 kw boiler and the 5 and 0 kw thermocompact boilers. The 8, 7 turbomax plus and 4, 8, 7 kw thermocompact boilers incorporate a 0 litre expansion vessel which is suitable for a sealed heating system with a maximum water content of 00 litres. If the nominal capacity of the built in expansion vessel is not sufficient for the heating system (for instance in case of modernization of old open systems) an additional expansion vessel can be installed external to the boiler. It should be fitted in the return pipe as close as possible to the boiler in accordance with BS 5449: Part. Guidance on the sizing of an additional expansion vessel is given in Table on page Filling and make up The system can be filled using the built in filling loop (turbomax plus only) or via a separate filling point fitted at a convinient position on the heating circuit (thermocompact). The connection must be removed when filling is completed. Where local Water Authority regulation does not allow temporary connection, a sealed system filler pump with break tank must be used. The heating system will not be filled automatically from the domestic hot water side. Instructions for Installation and Servicing turbomax plus and thermocompact R

14 4 General Requirements Vessel Volume [L] Initial system pressure (bar).0.5 Pressure relief valve setting (bar).0 Total water content of system ltres Lift [mbar] Pump switch in position III (pre-delivery setting) Pump switch in position II Fig. 4.6: Pump specifications 7 kw Volume flow [l/min] System by-pass An automatic system by-pass is included within the boiler. The boiler is suitable for use in systems with thermostatic radiator valves and no additional by-pass is required 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 For system volumes other than those given above, multiply the system volume by the factor across Circulating pump The circulating pump is included in the boiler. The pump head available for the heating system is shown in fig Lift [mbar] Pump switch in position III (Factory setting) Pump switch in position II Fig. 4.6: Pump specifications -8 kw Volume flow [l/hr] 4 Instructions for Installation and Servicing turbomax plus and thermocompact R

15 Boiler Installation Sequence 5 5 Boiler Installation Sequence 5. General Preparation of boiler location Clearances required Mount the boiler on a flat and vertical area of wall of sufficient area for the boiler plus the required clearances for installation and servicing. The clearances are as detailed below and are shown on the installation template supplied with the boiler: - 50 mm below the boiler - 5 mm on either side of the boiler - 0 mm on top of the boiler mm in front of the boiler* * Clearance is only required to enable easier access to the boiler for servicing and may be provided by an openable door, etc. Selecting position of boiler Refer to "Boiler location for information regarding siting the appliance. In general the boiler must be positioned such that. There is adequate space around the boiler for service and maintenance. The boiler can be correctly flued, i.e. the flue terminal position is sited in accordance with the flue termination section and the air/flue duct can be installed in accordance with the flue installation instructions supplied. All necessary pipework can be connected, including the pressure relief valve. te! Should it be necessary to run system pipework to above the boiler within the width of the casing, use the optional top connection accessory (Art ). te! If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with Institute of Gas Engineers Publication IGE/UP/7/998 "Guide for Gas Installations in Timber Framed Dwellings. ; y ; y ; y ; y Fig. 5.: Dimensions of boiler 8 Fig. 5.: Free space required for installation Instructions for Installation and Servicing turbomax plus and thermocompact R 5

16 5 Boiler Installation Sequence 5. Using boiler template Fix the paper template to the wall ensuring that the correct flue exit point has been identified, ensure that the template is vertical. The template shows - The position of the fixing holes for the boiler mounting bracket (). - The position of the connections. - The position of the flue exit hole. - Upper hole () indicates top outlet flue with flue turret facing rearward. - Lower hole () indicates rear outlet flue exiting directly through wall. Mark the position of the hanging bracket fixing holes (). Drill holes Ø 8 mm for the hanging bracket. te! Use alternative fixing holes where necessary. Identify correct flue exit Mark the centre of the selected air/flue duct and its circumference, e.g. by drilling through the template. For installation of a rear exit outlet please refer to the installation instructions of the rear exit outlet kit (Art ). Other flue options Flue instructions for other flue systems such as vertical RSF flues, flues run to the side of the boiler and the use of additional bends etc. are detailed in the flue installation instructions provided with the boiler. Remove the template from the wall and plug the drilled holes using the wallplugs supplied. 5. Fitting the boiler hanging bracket Fix the hanging bracket () to the wall using the screws supplied (). (it may be necessary to use additional or alternative fixings to ensure adequate support) / ,5 5 5,5 Fig. 5.4: Free space required for installation te! If the boiler is to be fitted in a timber framed building ensure that the bracket is secured to a substantial part of the timber frame capable of taking the weight of the boiler. turbomax only 07/00 00/0/40/4/80/8/84/88 Pro/Plus 46 Fig. 5.: Using Boiler template 6 Instructions for Installation and Servicing turbomax plus and thermocompact R

17 VRC-VC I 0 Boiler Installation Sequence Install the flue system Fit the flue restrictor to the boiler (if required) and install the flue system (refer to separate air/flue duct installation instructions for further information). 5.5 Fitting the boiler Lift the boiler () up to the wall so that it is slightly above the hanging bracket (). te! Lift the boiler from either side at the bottom edge. 5.7 Gas supply (turbomax plus) Connect the 5 mm compression gas service cock () and 5 mm copper outlet tail (mm copper tail with 87) () as supplied with the appliance () and tighten. Connect a gas supply pipe of not less than 5 mm diameter to the copper tail (minimum mm gas supply pipe with 87). Tighten all connections. (Ensure the gas supply pipework is adequately sized such that a 0 mbar gas pressure is available at the boiler inlet at full flow rate). Lower the boiler slowly onto the hanging bracket so that the cross member at the rear of the boiler fully engages onto the hanging bracket. 5.6 Removing boiler casing Turn both securing fasteners () anti-clockwise by 90 to release control panel (). Pull the case () forward at the bottom to disengage from the securing clips. Lift the case slightly to clear the top locations and pull forward to remove. I I 0 Fig. 5.6: Fitting the gas connection turbomax plus Fig. 5.5: Remove of boiler casing Instructions for Installation and Servicing turbomax plus and thermocompact R 7

18 5 Boiler Installation Sequence 5.8 Cold water mains inlet and hot water outlet (turbomax plus) Flush all foreign matter from the mains supply before connecting to the boiler. Connect the cold water service valve () to the cold inlet water connection () of the appliance with the washer () provided and tighten. Connect the 5 mm cold water inlet pipe copper tail (4) to the cold water service valve () and tighten. Connect the 5 mm hot water outlet copper tail (6) to the hot water outlet connection of the appliance (8) with the washer provided (7) and tighten. te! The hot water outlet union nut is packed in with the PRV fitting pack. Connect the cold water service pipe and hot water outlet pipework to the copper tails. I Central heating flow and return pipework (turbomax plus) Before connecting the heating circuit to the boiler appliance, all pipework and radiators must be thoroughly flushed to remove any installation debris. Connect the central heating flow (6) and return () service valves to the appliance (8 and ) with the washers provided ( and 7) and tighten the nuts. Ensure that the valve spindles face downwards and the drain points face to either side of the boiler. Connect the mm copper pipe tails to the service valves as shown in the illustration and tighten the nuts. Connect the central heating pipework to the flow (9) and return (4) tails. Pressure Relief Valve Connect a discharge pipe not less than 5 mm diameter to the outlet of this valve. The discharge pipework should be as short as possible and installed with a continuous fall away from the boiler. The pipe should terminate in a position which ensures that any discharge of water or steam from the valve cannot create a hazard to persons in or about the premises, or cause damage to any electrical components or external wiring, and the point of discharge should be clearly visible (see diagram in plastic bag). 4 I Fig. 5.7: Fitting the hot and cold water connections turbomax plus Fig. 5.8: Central heating flow and return pipework turbomax plus 8 Instructions for Installation and Servicing turbomax plus and thermocompact R

19 Boiler Installation Sequence Gas supply (thermocompact) Connect the 5 mm compression gas service cock () and 5 mm copper outlet tail ( mm copper tail with 67) () as supplied with the appliance and tighten. Connect a gas supply pipe of not less than 5 mm diameter to the copper tail (minimum mm with 67). Tighten all connections. (Ensure the gas supply pipework is adequately sized such that a 0 mbar gas pressure is available at the boiler inlet at full flow rate). 5. Central heating flow and return pipework (thermocompact) Before connecting the heating circuit to the boiler appliance, all pipework and radiators must be thoroughly flushed to remove any installation debris. Connect the central heating flow (6) and return () service valves to the appliance (8 and ), with the washers ( and 7) provided and tighten the nuts. Ensure that the valve spindles face downwards and the drain points face to either side of the boiler. Connect the mm copper pipe tails to the service valves as shown in the illustration and tighten the nuts. Connect the central heating pipework to the flow (9) and return (4) tails. I 0 Pressure Relief Valve Connect a discharge pipe not less than 5 mm diameter to the outlet of this valve. The discharge pipework should be as short as possible and installed with a continuous fall away from the boiler. The pipe should terminate in a position which ensures that any discharge of water or steam from the valve cannot create a hazard to persons in or about the premises, or cause damage to any electrical components or external wiring, and the point of discharge should be clearly visible (see diagram in plastic bag). I 0 Fig. 5.9: Fitting the gas connection thermocompact Fig. 5.0: Central heating flow and return pipework thermocompact Instructions for Installation and Servicing turbomax plus and thermocompact R 9

20 5 Boiler Installation Sequence 5. Connection to a VANTAGE unvented cylinder (thermocompact) For connecting a Vaillant VANTAGE unvented cylinder please refer to the VANTAGE installation instructions provided with the cylinder. 5. Connect the flue system to the boiler Refer to separate air/flue duct installation instructions included with the boiler. 5.4 Electrical installation General requirements Important! All electrical work shall be carried out by a competent person and shall comply with BS767 (IEE Regulations). The boiler is supplied for connection to 0 V, ~ 50 Hz supply fused at A rating. Connection to the mains supply shall be made via a fused pin plug to an unswitched shuttered socket, both complying to the requirements of BS6. (Alternatively, connection may be made via a A fused double pole isolator having a contact separation of at least mm in all poles and supplying the boiler and controls only). The point of connection to the mains supply must allow complete electrical isolation of the boiler and its ancillary controls. It should be readily accessible and adjacent to the boiler. A core flexible cord according to BS6500 tables 6, 8 or 6 ( x 0.75 to x.5 mm ) should be used. Warning! This appliance must be earthed. Fig. 5.: Wiring system L N 4 5 RT 4V 0V RT 0V Important! Ensure that all cords pass through the cable clamps in the rear of the control box and are securely fixed. Ensure that the power supply is connected such that the current carrying conductors become taut before the earth conductor should the supply cord slip from the cable clamp. Warning! Mains connection terminals L and N remain live even when the boiler on/off control is switched off. 5.5 Connection to the main supply Lower the control panel. Unclip the terminal box cover () from the control panel. Feed the power supply cord in to the appliance as shown (fig 5.). Use cable clamps. Fig. 5.: Exposed rear view of switchgear cabinet (picture shows turbomax appliance) Connect the power supply cord as follows (Fig. 5.). Green/yellow (earth) wire: boiler terminal Earth sign Blue (neutral) wire: boiler terminal N Brown (live) wire: boiler terminal L te! DO NOT use boiler terminal connections Refit the terminal box cover by pushing into place until it clips back into position. Raise the control panel and secure in place. 0 Instructions for Installation and Servicing turbomax plus and thermocompact R

21 Boiler Installation Sequence Electronic board layout Socket X for internal unit components Socket X4 for diverter valve Socket X7 for accessory box connection Socket X8 for VRC-VC connection Socket for fan control cable (67 and 87 only) F 4V 0V Do not use! L N 4 5 Mains power supply: connections L, N and earth Room thermostat, 0 V: connections, 4 and 5 Socket X: pump connection Socket X4: gas valve connection Socket X: fan connection Abb. 0.0 Bildunterschrift F Fig. 5.: Connection wiring Instructions for Installation and Servicing turbomax plus and thermocompact R

22 5 Boiler Installation Sequence 5.7 Controls (turbomax plus boiler) External electrical controls The boiler terminals, 4 and 5 are for connecting external electrical controls such as a time switch and/or room thermostat. Terminals and 4 are linked together when the boiler is supplied. If external controls are used, this link must be removed and the controls connected across terminals and 4. Terminal 5 is an additional neutral connection for external neutrals such as from the anticipator of a room thermostat. Connection of external controls Connection details for programmable room thermostats. Fig. 5.4 shows the connection details where a programmable room thermostat (time switch with built in room thermostat) is used to control the boiler. Attention! The arrowed numbers indicate connection into the relevant terminal in the boiler terminal strip. ACL Drayton Lyfestyle PT7, PT7 ACL Drayton Digistat,, 4 ACL Drayton Digistat RF - SCR Receiver Danfoss Randall TP4, TP5, TP5E Danfoss Randall TP5E RF with receiver RX Danfoss Randall TP75 Grässlin Towerchron RTC7 Honeywell CM6, CM67, CM, CM7 Horstmann Centaurstat, 7 Landis & Staefa REV, REV 5, REV Smiths Timeguard ProgramaSTAT PRT, PRT7 Sunvic TLX 650 Sunvic TLX RFP, TLX RFD Vaillant VRT 0, 0 L N 4 L N 4 Fig. 5.4 Connection details for programmable thermostats 4 L N L N 4 4 L N 4 L N 4 A B C 4 4 A B 4 C 4 4 L L 4 L N 4 L N 4 4 L N 4 L N Connection details for external time switches and boiler terminal strip. Fig. 5.5 shows the connection details where a time switch is used without a room thermostat to control the boiler. Attention! The arrowed numbers indicate connection into the relevant terminal in the boiler terminal strip. If a room thermostat is to be connected in addition to a time switch the wire between the time switch "ON terminal and boiler terminal 4 should be broken by the contacts of the room thermostat (see schematic layout, Fig. 5.6). Vaillant optional plug in timer accessories Refer to the instructions supplied with the optional accessories for connection details. Upon completion of all electrical connections refit the terminal box cover by pushing into place. The cover is secured by two locking clips. ACL Drayton Tempus, Tempus Lyfestyle LP, LP7 ACL Drayton Switchmaster SM00 ACL Drayton Switchmaster 980 Danfoss Randall 0 Series Danfoss Randall Set E, TS975 Danfoss Randall TS75 Grässlin Towerchron QE, QM Honeywell ST60A, ST600C Horstmann Channel Plus H, H7, 45 Coronet Horstmann Centaur Plus C, C7 Landis & Staefa RWB7, RWB0 Potterton Myson EP 400, EP 500 Smiths Timeguard SupplyMASTER FST, FST7 Sunvic Select 07 L N 4 L N 4 L N 4 L N 4 L N A B C L N E 4 L N L N E 4 L N E 4 L N 4 L N 4 L N 4 L N 4 L N 4 L N 4 L N E 4 L N E 4 L N E 4 L N E 4 L N 4 L N 4 N A B C D L N L N 4 L N 4 Fig. 5.5 Connection details for time switch E L N E mains supply 4 /L /N L N E 4 5 E 4 E Instructions for Installation and Servicing turbomax plus and thermocompact R

23 Boiler Installation Sequence 5 DO NOT USE IN UK! MAINS SUPPLY 0 V 50 Hz N L 0 VDC LN 4 5 A FUSE SWITCH CONTACTS ROOM THERMOSTAT Connection details for control systems utilising port motorised valve via external wiring centre/junction box Diagram only applies to the specific controls mentioned amp fused main supply THERMOcompact terminal strip Programmer for programmer connections see fig. 6.b L N L N 4 5 E N L X** Y** Z** L N L N 4 5 E ** see key below External wiring centre/junction box* N L N L *Do not use pre-wired printed circuit board type not used Fig. 5.6 L N CLOCK 5.8 Controls (thermocompact boiler) External electrical controls The boiler terminals, 4 and 5 are for connecting external electrical controls such as a programmer, room thermostat, etc. Terminals and 4 are linked together when the boiler is supplied. If external controls are used, this link must be removed, and the controls connected across terminals and 4. Terminal 5 is an additional neutral connection for external controls. Connection of external electrical controls N Cylinder thermostat ACL Drayton HTS Danfoss Randall ATC Tower CS Honeywell L64 Horstmann HTC Siemens-Landis & Staefa RAM Sunvic SA 45 Fig E C E YL BK RED C E EARTH Key: X Central heating on Y Hot water on Z Hot water off E BLUE BROWN OR WHITE Room thermostat Vaillant VRT 9090 ACL Drayton Digistat,, 4 ACL Drayton RTS, Danfoss Randall RX- Danfoss Randall RMT 0 Danfoss Randall RET 0 Tower SS Honeywell T660 Horstmann HRT Siemens-Landys & Staefa RAD Sunvic TLX 000 series GREY Port mid position motorised valve 4 ORANGE L N E E C A N 4 N L C L B E E E E Connection details using an external wiring centre The boiler should be connected to the system controls using an external wiring centre. Fig. 5.7, 5.8 shows connection details for a system utilising a port mid position motorised valve, figure 5.9, 5.0 shows the connection details for a system utilising two port motorised valves connected via an external wiring centre (Important: the arrowed numbers indicate connection into the relevant terminal of thre external wiring centre). Lifestyle LP4, LP 5, LP 7 Tempus 6, Tempus 7 Danfoss Randall CP 75, FP75 te: *Earth not required Danfoss Randall Set E, Set E te: *Earth not required, Link L N L not used 7 6 E N L not used 7 6 E N L 4 * 5 8 not used 7 6 E N L 4 * not used Grässlin Towerchron QE N L not used 7 6 Honeywell ST699B, ST799A L N te: Link L Honeywell ST600, ST600, ST6400 not used N L 4 Horstmann Channel Plus H, H7 te: *Earth not required, Link L Siemens-Landis & Staefa RWB, RWB9 5 8 not used 7 6 E N L 4 * N L not used not used Potterton Myson EP 00, EP 00, EP 600 te: Link L - 5 Sunvic Select 07 E N L 4 5 not used N L not used 7 6 Fig. 5.8 Instructions for Installation and Servicing turbomax plus and thermocompact R

24 5 Boiler Installation Sequence Connection details for control systems utilising x port motorised valves via external wiring centre/junction box Diagram only applies to the specific controls mentioned amp fused main supply THERMOcompact terminal strip Programmer for programmer connections see fig. 6.d L N E L N 4 5 N L X** Y** Z** L N L N ** see key below External wiring centre/junction box* N L N L *Do not use pre-wired printed circuit board type not used Cylinder thermostat 0 7 E Room thermostat L N E C E C A ACL Drayton HTS Vaillant VRT 9090 E Danfoss Randall ATC ACL Drayton Digistat,, 4 YL BK RED N L Tower CS ACL Drayton RTS, C C B Honeywell L64 Danfoss Randall RX- 4 Horstmann HTC Danfoss Randall RMT 0 E N L Siemens-Landis & Staefa RAM Danfoss Randall RET 0 4 E Sunvic SA 45 Tower SS Honeywell T660 4 E Horstmann HRT E Siemens-Landys & Staefa RAD 4 E Sunvic TLX 000 series E 5 0 EARTH BLUE BROWN GREY ORANGE Hot water port motorised valve 4 E 5 9 EARTH BLUE BROWN GREY ORANGE Central heating port motorised valve 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 TRV s are used they are used in conjunction with a programmable room thermostat or separate timer and room thermostat to ensure complete boiler shut down when the heating demand is satisfied. (The radiator in the room containing the room thermostat should not be fitted with a TRV). 5.0 Frost protection The boiler has an integral frost thermostat which is designed for protection of the boiler.to protect remote or exposed parts of the heating system or property additional frost protection measures must be taken such as the installation of an external frost thermostat. This frost thermostat should be connected across the boiler terminals and 4, in parallel with any external heating controls. External frost protection cannot be used when plug in timers have been fitted. Fig. 5.9 Key: X Central heating on Y Hot water on Z Hot water off Lifestyle LP4, LP 5, LP 7 Tempus 6, Tempus 7 Danfoss Randall CP 75, FP75 te: *Earth not required Danfoss Randall Set E, Set E te: *Earth not required, Link L Grässlin Towerchron QE Honeywell ST699B, ST799A te: Link L Honeywell ST600, ST600, ST6400 Horstmann Channel Plus H, H7 te: *Earth not required, Link L Siemens-Landis & Staefa RWB, RWB9 Potterton Myson EP 00, EP 00, EP 600 te: Link L - 5 Sunvic Select 07 N L 4 5 not used not used 7 6 E N L 4 5 not used not used 7 6 E N L 4 * 5 not used not used 7 6 E N L * 5 7 not used 6 not used N L 4 5 not used not used 7 6 L N not used 7 not used N L 4 5 not used not used 7 6 E N L * 5 7 not used 6 not used N L 4 5 not used not used 7 6 E N L 4 5 not used 5 not used 7 6 N L 4 not used 5 not used Circulating pump The boiler incorporates a built in circulating pump that is fully prewired (no additional wiring is necessary). The pump incorporates an automatic overrun period after the boiler switches off. 5. Anti-cycling economiser control The boiler incorporates a built in anti-cycling control to ensure that energy wasteful short cycling of the boiler cannot occur. This control prevents the boiler from reigniting for a preset period of 5 minutes after central heating operation (the hot water operation is unaffected by this control and hot water can be drawn at any time). te! To temporarily override the anti-cycling control turn the main boiler on/off switch to the off position 0 and then back to the on position I after a few seconds. Automatic pump spin control (APS) The boiler incorporates a built in control which will spin the built in circulating pump and operate the diverter valve (turbomax only) once in a 4 hour period. This control helps to prevent seizure when the boiler is not operated for a period of time. This control is not active when the power supply to the appliance is turned off. Fig Instructions for Installation and Servicing turbomax plus and thermocompact R