Table of Contents
Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R12
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1
General Information . . . . . . . . . . . . . . . . 5
2.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Boiler Specification . . . . . . . . . . . . . . . . . . . . . . 6
3.1
Technical data . . . . . . . . . . . . . . . . . . . . 6
3.2Boiler connections (turboMAX plus) . . . . . . . . 8
3.3Boiler connections (thermoCOMPACT) . . . . . . 8
3.4Functional diagram (turboMAX plus) . . . . . . . . 8
3.5Functional diagram (thermoCOMPACT) . . . . . . 9
4 General Requirements . . . . . . . . . . . . . . . . . . . . 10
4.1Related documents . . . . . . . . . . . . . . . . . . . . . . 10
4.2Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4.1Top outlet flue system . . . . . . . . . . . . . . . . . . . . 11
4.4.2Rear outlet flue system . . . . . . . . . . . . . . . . . . . 11
4.4.3 Extended top outlet flue system . . . . . . . . . . . 11
4.4.4 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6Cupboard or compartment ventilation . . . . . . 12
4.7 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.8 Guide to system requirements . . . . . . . . . . . . . 13
4.8.1 Water circulation system . . . . . . . . . . . . . . . . . . 13
4.8.2 Filling and make up . . . . . . . . . . . . . . . . . . . . . . 13
4.8.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . 13
4.8.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.8.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . 13
4.8.6 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . 14
4.8.7 System by-pass . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.8.8 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Boiler Installation Sequence . . . . . . . . . . . . . . . 15
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Using boiler template . . . . . . . . . . . . . . . . . . . . 16
5.3 Fitting the boiler hanging bracket . . . . . . . . . . 16
5.4 Install the flue system . . . . . . . . . . . . . . . . . . . . 17
5.5 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . 17
5.6Removing boiler casing . . . . . . . . . . . . . . . . . . . 17
5.7 Gas supply (turboMAX plus) . . . . . . . . . . . . . . . 17
5.8Cold water mains inlet and hot water outlet
(turboMAX plus) . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.9Central heating flow and return pipework
(turboMAX plus) . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.10 Gas supply (thermoCOMPACT) . . . . . . . . . . . . . 19
5.11 Central heating flow and return pipework
(thermoCOMPACT) . . . . . . . . . . . . . . . . . . . . . . 19
5.12 Connection to a Vantage unvented cylinder .
(thermoCOMPACT) . . . . . . . . . . . . . . . . . . . . . . 20
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5.13 Connect the flue system to the boiler . . . . . . . 20
5.14 Electrical installation . . . . . . . . . . . . . . . . . . . . . 20
5.15 Connection to the main supply . . . . . . . . . . . . 20
5.16 Electronic board layout . . . . . . . . . . . . . . . . . . . 21
5.17 Controls (turboMAX plus boiler) . . . . . . . . . . . . 22
5.18 Controls (thermoCOMPACT boiler) . . . . . . . . . 23
5.19 Thermostatic radiator valves . . . . . . . . . . . . . . 24
5.20 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.21 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . 24
5.22 Anti-cycling ‘economiser’ control . . . . . . . . . . . 24
6 Commissioning Part I . . . . . . . . . . . . . . . . . . . . 25
6.1 Preliminary electrical checks . . . . . . . . . . . . . . 25
6.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 Cold water supply (turboMAX plus only) . . . . . 25
6.4 Filling the heating system (turboMAX plus) . . 25
6.5 Filling the heating system (thermoCOMPACT) 26
6.6 Initial system flush ("cold“) . . . . . . . . . . . . . . . . 26
7 Gas supply adjustments (Commissioning Part II) 26
7.1 Gas inlet working pressure . . . . . . . . . . . . . . . . 26
7. 2 Main burner pressure . . . . . . . . . . . . . . . . . . . . 27
7. 3Adjusting the central heating output
(range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7. 4Adjusting to the maximum heat load
(nominal load) . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7. 5Adjusting the ignition rate . . . . . . . . . . . . . . . . 29
7. 6 Checking and adjusting to the operating point
(turboMAX plus 837E and
thermoCOMPACT 637E only) . . . . . . . . . . . . . . 30
7.7Setting or adjusting the mid-setting point . . . 31
7. 8 Fit combustion chamber cover . . . . . . . . . . . . . 33
7.9 Fit boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . 33
8 Functional checks (Commissioning Part III) 33
8.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 Functional check of operation
(turboMAX plus only) . . . . . . . . . . . . . . . . . . . . . 33
8.3 Functional check of operation
(thermoCOMPACT only) . . . . . . . . . . . . . . . . . . 34
8.4 Adjusting pump speed . . . . . . . . . . . . . . . . . . . . 34
8.5 Handing over to the user . . . . . . . . . . . . . . . . . 35
9 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1 Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.2 Cleaning the burner and primary heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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