Instruction/ maintenance manual of the product thermoCOMPACT/2 Vaillant
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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 .
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 .
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 . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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.
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.
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.
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 .
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 .
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.
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 .
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 .
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.
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.
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.
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.
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 .
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 .
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.
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 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 .
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.
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).
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 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 .
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 .
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.
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) •.
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 .
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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 .
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" po.
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.
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.
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 li.
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.
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 .
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.
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 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.
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.
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 R.
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