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Vaillant TURBOmax Pro 28/2 E User Manual

Vaillant TURBOmax Pro 28/2 E
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Supplied By www.heating spares.co Tel. 0161 620 6677
INSTRUCTIONS FOR
INSTALLATION AND SERVICING
TURBOmax Pro 28/2 E
Wall hung room sealed fan assisted combination boilers
The code of practice for the installation,
commissioning & servicing of central heating systems
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Table of Contents

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Vaillant TURBOmax Pro 28/2 E Specifications

General IconGeneral
Output28 kW
DHW Output28 kW
Fuel TypeGas
FuelNatural gas or LPG
Dimensions (H x W x D)700 x 400 x 300 mm
Weight34 kg
MountingWall-mounted
Max. working pressure3 bar
Boiler TypeCombi
Electrical supply230 V

Summary

Contents Included with Boiler

Introduction

General Information

Boiler overview, hot water priority, sealed system design, 28kW output, flue options.

EC Designation

CE Mark compliance with directives and regulations.

Technical Data

Boiler Specification

Boiler Connections

Diagram and key for boiler connection points.

General Requirements

Related Documents

Lists standards for installation and safety compliance.

Boiler Location

Guidelines for siting the boiler, considering space and regulations.

Gas Supply

Requirements for gas supply pipework, size, and testing.

Flue System

Details on top, rear, and extended flue system types and their uses.

Flue Termination

Regulations for flue terminal positioning and clearances.

Air Supply

Recommendations for ventilation, especially in cupboards.

Electrical Supply

Requirements for power connection, earthing, and isolation.

Water Circulation System

Pipework insulation, draining taps, and system cleansing.

Filling and Make Up

Procedures for filling the heating system with water.

Pressure Relief Valve

Details on the safety valve's function and discharge pipe.

Pressure Gauge

Information on the factory-fitted pressure gauge.

Expansion Vessel

Sizing and installation of the CH expansion vessel.

Circulating Pump

Details on the pump's head and settings.

System By-pass

Information on the built-in system bypass.

Venting

Requirements for system venting, including automatic vents.

DHW Expansion Vessel Accessory

Optional accessory for domestic hot water expansion.

Boiler Location Preparation

Required clearances around the boiler for installation.

Boiler Installation Sequence

Using Boiler Template

Guide to using the template for accurate boiler mounting.

Fitting Boiler Hanging Bracket

Steps for securely mounting the boiler bracket.

Install Flue System

Instructions for fitting the air/flue duct.

Fitting the Boiler

Procedure for lifting and hanging the boiler onto the bracket.

Removing Boiler Casing

Steps to safely remove the boiler's front casing.

Gas Supply Connection

Connecting the gas service cock and supply pipe.

Water Connections

Connecting water supply and outlet pipes.

Central Heating Pipework

Connecting heating circuit service valves.

Pressure Relief Valve Connection

Connecting the discharge pipe to the PRV.

Electrical Installation Requirements

Requirements for electrical work and compliance.

Main Supply Connection

Wiring the boiler to the mains power supply.

Electronic Board Layout

Diagram showing connections on the electronic board.

Programmable Thermostat Connections

Wiring diagrams for various thermostats.

Time Switch Connections

Wiring details for external time switches.

Frost Protection

How to connect an external frost thermostat.

Pump and Controls

Information on pump, anti-cycling, and pump spin controls.

Fit Boiler Casing

Steps for reattaching the boiler casing and securing the panel.

Commissioning Part I

Preliminary Electrical Checks

Verifying electrical safety and polarity.

Gas Supply Commissioning

Inspecting, testing, and purging the gas installation.

Water Supply Commissioning

Filling and purging the hot water system.

Filling Heating System

Step-by-step guide to filling the heating circuit.

Initial System Flush (Cold)

Procedure for flushing the system before operation.

Gas Supply Adjustments (Commissioning Part II)

Gas Inlet Working Pressure

Checking and setting the gas pressure at the inlet.

Main Burner Pressure

Procedure for checking natural gas and LPG burner pressure.

Adjusting Central Heating Output

Method for range-rating the central heating output.

Burner Pressure and Gas Rate

Tables detailing burner pressures and gas rates.

Functional Checks (Commissioning Part III)

Functional Checks Procedure

General procedure for checking boiler operation.

Operation and Indicator Lights

Using diagnostic lights to check boiler status.

Hot Water System Check

Checking DHW operation via indicator lights.

Heating System Check

Checking central heating operation via indicator lights.

Pump Speed and System Flush

Adjusting pump speed and performing hot flush.

Handing Over to User

Instructions for user operation and maintenance advice.

Servicing

Initial Inspection

Preliminary checks before servicing the boiler.

Functional Check of Boiler Operation

Verifying boiler functions after service.

Cleaning Burner and Heat Exchanger

Steps for cleaning key internal components.

Parts Replacement

Safety Instructions

Essential safety precautions before replacing parts.

Initial Preparation

Steps to prepare the boiler before part replacement.

Burner and Electrodes

Procedures for replacing burner and electrodes.

Fan Replacement

How to remove and replace the fan assembly.

Gas Valve Replacement

Procedure for replacing the gas valve.

Temperature Sensors (NTCs)

Replacing NTC sensors for temperature measurement.

Main Heat Exchanger

Steps for removing and replacing the main heat exchanger.

Expansion Vessel

Procedures for replacing the CH expansion vessel.

Electronic Control Board

Steps for replacing the main control board.

Pump and Air Pressure Switch

Procedures for replacing pump and air pressure switch.

System Bypass and Diverter Valve

Procedures for replacing bypass and diverter valve.

Pressure Gauge and Aqua Sensor

Procedures for replacing pressure gauge and aqua sensor.

DHW Heat Exchanger and Pressure Relief Valve

Procedures for replacing heat exchanger and PRV.

Checking Functions After Replacement

Final checks after part replacement.

Fault Finding

Fault Finding Introduction

Overview of diagnostic indicators and fault finding.

Logical Fault Finding Procedure

Step-by-step guide for diagnosing issues.

Preliminary Checks

Essential checks before starting fault diagnosis.

Troubleshooting Procedures

Diagnosing faults via electrical, pump, fan, controls, flue, gas, burner, DHW.

Diagrams

Functional Flow Diagram

Diagram showing the boiler's functional logic.

Wiring Diagram

Diagram illustrating electrical connections.

Short Parts List

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