INSTRUCTIONS FOR USE

TURBOmax Plus 824/2 E, 828/2 ETHERMOcompact 615/2 E, 620/2 E, 624/2 E, 628/2 E

The code of practice for the installation,commissioning & servicing of central heating systems

2

TABLE OF CONTENTS

General information

Safety

For your information . . . . . . . . . . . . . . . . . . . . . . . . . .3Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . .3Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Specified use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .5Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Factory Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Initial checks before turning ON . . . . . . . . . . . . . . . . . .9Domestic hot water operation (TURBOmax Plus only) . . . .10Heating operation . . . . . . . . . . . . . . . . . . . . . . . . . .13Resetting the appliance . . . . . . . . . . . . . . . . . . . . . . .14Turning the boiler OFF (TURBOmax Plus only) . . . . . . . .15Turning the boiler OFF (THERMOcompact only) . . . . . . .16Care and maintenance . . . . . . . . . . . . . . . . . . . . . . .17Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Important Note

☞ This symbol is used to indicateimportant instructions.

● This symbol is used to indicatea required step.

3

GENERAL INFORMATION

We can accept no liabilitywhatsoever for damage orinjury resulting from failure toobserve these instructions.

Key to symbols

Liability

For your information Thank you for choosing a Vaillantboiler. The information given in thisbooklet will enable you to obtain thebest performance from your boiler.

TURBOmax Plus provides both centralheating and domestic hot water,with the domestic hot water supplieddirectly from the boiler. The boilerwill operate automatically to providedomestic hot water whenever a hotwater tap is opened, and auto-matically adjusts to meet the demandfor both central heating and domestichot water in the most economical way.

THERMOcompact provides centralheating and domestic hot waterwhere a separate indirect hot watercylinder is also incorparated to thesystem.

If, after reading these instructions,you have any questions on the operation of the boiler, pleasecontact either your installer or VaillantTechnical Department.

The benchmark logbook should becompleted by the installer and/or thecommissioning engineer and handedto the user.

All CORGI registered installerscarry a CORGI ID card, and have a registration number.

Both should be recorded in yourBenchmark Log Book. You can checkyour installer by calling CORGI directon 01256 372300.

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GENERAL INFORMATION

Specified use

EC designation The purpose of EC designation is tocertify that the boiler complies withthe requirements of the directivescovering gasfired appliances(Council directive 90/396/EEC) and electromagnetic compatibility(Council directive 89/336/EEC).These appliances also comply withthe requirements of the directive onoperating efficiency (Council directive92/42/EEC).

Vaillant TURBOmax Plus andTHERMOcompact boilers are madeto fulfil the latest technical specifica-tions and official safety regulations.These appliances are designed as boilers for use in central heating andhot water supply systems.THERMOcompact boilers only supplydomestic hot water where a separateindirect hot water cylinder is alsoincorparated to the system.If the appliances are used for purposesother than or in excess of these specifications, this shall be classed asincorrect operation, and neither themanufacturer nor supplier will acceptany liability for resulting damage orinjury.Use of this type is entirely at theowner’s risk.The term „specified use” also coversobservance of the operating andinstallation instructions, along withadherence to the servicing schedules.

5

SAFETY

Safety instructions Setup and adjustments Installation and adjustment of the boiler as well as service maintenanceand repair of the boiler may only becarried out by a competent person inaccordance with the Gas Safety(Installation and Use) Regulations1998. (In the U.K. „CORGI“Registered installers undertake thework to a safe and satisfactory standard).If the boiler is installed in a compartment do not obstruct any purpose provided ventilation openings, and do not use the compartment for storage purposes.

Gas smellIf you smell gas or suspect a gasleak:

- Turn off the boiler.- Do not switch any electrical

switches in the hazardous areaON or OFF.

- Do not smoke in the hazardousarea.

- Turn off the gas supply at the gasmeter.

- Ventilate the room. - Consult your gas supplier, service

agent or other competent person.

Modifications in and around theboilerNo modifications may be made tothe following items:

- The boiler.- The gas, water and electrical

supply.- The flue system. - The safety valve for the heating

water. - Any structural changes around the

appliance that could affect theoperational safety of the boiler.

Follow the safety instructions!

Fig. S.1 Euro

B/S

002

/0_G

B

6

SAFETY

Explosive and flammable materialsDo not use or store any explosive orhighly flammable materials (e.g.gasoline, paper or paint) near to theappliance.

InspectionThe boiler should be serviced annually. We recommend that yousign a service agreement with yourservice agent or Vaillant Ltd.

Safety instructions

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Two year guarantee!

Fig. W.1 Euro

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122

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Your guaranteeVaillant undertakes to rectify anymanufacturing defect that occurs within twenty four months of the installation date.

Registering with usRegistration is simple. Just completethe Guarantee Registration Card andreturn to Vaillant within 30 days ofinstallation. Your details will then beautomatically registered within theVaillant scheme.

Note: No receipt will be issued.

Immediate helpIf your Vaillant boiler develops a faultyour first action should be to contactyour installer, as his professional assess-ment is needed under the terms of ourGuarantee. If you are unable tocontact your installer, phone VaillantService Solutions: 0870 6060 777

FACTORY GUARANTEE

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OPERATION

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Fig. B.1a: Operating elements TURBOmax Plus Euro

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THERMOcompact

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Fig. B.1b: Operating elements THERMOcompact Euro

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Overview

TURBOmax Plus

Operating controlsFor access to the controls press theupper middle of the lower front paneland drop it down. The following can be seen:

1 Maximum radiator temperaturecontrol (page 13)

2 The „+“ and „-“ buttons for the display panel

3 Main ON/OFF control (pages 10and 15)

4 Built in control/timer module (if fitted)

5 The „i“ information button6 Boiler display 7 Indicator lights to display the

current operating mode8 „Reset“ button: (see page 14) 9 Maximum hot water temperature

control and warmstart ON/OFFcontrol (page 11)

10Pressure gauge displaying thepressure in the heating system

THERMOcompactYou can identify a THERMOcompactboiler by the sticker which is situatedat the top left hand side of the controlpanel (see A, Fig. 1b)

Operating controlsFor access to the controls press theupper middle of the lower front paneland drop it down. The following can be seen:

1 Maximum radiator temperaturecontrol (page 13)

2 The „+“ and „-“ buttons for the display panel

3 Main ON/OFF control (pages 10and 16)

4 Built in control/timer module (if fitted)

5 The „i“ information button6 Boiler display 7 Indicator lights to display the

current operating mode8 „Reset“ button: (see page 14) 9 Pressure gauge displaying the

pressure in the heating system

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OPERATION

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1

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34

Fig. B.2: LED displays Euro

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074

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Initial checks before turning ON

Open the service valves● Ensure the cold water service valve

is open. This can be checked byopening a hot water tap and ensuring water flows.

● Ensure that the service valves inthe heating flow and return (2 and1) and the gas service valve (3)are open.

☞ The flow, return and gas service valves are open whenthe line marking has the samedirection as the pipe.

● The pressure relief valve (4) is provided for safety reasons andmust not be interfered with.

Note:A bottom cover is fitted to theappliance. The service valves canbe seen through the cover.

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Fig. B.3: Opening service valves Euro

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009

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☞ picture shows a TURBOmaxPlus boiler

Indicator lights/boiler display

TURBOmax Plus and THERMOcompactboilers have an advanced multi-function boiler display (1). When themain ON/OFF control is in the „ON“position the display will normallyshow the temperature of water in theboiler circuit (45 °C in the example),which confirms that the boiler is functioning correctly.

1 In the unlikely event of a faultdeveloping which prevents the boiler from operating, the displaymay show a fault code (page 14).

2 Red indicatorIlluminated = Boiler has locked out

3 Yellow indicatorIlluminated = Main burner ignited

4 TURBOmax PlusGreen warmstart indicator (3)Illuminated = Warmstart switchedONNot illuminated = Warmstart isswitched OFF and there is nodemand for hot waterFlashing = There is either ademand for hot water or warmstart

4 THERMOcompactGreen indicator (3) is illuminatedbut has no function.

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OPERATION

Check the water contents● Check the water contents of the

system on the pressure gauge (1).The needle on the pressure gaugeshould be within the green band(between 1 and 1.5 bar). If theneedle displays a value below 0.8 bar when the appliance iscold, follow the instructions left byyour installer to refill the system.Alternatively, your installer shouldbe called to refill the system.

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Fig. B.4: Checking the water level Euro

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076

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Fig. B.5: Domestic hot water supply Euro

B/S

077

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Domestic hot water operation (TURBOmaxPlus only)

The boiler should only be usedwhen the heating system con-tains water. Use of the boilerwithout water may causedamage to the boiler or itscomponents.

Setting the maximum domestichot water temperature control● Turn the main switch (2) to the „l“

position.● The display will show the boiler

flow temperature which indicateselectrical power to the boiler.

● The domestic hot water tempera-ture can be adjusted using the hotwater temperature control (3).

● Turn the control clockwise to increa-se the temperature and anti-clock-wise to decrease the temperature.

As a guide for normal circumstancesset the knob to the one o´clock positi-on.Note:

This control adjusts the maximumdomestic hot water temperature. Ifadjusting the control upwardsappears to have no effect on thetemperature, then the boiler isalready operating at full output forthe selected flow rate.

If you live in a hard waterarea please do not set thecontrol knob above the mid(12 o´clock) position to preventexcessiv scale formation (fig. B.5).

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OPERATION

Warmstart operation (TURBOmaxPlus only)The warmstart facility provides instantaneous delivery of domestichot water from the TURBOmax Plusboiler.When the warmstart system is switched ON the boiler will automatically light periodically tomaintain the internal temperature ofthe boiler at approximately 40 °C.When the warmstart system is switched OFF a short delay may beexperienced in obtaining hot water atthe tap.

● The warmstart system is activatedby turning the hot water tempera-ture control knob (1) all the way tothe very right for a short time.The green indicator light will nowilluminate. Reset the hot water temperature control knob to thedesired setting. The boiler will nowprovide instantaneous deliveryof hot water directly when a hotwater tap is turned ON.

● The warm start system is switchedOFF by turning the hot water temperature control knob (1) all theway to the very left for a shorttime. The green indicator light isNOT illuminated. Reset the hotwater temperature control knob tothe desired setting.

Note: Irrespective of whether the warm-start facility is switched ON orOFF, the boiler will automaticallyoperate to provide hot water whenever a hot water tap is opened.

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Fig. B.6: Switching the warm start on and off Euro

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OPERATION

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Fig. B.7: Drawing off hot water Euro

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Obtaining hot water (TURBOmaxPlus only)On opening a hot water tap (1) at asupply point (basin, shower, bath,etc.) the TURBOmax PLus boiler willautomatically operate to deliver hotwater.

On closing the tap the boiler switchesOFF (or continues to operate for cen-tral heating if required). The pumpand fan will continue to operate for ashort period.

TURBOm

ax Plus

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OPERATION

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Fig. B.8: Setting the flow temperature Euro

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Setting the external controls ● Set the room thermostat (3) and/or

the thermostatic radiator valves (4)according to the instructions supplied with the control(s).

HINT! Vaillant offer room thermostat/time control accessories whichgive accurate and economicroom temperature control aswell as improved comfort.

Ask your installer!

The boiler will now operate automatically to provide central heating for the conditions selected onthe external controls (TURBOmax Pluswill also provide domestic hot wateron demand).Whilst the boiler is operating, theboiler display (1, fig. B.2) indicatesthe temperature of the water withinthe boiler circuit. After the boilerstops operating the pump and fanwill continue to operate for a shortperiod to fully disperse the heat fromthe boiler.Note:

The boiler incorporates an anti-cycling economiser control to prevent energy wasteful ON andOFF operation of the boiler forshort periods when in the centralheating mode. When turning theroom thermostat to a higher settingthere may therefore be a shortdelay before the boiler operates.

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Fig. B.9: Setting the external controller Euro

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Heating operation

Setting the maximum radiatortemperature control ● Turn the main switch (1) to the „l“

position.

● Set the maximum radiator temperature control to the desiredsetting using the control knob (2).We recommend the following settings:

- Left setting during spring and autumn,

- Middle setting during mild winter,

- Right setting during cold winter.

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OPERATION

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max. 3 x

Fig. B.11: Reset Euro

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Fig. B.10: Reset Euro

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082

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Resetting the applianceWhen a hot water tap (TURBOmaxPlus only) or the central heatingsystem requires heat, the boiler auto-matically ignites and starts to operate.If the automatic ignition is not suc-cessful within 10 seconds, then theboiler does not go into operation andswitches to „Lock out“. This is indicated visually by the redindicator light (1) and the displayingof fault code „F.28“ or „F.29“ (flameextinguished during operation). Anew attempt to ignite the flame canthen only be performed after pressingthe „Reset“ button.

● Press the „Reset“ button (2) andhold for approx. 1 second.

If the boiler still shuts off aftera third attempt, then pleaseconsult your installer orVaillant Service Solutions.

The boiler also switches to „Fault“when there is not enough water in thesystem. This fault is indicated by faultcode „F 22“. The boiler can only beplaced back in operation after theheating system has been properlyrefilled with water (see page 10).

In the unlikely event of any other faultdeveloping, which prevents the boilerfrom operating, the display will alsoshow other fault codes. If a fault codeis displayed please contact yourinstaller or Vaillant Service Solutions.

Note:If contacting Vaillant ServiceSolutions please remember toquote the fault code, as this willhelp to pinpoint the fault.

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OPERATION

Turning the boiler OFF(TURBOmax Plus only)

To turn OFF the central heatingonly (Summer mode)

● Turn the maximum radiator temperature control knob used tocontrol the heating supply temperature (1) all the way to theleft.

HINT! You can switch off the heatingoperation in summer, forexample, but the boiler willcontinue to provide domestichot water whenever a hot watertap is opened.

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Fig. B.13: Shutting down the unit completely Euro

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Fig. B.12: Setting the summer operating mode Euro

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To turn OFF central heating andhot water for short periods oftime

● Turn the main ON/OFF control (2)to the „0“ position.

☞ If you want to turn theTURBOmax Plus boiler OFFfor a longer period of time(e.g. holidays), and there isno danger of frost, then youshould also turn off the gassupply, the cold water servicevalve (see page 9) and theelectrical supply. Please notethe frost protection hints in thisregard (page 17).

TURB

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OPERATION

Turning the boiler OFF(THERMOcompact only)

To turn OFF the central heating

● Turn the maximum radiator temperature control knob used tocontrol the heating supply temperature (1) all the way to theleft.

HINT! Do not turn theTHERMOcompact boiler OFFif a hot water cylinder is alsoincorporated in the systemunless there is no demand fordomestic hot water.

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THERMOcompact

Fig. B.15: Shutting down the unit completely Euro

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THERMOcompact

Fig. B.14: Setting the summer operating mode Euro

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To turn boiler OFF for short periods of time

● Turn the main ON/OFF control (2)to the „0“ position.

☞ Do not turn theTHERMOcompact boiler OFFif a hot water cylinder is alsoincorporated in the systemunless there is no demand fordomestic hot water.

THERMO

compact

17

OPERATION

TroubleshootingIn the unlikely event that a problemoccurs with the operation of theTURBOmax Plus or THERMOcompactboiler, the following points should bechecked:

1. Boiler fails to operate:

● Is the gas supply turned on? (seepage 9)

● Is the water supply turned on? (seepage 9)

● Is there enough water in the heating system? (see page 10)

● Is the electrical supply switchedON?

● Is the main ON/OFF control in the„ON” position? (switch position„I“) (see page 10)

● Is the burner lock out indicatorlight illuminated? (see page 14)

2. Hot water operates but no centralheating (TURBOmax Plus only)

● Is the heating turned ON? (seepage 13).

● Are all external heating controlsON? (see page 13)

If your boiler still does not operatethen please consult your installer orVaillant Service Solutions(0870 6060 777).

Care and maintenance Clean the outer casing of your boilerwith a damp cloth and a little soap.Do not use abrasive or solvent cleaning agents that may damagethe case or the plastic fittings.

The appliance should be serviced atleast once per year. To ensure regularservicing, it is strongly recommendedthat arrangements are made withyour service agent or Vaillant Ltd. Forfurther details please contact VaillantService Solutions: (0870 6060777).

Frost protectionYour boiler is equipped with a frostprotection function: If the heating water temperaturedrops below 5 °C when the mainswitch is ON, then the boiler goesinto operation and heats the boilercircuit to approx. 30 °C.

It cannot be guaranteed thatwater will circulate throughoutthe entire heating system.

If the boiler is not operated for several hours during very cold weather there is therefore the possibility of the system freezing.Please ensure that if you are absentduring a period of frost the centralheating remains in operation and allrooms are kept above freezing point.

It must be remembered, however, thatthe boiler will be automatically switched off by the built in monitoringdevices if certain faults occur, e.g.interruption in the gas or electricitysupply or faults in the flue gas system.To overcome this possibility you candrain both the central heating systemand boiler.

Frost protection and monitoring devices can onlyfunction when the main switchof the unit is set to the „I“position and the boiler isconnected to the electrical supply.

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OPERATION

Status display(For maintenance and service workperformed by your installer or serviceagent)

The status displays are activated bypressing the „i“ button (1). The current status code, e.g. „S.34“ forthe frost protection mode, is shownon the display (2). Pressing the „i“ button again willswitch you back to the normal mode.The „+“ and „-“ buttons will only beused by your installer or service agentduring service and maintenancework.

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Fig. B.16: Status displays

Table B.1: Status displays (A complete overview of the status codes can be found in the installation instructions).

* Heating operation** Hot water operation (TURBOmax Plus only)

Euro

B/S

081

/1

Display Meaning

S.00* No heating required

S.01* Fan running

S.03* Ignition sequence

S.04* Burner ignited

S.05* Fan and water pump over run

S.07* Water pump over run

S.08* Anti cycling mode (after heating operation)

S.10** Hot water demand

S.34* Frost protection mode

S.14** Burner ignited

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Head OfficeVaillant Ltd., Vaillant House,Medway City Estate, Trident Close,Rochester, Kent ME2 4EZ

Service Solutions 0870 6060 777Technical Advice 01634 292392