Académique Documents
Professionnel Documents
Culture Documents
GB
Table of Contents
Page
1 List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1
Contents included with boiler (turboMAX plus) 4
1.2
Contents included with boiler (thermoCOMPACT) 4
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . .
2.1
2.2
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
EC designation . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Boiler Specification . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . .
3.1
3.2
Boiler connections (turboMAX plus) . . . . . . . .
3.3
Boiler connections (thermoCOMPACT) . . . . . .
3.4
Functional diagram (turboMAX plus) . . . . . . . .
3.5
Functional diagram (thermoCOMPACT) . . . . . .
4 General Requirements . . . . . . . . . . . . . . . . . . . .
4.1
Related documents . . . . . . . . . . . . . . . . . . . . . .
4.2
Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4
Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Top outlet flue system . . . . . . . . . . . . . . . . . . . .
4.4.2 Rear outlet flue system . . . . . . . . . . . . . . . . . . .
4.4.3 Extended top outlet flue system . . . . . . . . . . .
4.4.4 Flue termination . . . . . . . . . . . . . . . . . . . . . . . .
4.5
Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6
Cupboard or compartment ventilation . . . . . .
4.7
Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Guide to system requirements . . . . . . . . . . . . .
4.8.1 Water circulation system . . . . . . . . . . . . . . . . . .
4.8.2 Filling and make up . . . . . . . . . . . . . . . . . . . . . .
4.8.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . .
4.8.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . .
4.8.6 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . .
4.8.7 System by-pass . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.8 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
10
10
11
11
11
12
12
12
12
13
13
13
13
13
13
14
14
14
5
5
5
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
20
20
20
21
22
23
24
24
24
24
6 Commissioning Part I . . . . . . . . . . . . . . . . . . . .
6.1
Preliminary electrical checks . . . . . . . . . . . . . .
6.2
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3
Cold water supply (turboMAX plus only) . . . . .
6.4
Filling the heating system (turboMAX plus) . .
6.5
Filling the heating system (thermoCOMPACT)
6.6
Initial system flush ("cold) . . . . . . . . . . . . . . . .
25
25
25
25
25
26
26
26
26
27
33
33
6
8
8
8
9
Page
27
29
29
30
31
33
33
33
34
34
35
9 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1
Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.2
Cleaning the burner and primary heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table of Contents
Page
10 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Indicator lights (turboMAX plus only) . . . . . . .
10.3 Indicator lights (thermoCOMPACT only) . . . . .
10.4 Logical fault finding procedure . . . . . . . . . . . .
10.5 Status Modes . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6 Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . .
10.7 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.9 Fault finding charts . . . . . . . . . . . . . . . . . . . . . .
37
37
37
37
36
38
39
40
40
41
11 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Functional flow diagrams . . . . . . . . . . . . . 48
11.1
12.2 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 50
1 List of contents
1 List of contents
1.2 Contents included with boiler (thermoCOMPACT)
Ensure that all contents are included before
commencing installation.
Note!
DO NOT remove the boiler from the polystrene
base at this stage.
12
11
1
1
2
11
10
o
C
VRC-V
o
C
VRC-V
o
C
o
C
10
I
0
8
4
7
5
Item
Quantity
Description
Item
Quantity
Description
Boiler
Boiler
packaging)
5
Template
Template
10
10
11
11
3
1
PRV packages
12
valve
packaging)
Hanging bracket
Introduction 2
2 Introduction
2.1 General Information
Note!
This boiler must be installed and serviced by a
competent person in accordance with the Gas
Safety (Installation and Use) Regulations 1998.
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 24 kW , 28 kW and 37
kW. All turboMAX plus boilers are available in Natural
Gas. The 24 and 28 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 15, 20, 24, 28 kW and 37 kW.
All thermoCOMPACT boilers are available in Natural Gas.
The 20 and 28 kW versions are also available in LPG.
3 Boiler Specification
3 Boiler Specification
3.1 Technical Data
turboMAX plus
turboMAX plus
turboMAX plus
824/2 E
828/2 E
837 E
(VUW GB 242/2-5) (VUW GB 282/2-5) (VUW GB 362/2-5)
Units
26.7 (91,200)
31.1 (106,200)
31.1 (106,200)
kW (Btu/h)
8.9 - 24
10.4 - 28
(30,400 - 81,900)
(35,500 - 95,500)
(37,200 - 95,500)
kW (Btu/h)
26.7 (91,200)
31.1 (106,200)
40.5 (138,300)
kW (Btu/h)
SEDBUK Band
79.6
79.7
79.8
24
28
36.9
kW
9.8
11.5
15.1
l/min
8.2
9.5
12.6
l/min
0.5
0.5
0.5
bar
1.5
1.5
1.5
l/min
0.15
0.15
0.15
bar
10
10
10
bar
20
20
20
mbar
37.8
37.8
37.8
MJ/m3
9.8
10.5
12.0
mbar
1.9
1.8
1.2
2.8
3.3
4.3
mbar
m3/h
35 - 82
35 - 82
35 - 82
(for 20 C rise)
1032
1203
1203 **
l/h
0.25 (25)
0.25 (25)
0.25 (25)
bar (KPa)
0.75
0.75
0.75
bar
Expansion vessel
pre-charge pressure
Maximum CH system pressure
bar
Weight
43
45
48
kg
2.0
2.0
2.2
Electrical supply
230/50
230/50
230/50
V~/Hz
External fuse
Power input
150
150
130
Case height
800
800
800
mm
Case width
440
440
440
mm
Case depth
338
338
338
mm
Boiler Specification 3
16.5
22.0
26.7
31.1
40.5
kW
(net)
(56,100)
(74,800)
(91,200)
(106,200)
(138,300)
(Btu/h)
6.5. - 15
7.7 - 20
8.9 - 24
10.4 - 28
10.5 - 36.9
kW
(80/60 C)
(22,300-51,200)
SEDBUK Band
79.0
79.7
79.7
79.8
79.8
20
20
20
20
20
mbar
37.8
37.8
37.8
37.8
37.8
MJ/m3
9.9
9.0
9.8
10.5
12.0
mbar
2.2
1.5
1.9
1.8
1.2
mbar
35 - 82
35 - 82
35 - 82
35 - 82
35 - 82
(for 20 C rise)
650
860
1032
1203
1587
l/h
0.25 (25)
0.25 (25)
0.25 (25)
0.25 (25)
0.17 (17)
bar
Gross CV (s.t.)
Gas burner pressure
max. rate
Gas burner pressure
ignition rate
CH temperature
flow range
Minimum CH water flow
(KPa)
Expansion vessel
pre-charge pressure
0.75
0.75
0.75
0.75
0.75
bar
Maximum CH
bar
Weight
38
39
41
43
45
kg
2.0
2.0
2.0
2.0
2.2
Electrical supply
230/50
230/50
230/50
230/50
230/50
V~/Hz
system pressure
External fuse
Power input
150
150
150
150
130
Case height
800
800
800
800
800
mm
Case width
440
440
440
440
440
mm
Case depth
338
338
338
338
338
mm
3 Boiler Specification
Key:
1
2
3
4
5
6
264
145
102
7
638
902
1
31
2
30
4 3
130
35
100
29
180
35
28
100
27
26
25
Key:
1
Heating system return (22 mm tail)
2
Cold water connection with shut off valve
(15 mm tail)
3
Gas connection (15 mm tail, 22mm for 837)
4
Hot water connection (15 mm tail)
5
Heating system flow (22 mm tail)
6
Flue outlet (100 mm flue with turret)
7
Hanging bracket
8
Rear flue outlet
24
23
22
21
10
20
11
19
12
18
13
14
17
16
15
145
102
638
902
4 3
80
130
55
100
100
180
55
Key:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Air duct
Fan
Main heat exchanger
Temperature sensor (NTC I)
Flame sensing electrodes
Modulating burner
Fully modulating automatic gas value
Maximum hot water temperature control
Maximum radiator temperature control
Diverter valve
DHW heat exchanger
Automatic bypass valve
CH flow service valve
Hot water outlet
Gas service valve
Cold water service valve
CH return service valve
Pressure relief valve
Aqua sensor (DHW flow switch)
Temperature sensor (NTC III)
Main on/off control
Boiler Specification 3
22
23
24
25
26
27
28
29
30
31
Pressure gauge
Display
Expansion vessel
Expansion vessel charging valve
Circulating pump
Automatic air vent
Ignition electrode
Temperature sensor (NTC II)
Air pressure switch
Flue gas duct
19
20
21
22
23
24
25
23
4
5
22
21
7
20
19
18
17
8
9
16
15
10
14
11
13
12
Air duct
Fan
Main heat exchanger
Temperature sensor (NTC I)
Flame sensing electrodes
Modulating burner
Fully modulating automatic gas value
This control has no function on this boiler
Maximum radiator temperature control
Automatic bypass valve
CH flow service valve
Gas service valve
CH return service valve
Pressure relief valve
Main on/off control
Pressure gauge
Display
Expansion vessel
4 General Requirements
4 General Requirements
4.1 Related Documents
The installation of the boiler must be in accordance with
the relevant requirements of Gas Safety (Installation and
Use) Regulations 1998, Health and Safety Document No.
635 (The Electricity at Work Regulations 1989), BS7671
(IEE Wiring Regulations) and the Water Supply (Water
Fittings) Regulations 1999, or the Water Bylaws 2000
(Scotland). It should also be in accordance with the
relevant requirements of the Local Authority, Building
Regulations, Building Regulations (Scotland), Building
Regulations (Northern 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 1: Flues
- Part 2: 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 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd family gas).
BS 7593: Treatment of water in domestic hot water
central heating systems.Institute of Gas Engineers
Publication IGE/UP/7/1998: Guide for Installation in
Timber Framed Housing. Benchmark Code of Practice.
Building Regulations Approved Documents Part L 2002
Part J 2002.
10
Note!
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
6891. In IE the current edition of IS 813.
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/7/1998 "Guide for Gas
Installation in Timber Framed Housing.
Important!
The appliance must be installed and serviced by
a competent person as stated in the Gas Safety
(Installation and Use) Regulations 1998. In IE,
the installation must be in accordance with the
current edition of IS 813 '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.
General Requirements 4
48
48
750
1103
603
70
1285
15
70
48
11
4 General Requirements
300
25
Below eaves
25
25
25
25
300
600*
1200
into a dweling
1200
1500
300
A
G
B F
G
BCD
H,
A
A
E
A
G
M
L
K
L K
mm
500
12
General Requirements 4
13
4 General Requirements
700
Lift [mbar]
2.7
3.9
50
5.4
7.8
100
10.9
15.6
125
13.6
19.5
650
600
550
500
450
400
350
300
150
16.3
23.4
175
19.1
27.3
200
21.8
31.2
250
200
150
100
50
225
24.5
35.1
250
27.2
39.0
275
30.0
42.9
300
32.7
46.8
325
35.7
50.7
350
38.1
54.6
375
40.9
58.5
400
43.6
62.4
425
46.3
66.3
450
49.0
70.2
475
51.8
74.1
500
For system volumes other than those given
above, multiply the system volume by the
factor across
54.5
78.0
0.109
0.156
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
700
650
600
550
500
450
400
350
300
250
200
150
100
50
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
14
Note!
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.No. 306 251).
440
yy
;;
yyyyyy
;;;;;;
y
;
;
y
;
y
;
y
;
y
Note!
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/7/1998 "Guide for Gas Installations in
Timber Framed Dwellings.
800
yyy
;;;;
y
y
;
yy
;;
338
15
Note!
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. No. 303 817).
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.
5.3 Fitting the boiler hanging bracket
Fix the hanging bracket (1) to the wall using the screws
supplied (2). (it may be necessary to use additional or
alternative fixings to ensure adequate support).
402
60/100
210
171
174,5
2
1
12,5
3
1
Note!
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.
07/2002
turboMAX only
200/202/240/242/280/282/824/828 Pro/Plus
124163 21
16
90
90
2
VRC-VC
I
0
I
17
I
0
I
0
6
1
2
7
3
1
Fig. 5.7: Fitting the hot and cold water connections turboMAX
plus
9
3
6
7
8
18
I
0
2
I
0
1
2
9
3
6
7
8
19
7 8 9
L N
3 4 5
RT 24V
230V
RT 230V
Warning!
This appliance must be earthed.
1
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.
20
F3
7 8 9
24V
Do not use!
L N
3 4 5
230V
F1
21
Attention!
The arrowed numbers indicate connection into
the relevant terminal in the boiler terminal strip.
L
L
ACL Drayton
Digistat 2, 3, 4
3
ACL Drayton
Digistat RF - SCR Receiver
Danfoss Randall
TP4, TP5, TP5E
L
L
Danfoss Randall
TP75
Grsslin Towerchron
RTC7
2
3
Smiths Timeguard
ProgramaSTAT PRT11, PRT17
Sunvic
TLX 6501
Sunvic
TLX RFP, TLX RFD
4
2
ACL Drayton
Switchmaster 980
1
4
L1
4
N
Danfoss Randall
Set 1E, TS975
Grsslin Towerchron
QE1, QM1
3
3
Horstmann
Channel Plus
H11, H17, 425 Coronet
Horstmann
Centaur Plus
C11, C17
Potterton Myson
EP 4002, EP 5002
Smiths Timeguard
SupplyMASTER
FST11, FST17
Sunvic
Select 107
3
2
4
4
2/L 1/N
2
3
B
L
1
3
6
Honeywell
ST610A, ST6100C
Danfoss Randall
103 Series
22
Danfoss Randall
TS715
4
B
L
Vaillant
VRT 230, 220
ACL Drayton
Switchmaster
SM300
ACL Drayton
Tempus 1, Tempus 2
Lyfestyle LP111, LP711
1
3
Danfoss Randall
TP5E RF with receiver RX1
Horstmann
Centaurstat 1, 7
Honeywell
CM61, CM67, CM31, CM37
Attention!
The arrowed numbers indicate connection into
the relevant terminal in the boiler terminal strip.
ACL Drayton
Lyfestyle PT271, PT371
N
5
mains supply
20 VDC
7 8 9 L N
34 5
MAINS
SUPPLY
230 V
50 Hz
N
L
3 A FUSE
SWITCH
CONTACTS
Programmer
for programmer connections see fig. 16.b
ROOM
THERMOSTAT
L
N CLOCK
THERMOcompact
terminal strip
X** Y**
Cylinder thermostat
C
1
Fig. 5.16
10
not used
Room thermostat
BK RED
Honeywell L641
Horstmann HTC1
Tower SS
4
2
2
3
1
1
Sunvic SA 2452
Horstmann HRT 1
Siemens-Landys & Staefa RAD 1
YL
Honeywell T6360
Tower CS1
Z**
6
7
8
** see key below
EARTH
BLUE
BROWN
OR
WHITE
GREY
ORANGE
Fig. 5.17
Key:
X
Y
Z
Central heating on
Hot water on
Hot water off
Tempus 6, Tempus 7
8 not used 7
4
6
3
not used 7
4
6
4
8 not used 7
8 not used 7
Link L - 5 - 8
7
2
not used
8 not used 7
Link L - 5
8 not used 7
L
3
6
not used
4
6
6
4
6
3
6
not used
4
6
3
not used
8 not used 7
Fig. 5.18
23
THERMOcompact
terminal strip
Programmer
for programmer connections see fig. 16.d
X** Y**
10 7
Cylinder thermostat
ACL Drayton HTS3
C
1
10
not used
Room thermostat
Tower CS1
YL
BK RED
Honeywell L641
Tower SS
4
2
2
3
1
1
Horstmann HTC1
Sunvic SA 2452
Z**
7
8
** see key below
Honeywell T6360
Horstmann HRT 1
Siemens-Landys & Staefa RAD 1
Sunvic TLX 2000 series
EARTH
BLUE
10
BROWN
3
GREY
ORANGE
EARTH
BLUE
BROWN
GREY
4
ORANGE
Key:
Central heating on
Hot water on
Hot water off
Tempus 6, Tempus 7
not used
7
3 not used
6
3
not used
7
3 not used
Note:
Link L - 5 - 8
3 not used
Link L - 5
6
4
6
4
not used
6
3
3 not used
2
not used
6
not used
Note!
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 24 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.
not used
not used 6
7 not used
not used
not used 6
Fig. 5.19
X
Y
Z
Fig. 5.20
24
Commissioning Part I 6
6 Commisioning Part I
6.1 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.
2
3
90
25
6 Commissioning Part I
26
thermoCOMPACT only
Record the heat input in the boiler logbook.
After completion of all tests tighten sealing screw,
and check all test points for soundness (1/1a).
2a
Fig. 7.2
27
Note!
Following adjustment of the central heating
output, the new output can be checked using
the gas rate table as detailed.
Fig. 7.3: Using burner pressure to check and adjust the heating
system partial load (picture shows a turboMAX plus boiler)
Note!
This illustration shows the U-tube pressure
gauge connected to a system configured to run
on natural gas. When connecting the U-tube
pressure gauge to a system running on LPG,
please refer to Fig. 7.2 on page 27.
Simultaneously press the i and + buttons keys.
~5s
28
Attention!
The plastic cap (2) must be fitted for the gas
valve assembly to function correctly.
Note!
If installing/commissioning a turboMAX plus
837 or a thermoCOMPACT 637 boiler go to page
30.
turboMAX only:
Turn off the hot water tap.
thermoCOMPACT only:
To cancel selected P1 or P2 mode press the i and
+ buttons simultaneously.
Attention!
The main burner pressure must be rechecked
after adjusting the ignition rate.
Refit cap (1) and replace screw. Re-check ignition and
main burner pressures. After completion of these tests
tighten the sealing screw and check all joints and test
points for soundness.
29
Note!
The "-" button has no function in this mode, if
the required pressure is exceeded during set up,
this operation should be recommenced from the
beginning.
When the pressure is correct, to save the setting to
memory, press and hold the "i" button until the display
stops flashing.
Gas type
5.3 mbar
LPG (G30/31)
15.3 mbar
Program No.
Gas type
P.11
5.3 mbar
P.12
P.13
LPG (G30/31)
15.3 mbar
30
Output[kW]
Gas type
Natural gas 2H
for G20
Ignition rate
6.5
8.0
10.0
12.0
14.0
15.0
2.2
2.2
3.2
4.7
6.6
8.7
9.9
7 / 120
LPG 3 B/P
for G30
4.1
4.1
6.2
9.6
13.6
18.1
20.6
7 / 072
for G31
5.8
5.8
8.7
13.3
18.7
24.9
28.3
Output[kW]
Gas type
Natural gas 2H
for G20
8.0
10.0
12.0
20.0
1.5
1.5
1.6
2.4
3.4
4.6
5.9
7.4
9.0
7 / 120
LPG 3 B/P
for G30
2.0
2.0
3.2
5.0
7.3
9.9
12.8
16.1
19.7
7 / 072
for G31
4.3
4.3
4.5
71
10.1
13.7
17.6
22.0
26.9
Output[kW]
Ignition rate 8.9 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0
Natural gas 2H
for G20
1.9
1.9
2.1
2.9
3.7
4.7
5.8
6.7
8.4
9.8
7 / 120
LPG 3 B/P
for G30
3.9
3.9
4.8
6.8 9.0
11.6
14.3 17.4
20.6
24.1
7 / 072
for G31
5.2
5.2 6.4
8.8 11.6
26.2
30.6
Output[kW]
Ignition rate 10.4 12.0 14.0 16.0 18.0 20.0 22.0 24.0 26.0 28.0
Natural gas 2H
2)
for G20
1.8
1.8
2.3
3.0
3.9
4.8 5.8
6.8
8.0
9.2
10.5
18.8
21.7
24.8
25.2 29.1
33.2
7 / 120
LPG 3 B/P
for G30
4.1
4.1
5.3
7.1
9.0
11.2
7 / 072
for G31
5.5
5.5
7.1
9.5
12.1
15.0 18.1
13.5 16.1
21.6
31
Output[kW]
Ignition rate 10.5 12.0 16.0 18.0 20.0 24.0 28.0 30.0 33.0 36.9
Natural gas 2H
2)
1.2
for G20
1.2
1.5
2.5
3.1
3.8
5.3
7.1
8.1
9.7
12.0
19.1
22.9 28.2
7 / 120
Setting-up program: P.11
LPG 3 B/P
for G30
2.8
2.8
3.5
5.9
7.3
8.9
12.6 16.8
7 / 072
for G31
3.5
3.5
4.4
7.3
9.1
11.1
28.3 34.9
for G20
Output[kW]
6.5
8.0 10.0
12.0
14.0
15.0
0.8
1.3
1.4
1.7
1.7
1.0
7 / 120
7.7
8.0
Output[kW]
10.0 12.0 14.0
16.0
18.0
20.0
0.9
1.0
1.2
1.7
1.9
2.1
2.3
Output[kW]
14.0 16.0
18.0
2.1
2.4
2)
per G20
1.4
7 / 120
for G20
8.9
10.0
12.0
1.1
1.2
1.4
1.7
1.9
2.6
2.8
7 / 120
per G20
10.4 12.0
14.0
Output[kW]
16.0 18.0 20.0 22.0 24.0 26.0
28.0
1.3
1.7
1.9
3.3
10.5 12.0
16.0
Output[kW]
18.0 20.0 24.0 28.0 30.0 33.0
36.9
1.3
1.9
2.2
4.3
1.5
2.1
2.4
2.6
2.8
3.1
7 / 120
2)
per G20
1.5
2.4
2.8
3.3
3.5
3.9
7 / 120
Table 7.2: Gas flow rate
32
1) 15 C, 1013mbar, dry
2) The nozzles are stamped with the mark shown in this table.
The marking corresponds to the nozzle hole diameter multiplied by 100
8 Functional Checks
8.1 Functional checks
Procedure
Once the unit has been installed and the gas supply has
been checked, operate the system to ensure that it is
working correctly.
Operate the system, following the operating
instructions supplied with the boiler.
Check the system for water leaks and escaping gas.
Check that the flue has been correctly installed,
according to the fitting instructions supplied with the
flue assembly.
Check the burner for correct ignition and flame
picture.
turboMAX plus only: Check the hot water system
for correct operation.
Check the heating system for correct operation.
0
1
90
90
VRC-VC
I
0
33
1
3
2
34
9 Servicing
35
9 Servicing
2
1
2a
4
4
5
5
10
Note!
It is not necessary to carry out this check every
year a check every three years should be
sufficient.
5
5
6c
6a
6b
8
10
36
Instructions for
Servicing 9
10 Fault Finding
10.1 Introduction
The turboMAX plus and thermoCOMPACT boilers have
an inbuilt advanced multifunction diagnostic display to
assist with fault finding in the unlikely event of a boiler
malfunction.
The display features the following four modes:
Normal Mode
Under normal conditions the boiler display will show the
boiler flow temperature, this indicates that the boiler is
operating correctly after an internal self check.
Status Mode
The status display is helpful in diagnosing faults where a
fault code is not displayed.
Diagnostic Mode
In order to assist with the pinpointing of a particular
fault it is possible to use the boiler display in a
diagnostic mode to interrogate the boiler about the
status of certain components.
Fault Mode
Should a fault develop in the boiler the display will show
a fault code indicating what the problem may be.
10.2 Indicator lights (turboMAX plus only)
The boiler control panel also contains three indicator
lights whose function is as follows:
Red lock out indicator (1), when illuminated boiler is at
lock out.
Yellow flame indicator (2), when illuminated main
burner is ignited.
Green warmstart indicator (3):
1
3
2
Note!
Always check the operation of the boiler for
central heating first before checking hot water
operation. Do not open a hot water tap unless
instructed to do so by the fault finding guide
(turboMAX only).
1. If a fault code is showing in the boiler display follow
the fault finding charts referring also to the fault code
and diagnostic mode tables.
2.If the boiler is not functioning correctly and a fault
code is not showing in the boiler display follow the
fault finding charts referring also to the status mode
table.
Note!
If the boiler display is completely blank initially
check the two fuses (Isolate the electrical
supply before checking the fuses, spare fuses
are located on the inside of the control box rear
cover).
37
10 Fault Finding
Status mode
Diagnostic mode
To display
Press i button
+ button
simultaneously
To return to
Press i button
Normal mode
Note!
If no key is pressed for approx. 4 minutes the
display will automatically change back to
Normal mode.
Display
Indication
turboMAX plus
thermoCOMPACT
S.00
S.01
S.02
S.03
S.04
S.05
S.07
S.08
S.10
S.11
S.13
S.14
S.16
S.17
S.20
S.21
S.23
S.24
S.27
S.28
S.30
S.31
S.32
Main heat exchanger anti freeze protection due to fan speed deviation
S.33
S.34
S.36
S.39
S.53
S.54
(approx 10 mins.)
38
Fault Finding 10
Display
d.00
d.01
d.02
d.05
d.07*
d.08
d.10
d.11
d.21
d.22*
d.23
d.24
d.25*
d.30
d.33
d.34
d.35*
d.37
d.40
d.41
d.50
d.60
d.61
d.64
d.65
d.67
d.68
d.69
d.71
d.72*
d.73*
d.75
d.76
Indication
Part load setting
Water pump over run
Maximum burner anti cycling period at 20 C flow temperature
Flow temperature setting
1. Vantage hot water temperature (not applicable)
2. Warmstart temperature setting (applies to turboMAX plus only)
External controls heat demand
Pump status
External pump status
Flame rectification
Domestic hot water demand
Summer/winter function (control knob)
Air pressure switch
Warmstart status (turboMAX plus)
Gas valve status
Required value of the rotary speed of the fan
Actual value of the rotary speed of the fan
Diverter valve position
Modulator current
Actual flow temperature
Current return temperature (837/637 only)
Maximum flow temperature
Number over heat cut off operations
Number of lock outs
Average ignition time
Maximum ignition time
Remaining anti cycling period
Number of unsuccessful attempted 1st ignitions
Number of unsuccessful attempted 2st ignitions
Maximum target value for heating system flow temperature
Pump over run (for loading warmstart)
Offset warmstart temperature value
Maximum hot water priority operation time (Vantage only)
Gas type set (837/637 only)
d.80**
d.81*
d.82
d.83*
0 = 82 C ; 1 = 87 C (factory setting: 82 C)
0, 1, 2, 250 s (factory-adjusted to: 80 s)
-15, -14.......+5 K (factory-adjusted - 5 K)
20, 21, 22 90 min (factory-adjusted to: 30 min)
H36 (nat gas) P36 (LPG) E36 (E+ gas).
Factory setting H36
h
h
39
10 Fault Finding
Display
F.00
F.01
Indication
Flow-NTC:
NTC broken; NTC cable broken; Defective connection at NTC
Defective connection at electronics
Return NTC:
NTC broken; NTC cable broken; Defective connection at NTC
Defective connection at electronics
Short circuit - flow-NTC (<130C)
Short circuit - return-NTC (<130C)
Over heat cut off activated
Dry fire protection
40
No
Go to sheet B
No
Is the continuity
across fuse F1?
No
Yes
Replace electronic
board
No
Is there continuity
across fuse F3?
No
No
Yes
Yes
Is voltage between
16-26 VDC present across
terminals 8 and 9?
Yes
Yes
Note 1:
Replace switch
mechanism
No
Yes
No
Is there a display on
the LCD Panel?
Yes
Yes
Check transformer
Replace if
necessary
Go to sheet C
Sheet A
Fault Finding 10
41
42
No
Yes
Check/replace fan
Check/replace pump
No
Yes
No
No
Yes
Replace fuse F1
Yes
Go to sheet A
Sheet B
10 Fault Finding
Replace defective
timer
No
Go to sheet D
Does ignition
commence?
Yes
No
No
Yes
No
Sheet C
Fault Finding 10
43
44
Yes
No
No
No
Yes
Check/replace fan
Yes
Yes
No
Yes
No
No
Yes
No
Yes
Go to sheet E
Sheet D
10 Fault Finding
Yes
Yes
Yes
No
No
No
No
Reset boiler
Yes
No
Is burner indicator
illuminated
No
No
show S. 53?
Check flame
rectification lead and
electrode
Yes
Yes
Yes
No
Is burner indicator
illuminated?
Yes
No
Replace pump
Go to sheet F
Sheet E
Fault Finding 10
45
46
Go to sheet G
No
Yes
Yes
No
No
Yes
No
No
Yes
Yes
Yes
No
No
Yes
Go to sheet G
Sheet F
10 Fault Finding
No
Yes
Check/Clear impeller in
Aquasensor, replace if necessary
No
No
indicator flash?
No
Yes
Yes
Sheet G
Fault Finding 10
Note!
turboMAX plus only
47
11 Diagrams
CONTROL BOX
MAIN SWITCH
F2A
MAIN
TRANSFORMER
Hot water/warmstart
demand indicator
230V
20V
POWER SUPPLY
display
F1,25A
MAIN SWITCHBOARD
AIR
PRESSURE
SWITCH
gr
gr
plug in
connector
837 only
r
bl
FAN
gr
br
y/g
b
br
reset button
PUMP
info button
DHW
Aqua
Sensor
DIVERTER
VALVE
y/g
p
p
bl
bl
bl
bl
NTC RETURN
TEMPERATURE
SENSOR
br
Legend
b
br
y/g
r
p
or
t
bl
gr
w
NTC FLOW
TEMPERATURE
SENSOR
NTC
WARMSTART
TEMPERATURE
SENSOR
or
blue
brown
yellow/green
red
pink
orange
transparent
black
grey
white
br b
br
br
GAS
VALVE
IGNITION
ELECTRODES
FLAME
SENSOR
y/g
48
Diagrams 11
CONTROL BOX
MAIN SWITCH
F2A
MAIN
TRANSFORMER
230V
20V
POWER SUPPLY
display
F1,25A
MAIN SWITCHBOARD
AIR
PRESSURE
SWITCH
gr
gr
plug in
connector
637 only
r
bl
b
gr
FAN
br
y/g
b
br
reset button
PUMP
info button
y/g
NTC FLOW
TEMPERATURE
SENSOR
t
w
NTC RETURN
TEMPERATURE
SENSOR
br
Legend
b
br
y/g
r
p
or
t
bl
gr
w
blue
brown
yellow/green
red
pink
orange
transparent
black
grey
white
br b
br
br
GAS
VALVE
IGNITION
ELECTRODES
FLAME
SENSOR
y/g
49
Ionisation
electrode
T 1,25
= F3
L N
3 4 5
1
3
NTC flow
8
20
7
19
6
18
5
17
4
16
3
15
2
14
1
13
NTC Warmstart
X3
X12
X14
X13
U100
T2
= F1
NTC
earth
Ionisation
electrode
NTC
flow
Coding resistor
Pressure sensor
NTC
Warmstart
NTC
return
Pump
Aqua
sensor
Lifting magnet
22 10
X2
X1
7 8 9
3
13
21
X2
X20
4
14
X4 (VUV) X7 Accessories X8
5
15
Switchgear cabinet
6
16
Aqua
sensor
7
17
Gas valve
8
18
Diverter valve
9
19
20
Ignition
electrodes
EV1
21
23 11
24 12
22 10
23 11
50
EV2
24 12
Fan unit
X2
11 Diagrams
(837 E only)
NTC return
Fan unit
X2
T 1,25
= F3
X1
L N
3 4 5
X3
X14
X13
U100
T2
= F1
Bridge
X2
NTC return
Pressure sensor
NTC
earth
3
13
Coding resistor
Ionisation
electrode
4
14
X12
5
15
7 8 9
6
16
NTC flow
9
21
8
20
7
19
6
18
5
17
4
16
3
15
2
14
1
13
X2
X20
7
17
2
4
1
3
X4 (VUV) X7 Accessories X8
8
18
Pump
22 10
Gas valve
9
19
Switchgear cabinet
20
Ignition
electrodes
EV1
21
22 10
24 12
23 11
EV2
24 12
Ionisation
electrode
Diagrams 11
(637 E only)
51
NTC return