Vocera Linea Plus AG Installation & Servicing Instructions Manual

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Plus AG

Installation & Servicing Instructions

British Gas Service Listed G.C. No. 47 094 27 (Linea 24) G.C. No. 47 094 28 (Linea 28)

G.C. No. 47 094 29 (Linea Plus)

THESE INSTRUCTIONS TO BE RETAINED BY USER

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CONTENTS Section Subject Page no

Section 1 Introduction 1

General Layout 1

Section Subject Page no

Concluding Operations 20

Section 7 Instructing The User 20

Section 2 Design Principles & Operating

Sequence 2

Schematic Diagram 2 Central Heating Mode 2 Domestic Hot Water Mode 2 Safety Devices 2 Frost Thermosat 2

Section 3 Technical Data 3

Dimensions & Contents 3 Connection Sizes 3 Installation Requirements 3 Electrical Details 3 Performance & Limitations 3 Working Pressure (H/W & C/H) 3 Flow Rates 3 Central Heating Pump Duty 4

Section 4 General Requirements 5

Related Documents 5 Location of Appliance 5 Gas Supply 5 Flue System 5 Air Supply 6 Water Circulation (C/H) 6 Pipework 6 By-Pass 6 System Design 6 Filling Point 8 Electrical Supply 8 Showers 8

Section 5 Installation 9

Delivery 9 Unpacking 9 Preparing For Mounting 9 Mounting The Appliance 10 Fitting The Flue Horizontal - Vertical Twin 10-11 Connecting Gas & Water Supplies 15 Electrical connections 15

Section 6 Commissioning 17

Gas Installation 17 Initial Flushing of Pipework 17 Initial Filling of System 17 System Design Pressure 17 Checking Electrical supply 17 Lighting The Boiler 17 Checking Burner Pressures 18 Range Rating C/H 19 Checking The Flue System 19 Checking The Heating Thermistor 19 Regulating The C/H System 19 Final Flushing The C/H System 19 Filling & Testing H/W System 19 Final Checks For Operation 20

Section 8 Servicing Instructions 21

General 21 Recommended Routine Servicing 21 Replacement Of Parts 21 To Gain General Access 22

To Remove:

Room Sealed Chamber Front Cover22 Main Burner & Electrode 23 Main Burner Injectors 23 Main Heat Exchanger 23 Fan 24 DAPS Combustion Chamber Insulation Panel Ignition PCB 25 Gas Control Valve 25 Pump 26 Domestic Flow Switch 26 Diverter Domestic Heat Exchanger 27 Diverter Valve 27 Main Expansion Vessel 27 Safety Valve 28 Pressure Switch 28 Motorised Valve 29 Printed Circuit Board 29 Display Printed Circuit Board 29 Safety Thermostat 29 Thermistor Sensors 29 Pressure Gauge 30 Setting Gas Pressures 31

Section 9 Operational Checks & Wiring 32

Sequence of Functions 32 Diagnostic Error Codes 33 Fault Finding Guides 34-43

Section 10Appendix 44

Internal Time Clock Installation 44 External Time Clock Installation 46 S & Y Plan Installations 47 Exploded Diagrams 48-52 Abling & Disabling Controls 53 Functional Flow Diagram 54 Illustrated Wiring Diagram 55 Preliminary Electrical System Checks56 LPG Instructions 57-58

Valve 26

24 24

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SECTION 1 INTRODUCTION

The Vokèra Linea Plus is a combined central heating and domestic hot water appliance. By design it incorporates full sequence electronic ignition, circulating pump, expansion vessel, safety valve, temperature gauge, pressure gauge and 3 port diverter valve. The Plus also benefits from an air/gas modulation system and has low NOx emissions.

The boiler is produced as a room sealed appliance suitable for wall mounting applications only. It is provided with a fan powered flue outlet with an annular co-axial combustion air intake which can be rotated through 360 degrees. A vertical & twin flue option is available.

The appliance is designed for use with a sealed heating system only and is not intended for use on an open vented system.

The provision of stored domestic hot water is possible by the addition of an indirect cylinder with 'S' or 'Y' plan controls.

An automatic range-rating facility is incorporated in the boiler for the central heating system in conjunction with the electronic burner modulation. The domestic hot water (dhw) service utilises a motorised control combined with a 3 port diverter valve to give hot water priority which also benefits from a preheat function.

Fig.1 General Layout

1 Flue Outlet 2 Air Intake 3 Differential analog Pressure Switch (DAPS) 4 Silicone Pressure Tube 5 Silicone Negative Pressure Tube 6 Expansion Vessel 7 Main Heat Exchanger 8 Electrode 9 Burner Temperature control 9a Transformer 10 Gas Valve 11 Modulator Coil 12 Domestic Heat Exchanger 13 Domestic Hot Water Flow Switch 14 Safety Valve 15 Pressure Switch 16 Diverter Valve Motor 17 Pump 18 Automatic Air Release Valve 19 Main Burner 20 Combustion Chamber 21 Fan Assembly 22 Air Chamber (with front removed) 23 Flue Gas Analysis Test Point 24 Hot Water Temperature Control 25 Mode Selector Switch 26 Status LED 27 Temperature Indicator 28 Central Heating Temperature Control 29 Combustion Switch 30 Timeclock Aperture (optional) 31 Pressure Gauge

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SECTION 2 DESIGN PRINCIPLES AND OPERATING SEQUENCE

2.1 Fig.1 illustrates the general layout of compo-

nents. Fig.2 illustrates the operating principles described below.

2.2 Central Heating Mode

2.2.1 When the various switches and controls im-

pose a demand for heat, the pump is started. If the primary pressure is sufficient, the electronic circuitry is energised. The fan is started, the gas valve is energised at an intermediate rate and the electronic ignition goes through an ignition attempt.

2.2.2 The burner ignition is checked by the electronic circuitry to ensure correct ignition of the burner; once successful the gas will flow at 75% of maximum heat input for a period of approximately 15 minutes and then go to maximum heat input to maximise heating performance, unless the boiler nears optimum temperature where it will modulate down to suit system load.

2.2.3 As water temperature increases this is sensed by the temperature sensor on the flow pipe which modulates the fan and burner to match the heat output to the heat requirement of the system.

2.2.4 Depending on the load, either a) The water temperature will continue to rise and the fan and burner will continue to modulate down; The burner will switch off at maximum temperature, or b) the water temperature will fall; the fan and burner

Air Intake

Flue Outlet

NOTE

Fig. 2

BCD

will return to a higher output to match demand.

2.3 Domestic Hot Water Mode

2.3.1 The appliance incorporates a hot water

preheat facility. The appliance will therefore ignite periodically to maintain heat within the appliance.

2.3.2 The appliance will operate in domestic hot water mode whenever the mode selector switch is on regardless of mode selector switch position and any demand for central heating.

2.3.3 The diverter valve will automatically energise into the hot water position after central heating demand, or will stay in the hot water position after hot water demand. Opening a draw off tap will energise the pump and fan sending primary water to the domestic hot water heat exchanger.

2.3.4 Temperature control is transferred to the domestic hot water thermostat (potentiometer) which modulates the fan and burner output between high and low flame to maintain an average heat input to suit the dhw output required.

2.3.5 An overrun is incorporated in the boiler in both c/h & dhw modes. The fan overruns until the boiler water cools to approximately 80°C (176°F).

2.4 Safety Devices

2.4.1 In both central heating and hot water modes

safe operating is ensured by: A. Differential pressure unit in the primary

circuit which prevents burner operation if water pressure is too low.

B. An electronic device that checks the primary pressure unit for activation. Failure results in deactivation of the pump, after approximately 10 minutes of operation.

C. A safety thermostat, which interrupts the control circuit shutting off the gas valve. At the same time the fan will still operate.

D. A DAPS in the flue system to check the fan's operation before allowing ignition.

2.4.2 A safety valve is provided to relieve excess pressure from the primary circuit.

2.4.3 Frost Thermostat

The appliance has a built in frost protection circuit. Should the boiler temperature sensed at the primary thermistor fall below 5°C, the boiler will operate in central heating mode and continue to operate until the primary thermistor reaches approximately 40°C.

KEY: A Central Heating Return. B Central Heating Flow. C Hot Water Outlet. D Cold Water Inlet.

NOTE: Pressure switch.

Senses water pressure in the primary circuit and operates the pressure switch (15)

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SECTION 3 TECHNICAL DATA

3.1 Units Dimensions and values are given in the

preferred Sl Units with Imperial units in brackets where applicable.

3.2 Dimensions and Contents

Plus AG

Height Width Depth Weight dry Weight full

820mm (32.3) 500mm (19.7)

355mm (14.0) 48kg (105.6lb) 51kg (112.2lb)

Water content: 3 litres (.66 gals) for further dimensions see figs 12 - 16

3.3 Connection sizes

Heating flow and return: Nut and olive for 22mm o.d. Cold water inlet: Nut and olive for 15mm o.d. Hot water outlet: Nut and tail for 15mm o.d. Gas Service: Nut and tail for 15mm o.d. Safety valve outlet: 15mm comp.or capillary

Flue outlet/Air inlet: nom dia 60/100mm specially supplied with boiler (concentric). Flue outlet/Air inlet: nom dia 80/80mm specially supplied with boiler (twin).

3.4 Installation Requirements

3.4.1 Clearances (Horizontal or Vertical Flue)

Minimum - above casing 225mm (9in) Minimum - below casing 200mm (8in) Minimum In front 600mm (24in) Minimum - At sides 12mm (1/2in) from casing

3.4.2 Maximum heating system contents approx.

76.4 litres (16.8 gals). Acceptance capacity of expansion vessel 10 litres (2.2 gals).

3.4.3 Means of filling sealed system: to accord with BS and/or local Water Authority requirements.

3.4.4 The standard concentric horizontal flue allows a maximum length of duct as follows: Rear flue: 700mm (wall thickness) Side flue: 890mm (to centre line of boiler).

Using extension tubes the flue may be extended to the following lengths.

Concentric

Plus AG

Horizontal Vertical

3.0m

Concentric Flue

Reduction in flue

Bend

45° 90°

length for each bend

0.5 m

1.0 m

Twin Flue

Reduction in flue

Bend

45° 90°

length for each bend

1.0 m

3.5 Electrical Details

Mains supply 230v ~ 50Hz Fused 3A Internal fuse rating F2A and T100mA Power consumption:160W

3.6 Performance and Limitations Plus AG Max. input 34.9 kW (119,080 Btu/h)(net h/w) Max. inpu 38.7 kW (132.050Btu/h)(grossh/w) Max. input 34.9 kW (119.080 Btu/h)(net c/h) Max. input 38.7 kW (132.050Btu/h)(gross c/h) Min. input 9.95 kW (34.052 Btu/h)(net)(c/h) Min. input 9.95 kW (34.052 Btu/h)(net)(h/w) Min. input 11.07 kW (37.770 Btu/h)(gross)(c/h) Min. input 11.07 kW (37.770 Btu/h)(gross)(h/w)

Max. output 32.00 kW (109,200 Btu/h)(h/w) Max. output 32.00 kW (109,200 Btu/h)(c/h) Min. output 9.0 kW (30,700 Btu/h)(h/w) Min. output 9.0 kW (30,700 Btu/h)(c/h)

Central heating output range

Max. 32.0 kW (109,200 Btu/h) Min. 9.0 kW (30,700 Btu/h)

Nominal hot water production

Temp. rise of 30°C 15.3l/min. Temp. rise of 35°C 13.1l/min.

Gas Pressures

Max. gas pressure 10.1 mbar h/w Min. gas pressure 1.1 mbar h/w

Gas Rate

Max. 3.69m3/h 138.8 ft3/h (h/w) Min. 1.05 m3/h 35.6 ft3/h (h/w) Note: Use gross input values when gas rating the appliance

Twin (+ concentric terminal)

Horizontal Vertical

Plus AG

14/14m 14/14m

3.7 Working Pressure Heating System

3.8 Flow Rates Min. waterflow (dhw) 2.0l/min.

The reduction in flue length for each bend used is listed opposite.

Linea Plus AG

Burner Details Main burner:

Polidoro type Main burner injectors 16 x 1.35

Maximum 1.5bar/15m w.g./50ft w.g. Minimum 0.15bar/1.5m w.g./5ft w.g. Safety valve setting 3bar/30m/102ft w.g.

(0.45 gal/min) Min central heating flow rate through appliance 350litres/hr (1.28 gal/min)

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3.9 Working Pressure Hot Water System

Maximum 6.0 bar/90psig Minimum 0.6 bar/ 7psig

For LPG instructions see page 62.

3.10 Central Heating Pump Duty

Fig.3 indicates the flow rate available plotted against system pressure drop.

N.B. When using this graph apply only the pressure drop of the system. The curve has been modified to allow for the pressure drop through the appliance.

Fig. 3

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SECTION 4 GENERAL REQUIREMENTS

4.0 General Requirements

This appliance must be installed by a competent person in accordance with the Gas Safety (Installation & Use) Regulations 1998.

4.1 Related Documents

The installation of this boiler must be in accordance with the relevant requirements of the Gas Safety (Installation & Use) Regulations 1998 the Local Building Regulations, the current l.E.E. Wiring Regulations, the by-laws of the local water undertaking, and in Scotland, in accordance with the Building Standards (Scotland) Regulation. In Ireland the local building regulations (IE).

It should be in accordance also with any relevant requirements of the local authority and the relevant recommendations of the following British Standard Codes of Practice:

BS 6891 1988 Low pressure installation pipes. BS 6798 1987 Boilers of rated input not exceeding 60kW. BS 5449 Part 1 1990 Forced circulation hot water systems BS 5546 1990 Installation of gas hot water supplies for domestic

BS 5440 Part 1 1990 Flues. BS 5440 Part 2 1989 Flues & Ventilation. BS 7074 Part 1 1989 Application, selection & installation of expansion

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 this purpose.

Details of essential features of cupboard/ compartment design including airing cupboard installations are given in BS 6798:1987. This appliance is not suitable for external installation.

4.3 Gas Supply

A gas meter is connected to the service pipe by the gas supplier.

An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the rate of gas supply required for all appliances it serves.

purposes (2nd family gases).

vessels & ancillary equipment for sealed water systems.

4.2 Location of Appliance

The combination boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current l.E.E. Wiring Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the combination boiler in a room or internal space containing a bath or shower.

Where a room-sealed appliance is installed in a room containing a bath or shower, any electrical switch or appliance control, utilising mains electricity, should be located in such a position that it cannot be touched by a person using the bath or shower.

The location chosen for the boiler must permit the provision of a satisfactory flue and termination. The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the boiler.

Where the installation of the boiler will be in an unusual location special procedures may be necessary and BS 6798:1987 gives detailed guidance on this aspect.

Installation pipes should be fitted in accordance with BS 6891:1988.

Pipework from the meter to the boiler must be of adequate size. Pipes of a smaller size than the boiler inlet connection should not be used.

The complete installation must be tested for soundness as described in the above code.

N.B. If the gas supply for the boiler serves other appliances ensure that an adequate supply is available both to the boiler and the other appliance when they are in use at the same time.

4.4 Flue System

The terminal should be located where dispersal of combustion products is not impeded and with due regard for the damage or discoloration that might occur to building products in the vicinity (see fig 4).

The terminal must not be located in a place where it is likely to cause a nuisance.

In cold and/or humid weather water vapour may condense on leaving the flue terminal. The effect of such ‘steaming’ must be considered.

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For protection of combustibles, refer to BS 5440:1 where the terminal is less than 2m (6.6ft) above a pavement or platform to which people have access (including any balcony or flat roof the terminal must be protected by a guard of durable material).

A suitable guard is available from Vokera Ltd. Part No 018, G.C. No. 301 106

This guard must be fitted centrally over the terminal. Mark the positions of the fixings, drill the wall and secure using wall plugs and 3 of 1˚" No.8 plated screws.

Fig. 4

Terminal position for fan assisted boiler

(minimum distance) mm A - Directly below an open window or other 300

opening (e.g. air brick) B - Below gutters, soil pipes or drain pipes 25 C - Below eaves 25 D - Below balconies or car port roof 25 E - From vertical drain pipes and soil pipes 75 F - From internal or external corners 25 G - Above ground or below balcony level 300 H - From a surface facing a terminal 600 I - From a terminal facing a terminal 1200 J - From an opening in the car port (e.g. door

window) into dwelling. 1200 K - Vertically from a terminal on the same wall 1500 L - Horizontally from a terminal on the same wall 300 M - Horizontally from a vertical terminal to a wall 300

N - Horizontally from an opening, airbrick, openable

window, etc. 300

4.6 Water Circulation (Central Heating)

Detailed recommendations are given in S6798: 1987 and BS 5449: 1: 1990 (for smallbore and microbore central heating systems).

4.6.1 The following notes are given for general guidance.

4.6.2 Pipework

Copper tubing to BS 2871:1:1971 is recommended for water pipe. Jointing should be either by capillary soldered or with compression fittings.

Where possible, pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps.

It should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air.

Except where providing useful heat, pipes should be insulated to prevent heat loss and to avoid freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.

4.6.3 By-Pass

An automatic by-pass is incorporated in the boiler, but systems should be designed to ensure that with all radiators turned off a flow rate of at least 350 litres/hour (1.28 gals/min) is achieved through the system. See 6.9.4.

4.6.4 System Design

Figs 5 & 5a illustrates typical system layouts showing options of either, pipe connection from below as fig. 5, or pipe connection from above utilising the purpose made duct in the rear frame of the appliance.

4.6.5 Draining Taps

These must be located in accessible positions to permit the draining of the whole system. The taps must be at least 15mm nominal size and manufactured in accordance with BS 2879:

1980.

NOTE: The flue must be terminated in a place not likely

to cause a nuisance.

4.5 Air Supply

The following notes are intended for general guidance.

The room sealed fan flued boiler does not require a permanent air vent for combustion air supply.

Where installed in a cupboard or compartment ventilation is not required.

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Fig. 5

Fig. 5a

N.B. Vokèra Ltd recommend a 2-pipe system. Single pipe systems are more liable to be troublesome unless

carefullly designed and installed.

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4.6.6 Air Release Points

These must be fitted at all high points where air will naturally collect, and must be sited to facilitate complete filling of the system.

4.6.7 The appliance has an integral sealed expansion vessel to accommodate the increase of water volume when the system is heated. It can accept up to 10 litres of expansion water. If the appliance is connected to a system with an unusually high water content. Calculate the total expansion and add additional sealed expansion capacity as appropriate.

In general, modern systems will present no problem.

4.6.8 Filling Point

A method for filling the system and replacing water lost during servicing is provided on the appliance.

This method complies with the Water Supply (Water Fittings) Regulations 1999.

4.7 Electrical Supply

The appliance is supplied for operation on 230V ~ 50Hz electricity supply. It should be protected with a 3-amp fuse.

THIS APPLIANCE MUST BE EARTHED. The method of connection to the mains elec-

tricity must allow complete isolation from the supply.

The preferred method is by using a fused double pole switch with a contact separation of at least 3mm.

The switch must supply ONLY the appliance and immediate electrical control circuits (e.g. programmer / room thermostat)

Alternatively, use an unswitched shuttered socket outlet with a fused 3-pin plug both complying with BS 1363.

4.8 Showers

If a shower control is to be supplied from the combination unit it should be of the type which incorporates a thermostatic control and by design is suitable for use with a combination boiler. Check application with shower manufacturer.

C/H Flow

Valve

C/H Return

Valve

Safety valve

outlet

Filling Loop

Cold water

Inlet Stopcock/

filling valve

Gas

Cock

Hot water

Outlet

Fig.6

Fig. 7

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SECTION 5 INSTALLATION

Fig. 8

Fig. 9

5.1 Delivery (fig. 8)

The appliance is delivered in a heavy duty cardboard carton.

Lay the carton on the floor with the writing the correct way up.

5.2 Unpacking (fig. 9) Pull both sides of the top of the carton open.

Do not use a knife. Remove the hanging bracket, literature pack and fittings pack, from the packaging. Remove the package supports.

Lift the appliance from the carton and lay the appliance down with the white frame on the floor.

Remove the protective bag, and the polystyrene support from the back of the appliance.

Do not remove the insulation jacket on the domestic heat exchanger.

The fittings pack contains

Wiring harness for optional built in timer 15mm nut & olive Adjustable stopcock Safety valve outlet pipe (1) Filling loop hose (1) Various washers Flue kit supplied in separate carton.

5.3 Preparing for Mounting

5.3.1 Push to release front door panel and lower to

reveal controls. Loosen the 2 captive screws securing the front control panel to the lower part of the casing and lower to reveal inside of boiler (fig. 10).

5.3.2 Remove two screws at base of casing, slightly lift the casing and slide it gently towards the top of the appliance to disengage the case from the top suspension hooks (fig. 11).

5.3.3 Ensure the casing and screws are put to one side in a safe place.

Fig. 10

Fig. 11

Case Screws

Linea Plus AG

Case screws

(one either side)

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5.4 Mounting the appliance

The appliance should be mounted on a smooth, vertical surface, which must be capable of supporting the full weight of the appliance. Care should be exercised when determining the position of the appliance with respect to hidden obstructions such as pipes, cables, etc.

When the position of the appliance has been decided – using the template supplied – carefully mark the position of the fixing jig/mounting bracket assembly (see fig. 7) and flue-hole (if applicable).

5.4.1 Important There are two holes on the template. The lower hole should be used with the telescopic flue kit (part no. 0225705 & 0225710). The upper hole is for use with all other horizontal flue kits.

5.4.2 Maximum flue lengths

Flue system Linea Plus AG Concentric Horizontal 3.0m

Concentric Vertical 3.0 m Twin flue 14m/14m + terminal

5.5 Fitting the flue

The top flue outlet permits both horizontal and vertical flue applications to be considered, alternatively, the Vokera twin flue system can be utilised if longer flue runs are required.

5.5.1 Concentric horizontal flue

(For concentric vertical flue, see 5.5.2) (For twin flue applications, see 5.5.3) The appliance flue outlet elbow can be rotated through 360º on its vertical axis. In addition the flue may be extended from the outlet elbow in the horizontal plane (see 5.4.2), however if the flue is to be extended or additional bends are to be fitted, the standard horizontal flue kit (part no.

2359029) must be used. A reduction must also be made to the maximum length (see table) when additional bends are used.

Horizontal flue terminals and accessories

Part No. Description Min-Max Length

0225705 Standard telescopic flue 380mm – 600mm

(Dimension ‘X’)

0225710 Extended telescopic flue 600mm – 920mm

(Dimension ‘X’)

2359029 Horizontal flue kit 833mm

For use with add. (Dimension ‘X’) Bends & extensions

2359069 750mm extension 750mm 2359079 1500mm extension 1500mm 2359049 45º bend (pair) N/A 2359059 90º bend N/A 0225760 Wall bracket (5) N/A

FITTING THE TELESCOPIC FLUE KIT (0225705 &

0225710)

Carefully measure the distance from the centre of the appliance flue outlet to the face of the outside wall (dimension ‘X’ see fig. 12). Add 50mm to dimension ‘X’ to give the overall flue length (dimension ‘Y’). Using the complete telescopic flue assembly adjust the length to suit dimension ‘Y’. Once the telescopic flue terminal has been adjusted to the correct length, secure the flue assembly with the screw supplied.

Insert the flue assembly into the previously drilled flue hole and locate the flue bend over the appliance flue outlet. Push the flue bend down over the appliance flue outlet and ensure the correct seal is made. Pull the flue assembly towards and over the flue bend – using a twisting action – ensuring the correct seal is made. Check that the terminal protrudes past the finished outside wall by the correct length (115mm).

NOTE

You must ensure that the entire flue system is properly supported and conncented.

Reduction for bends

Bend Reduction in maximum flue length

for each bend

45º bend 0.5 metre 90º bend 1.0 metre

Using the template provided (see 5.4.1), mark and drill a 125mm hole for the passage of the flue pipe. The hole should have a 1º drop from the boiler to outside, to eliminate the possibility of rainwater entering the appliance via the flue.

The fixing holes for the wall-mounting bracket & jig should now be drilled and plugged, an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely. Once the bracket & jig has been secured to the wall, mount the appliance onto

Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The interior and exterior trim can now be fitted.

the bracket.

Fig. 12

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FITTING THE STANDARD (2359029) HORIZONTAL FLUE KIT (see 5.4.1)

Carefully measure the distance from the centre of the appliance flue outlet to the face of the outside wall (dimension ‘X’ see fig. 13). Ensure the inner (60mm) pipe is fully inserted into the outer (100mm) pipe (when the inner pipe is fully inserted, it stands proud of the outer pipe by 7.5mm). Add 32mm to dimension ‘X’ to give the overall flue lenghth (dimension 'Y')standard horizontal flue kit (part no. 2359029) is suitable for a distance (dimension ‘Y’) of up to 865mm.

Fig. 13

NOTE

Dimension ‘Y’ is measured from the end of the terminal to the end of the outer (100mm) pipe. The internal trim should be fitted to the flue pipe before connection of the 90º bend.

If the horizontal flue kit (2359029) requires to be cut to the correct size (dimension ‘Y’), you must ensure that the inner (60mm) pipe stands proud of the outer (100mm) pipe by 7.5mm (see fig. 13A). Ensure any burrs are filed or removed and that any seals are located properly before assembly.

Connect the inner (60mm) pipe of the terminal assembly to the push-fit end of the 90º bend (supplied) using a twisting action. Insert the assembled flue into the previously drilled hole. Using the clips & screws supplied, connect the flue assembly to the boiler, ensuring that the terminal protrudes past the finished outside wall by the correct length (135mm).

You must ensure that the entire flue system is properly supported and connected.

EXTENDING THE HORIZONTAL FLUE

If the horizontal flue requires extension/s or additional bend/s, the horizontal flue terminal kit (2359029) must be used. Connect the bend – supplied with the terminal kit – to the top of the boiler using the clips, screws, & gaskets supplied. The additional bends & extensions have an internal push-fit connection, care should be taken to ensure that the correct seal is made when assembling the flue system. Connect the required number of flue extensions or bends (up to the maximum equivalent flue length) to the flue terminal using the clips, screws, & gaskets supplied (see fig. 13 & 13A).

NOTE

When cutting the horizontal flue terminal or an extension to the required length, you must ensure that the excess is cut from the plain end of the terminal or extension, and that the inner (60mm) pipe is 7.5mm longer than outer (100mm) pipe (see fig. 13 & 13A). Remove any burrs, and check that any seals are located properly.

You must ensure that the entire flue system is properly supported and connected.

Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The interior and exterior trim can now be fitted.

5.5.2 CONCENTRIC VERTICAL FLUE

The vertical flue terminal can be connected directly to the appliance flue outlet. Alternatively, an extension or bend can be connected to the appliance flue outlet if desired (see 5.4.2), however if additional bends are fitted, a reduction must be made to the maximum flue length (see table below).

Reduction for bends

Bend Reduction in maximum flue length for

each bend

45º bend 0.5 metre 90º bend 1.0 metre

Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The exterior trim

Vertical flue terminal and accessories

can now be fitted.

Fig. 13A

Linea Plus AG

Part No. Description Length

2359039 Vertical flue terminal 1.0 metre 0225770 Pitched roof flashing N/A

plate 0225765 Flat roof flashing plate N/A 2359069 750mm extension 750mm 2359079 1500mm extension 1500mm 2359049 45º bend (pair) N/A 2359059 90º bend N/A 0225760 Wall bracket (5) N/A

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Using the dimensions given in fig. 14 as a reference, mark and cut a 105mm hole in the ceiling and/or roof.

Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing.

The fixing holes for the wall-mounting bracket & jig should now be drilled and plugged, an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely. Once the bracket has been secured to the wall, mount the appliance onto the bracket & jig.

IMPORTANT

The vertical flue terminal is 1.0 metre in length and cannot be cut; therefore it may be necessary to adjust the height of the appliance to suit or use a suitable extension.

Remove or discard the flue restrictor ring from the appliance flue outlet (see fig. 1), if the total flue length – including the allowance for any additional bends – exceeds 1.0 metre.

Connect the vertical flue assembly to the boiler flue spigot using the 60mm & 100mm clips, gaskets, & screws (supplied), ensuring the correct seal is made. The flue support bracket (supplied with the vertical flue kit) can now be fitted.

If the vertical flue requires extension/s or additional bend/s, connect the required number of flue extensions or bends (up to the maximum equivalent flue length) between the boiler and vertical flue assembly (see fig. 13A).

5.5.3 TWIN FLUE SYSTEM

The Vokera twin flue system enables greater flue distances to be achieved (see 5.4.2) than that of the standard concentric flue system. It can be used for horizontal or vertical applications, however the twin flue system must be converted to the dedicated concentric flue kit for termination. It is essential that the installation of the twin flue system be carried out in strict accordance with these instructions.

GUIDANCE NOTES ON TWIN FLUE INSTALLATION

• The flue must have a fall back of 1º back to the appliance to allow any condensate that may form in the flue system to drain via the condensate drain. Consideration must also be given to the fact that there is the possibility of a small amount of condensate dripping from the terminal.

• Ensure that the entire flue system is adequately supported, use at least one bracket for each extension.

• The entire flue system must be adequately insulated to maintain heat within the flue system thereby reducing the possibility of condensate production.

As the exhaust outlet pipe can reach very high temperatures it must be protected to prevent persons touching the hot surface.

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension and that the inner (60mm) pipe is 7.5mm longer than outer (100mm) pipe (see fig. 13A). Remove any burrs, and check that any seals are located properly.

You must ensure that the entire flue system is properly supported and connected.

Fig. 14

Reduction for bend

Bend Reduction in maximum flue length for

each bend

45º bend 1.0 metre 90º bend 1.0 metre

Twin flue accessories

Part No. Description Length

0225805 Horizontal flue terminal 1.0 metre 0225810 Vertical flue terminal 1.0 metre 300 Twin adapter kit N/A 0225770 Pitched roof flashing plate N/A 0225765 Flat roof flashing plate N/A 0225815 Condensate drain kit N/A 0225820 0.25m extension (pair) 250mm 0225825 0.5m extension (pair) 500mm 0225830 1.0m extension (pair) 1000mm 0225835 2.0m extension (pair) 2000mm 0225840 45º bend (pair) N/A 0225845 90º bend (pair) N/A 0225850 Twin bracket (5) N/A 0225855 Single bracket (5) N/A

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Mounting the boiler

The fixing holes for the wall-mounting bracket & jig should now be drilled and plugged, an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely. Once the bracket has been secured to the wall, mount the appliance onto the bracket & jig.

5.5.3.1 Installation of twin adaptor kit (fig. 15)

The condensate drain kit must be fitted within 1 metre of the appliance flue outlet. It is recommended that the condensate drain kit should be fitted in the vertical plane, however it can be fitted horizontally with care.

• Fit the first bend to the condensate drain kit or exhaust connection manifold by firmly pushing in to position.

• Using the two holes in the exhaust connection manifold as a guide, drill a 3mm hole in each and secure using the screws provided.

• Connect the air inlet pipe to the air baffle as above.

• The twin flue pipes extensions and accessories can now be installed by pushing together (the plain end of each extension or bend should be pushed approximately 50mm into the female socket of the previous piece).

The condensate drain trap must be connected to the drain in accordance with Building Regulations or other rules in force

Fig. 15

5.5.3.2

• Remove or discard the flue restrictor ring from the appliance flue outlet (see fig. 1).

• Insert the small restrictor ring (supplied with the twin adapter kit) if the total flue length – including the allowance for any bends – is less than 8 metres.

• Insert the exhaust connection manifold onto the appliance flue outlet.

• Place the silicone seal (supplied with twin adapter kit) over the rim of the exhaust connection manifold.

• Remove one of the blanking plates (located to the left & right of the appliance flu

• Remove one of the blanking plates (located to the left & right of the appliance flue outlet) and – using the same screws – install the air baffle.

Installation of condensate drain kit (fig. 16)

5.5.3.3 Horizontal termination ( fig. 17)

The twin flue system must be converted to the dedicated concentric flue kit for termination.

• The horizontal terminal is supplied with a built-in converter box and cannot be shortened.

Fig. 17

• A 130mm hole is required for the passage of the concentric terminal through the wall.

Depending on site conditions it may be preferable to install the terminal assembly prior to fitting the twin flue pipes.

Fig. 16

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Mark and drill a 130mm hole for the passage of the horizontal flue terminal, ensuring that there is a 1º fall back to the boiler (17mm per 1000mm). Insert the terminal assembly into the flue hole.

Push-fit the twin flue pipes onto the concentric to twin converter ensuring that the exhaust pipe connects to the exhaust connection on the concentric to twin converter. If necessary cut the plain ends (male) of the twin flue pipes to allow connection to the

concentric to twin converter.

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NOTE

• Before cutting twin flue pipes ensure allowances have been made for connection onto the previous piece and onto the concentric to twin converter. The last twin flue pipes must be pushed 50mm onto the male spigots of the concentric to twin converter.

NOTE

You must ensure that the entire flue system is properly supported and connected.

When cutting an extension to the required length, you should ensure that the excess is cut from the plain end of the extension. Remove any burrs, and check that both seals are located properly.

Seal the flue terminal assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The interior and exterior trim can now be fitted.

5.5.3.4 Vertical termination (See fig. 18)

The twin flue system must be converted to the dedicated concentric flue kit for termination.

• The vertical terminal is supplied with a builtin converter box and cannot be shortened.

• A 130mm hole is required for the passage of the concentric terminal through the ceiling and/or roof.

Depending on site conditions it may be preferable to install the terminal assembly prior to fitting the twin flue pipes.

Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing.

Fig. 18

• You must ensure that the entire flue system is properly supported and connected.

• Ensure that any horizontal sections of pipe have a 1º fall towards the appliance (17mm per 1000mm).

• The convertor box on the vertical terminal will have to be temporarily removed when inserting the terminal through the flashing.

• The condensate trap must be primed with water prior to commissioning the boiler.

• The condensate drain trap must be connected to the drain in accordance with building regulations or other rules in force.

NOTE

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5.6 Connecting the Gas and Water

5.6.1 Figs. 6 and 15 show the locations of the

fittings.

5.6.2 Do not over tighten nuts, use another spanner to apply counter force to avoid damaging the appliance

5.6.3 Gas Supply

Connecting the gas supply. Connect a 15mm gas pipe to the gas service

tap and tighten the union nut securing the tap to the appliance.

Pipework from the meter to the appliance must be of adequate size.

A minimum gas pressure of 20mb (8 in. w.g.) must be available at the appliance inlet at full flow rate. See section 3.

DO NOT use pipes of a smaller size than the appliance inlet connection.

5.6.4 Central Heating

Connect the central heating pipework (22mm o.d) to the respective valves, right hand: flow, left hand: return, and tighten the nuts.

5.6.5 Hot Water

Connect a 15mm pipe to the hot water outlet connection of the appliance. Tighten the nut.

If the hot water system does not include a tap below the hot water outlet connection, provide a suitable drain tap to permit draining of the appliance hot water side during servicing.

5.6.6 Cold Water

Connect a 15mm cold water service pipe to the inlet stopcock of the appliance. Tighten the nut.

If the cold water supply is liable to high pressure or large pressure fluctuations, a flow/ pressure regulator should be fitted in the supply pipe.

Should the appliance be subject to 'mains knock' it would be advisable to install an non return valve in the hot water outlet pipe to prevent unnecessary activation of the domestic flow switch.

5.6.7 Safety Valve Discharge

Connect a 15mm pipe to the discharge outlet of the appliance.

The discharge should terminate facing downwards outside the building in a position where discharging (possibly boiling) water will not create danger or nuisance; but in an easily visible position.

5.7 Electrical Connections

5.7.1 The electricity supply must be as specified in

4.7. If controls external to the appliance are required, design of the external electrical circuits should be undertaken by a competent person.

See Section 10 for further advice.

N.B. IT IS ESSENTIAL THAT ALL EXTERNAL CONTROL CIRCUITS AND WIRING IS WIRED FROM THE SAME ELECTRICAL ISOLATOR AS SERVES THE APPLIANCE.

Factory fitted internal wiring must not be disturbed when wiring external controls.

5.7.2 To gain access to the electrical terminals

Remove electrical cover by releasing four securing screws. Fig.18.

The mains input terminal block is now easily visible (see fig. 18a).

5.7.3 The electricity supply cable from the isolator and the appliance terminal block must be 3 core flexible sized 0.75mm˝ (24 x 0.2mm) to BS6500.

Wiring to the appliance should be rated for operation in contact with surfaces up to 90°C.

Electrical Cover Screws

Fig. 18

Factory Fitted Earth Screw

Fig. 18a

Link Between

= & TA

Mains Input and External Controls Terminal Block

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5.7.4 Pass the cable through one of the cord anchorage points and connect the wires Brown to L, Blue to N, and Green/Yellow to . Arrange the cable so that should the cable slip the anchorage the current carrying conductors become taut before the earthing conductor.

5.7.5 Securely tighten all terminal screws and arrange the cable with slack between the cable anchor and the terminal block. Tighten the cord anchorage screw until the cable is secure.

5.7.6 Neatly arrange the external cable in such a way that unrestricted opening of the controls fascia is possible without strain on the cable.

5.7.7 External controls may be wired from terminals TA to TA after removing the factory fitted link (see fig. 18 & pages 49 - 52 for further details). If a neutral is needed use the terminal marked N on the terminal strip.

DO NOT CONNECT ANY WIRES TO THE TERMINAL STRIP MARKED 'S' '-' 'POS' 'POS'

When connecting wires to the terminal strip it is possible to remove the terminal strip from the circuit board: Grasp the terminal strip firmly and slide up to clear pcb. See fig.21.

When refitting the terminal strip it is important that it is replaced correctly (with the screws facing left).

Section 10 gives details of fitment for external and internal controls (ie Vokera time clock).

If required pass the external controls cable through the spare cord anchorage and arrange the cable so that should the cable slip the anchorage the current carrying conductors become taut before the earthing conductor.

Main Burner

Test Point

Incoming Gas Pressure Test

Point

Closed Position

Fig. 19

Normal Operating Position

Filling Position

Do not connect wires to this terminal strip

Fig. 21

Controls terminal strip

Fig. 20

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SECTION 6 COMMISSIONING

6.1 Where the text bears identifying numbers in

brackets, refer to figs. 1 and 2 unless otherwise instructed.

6.2 Gas Supply Installation

Inspect the entire installation including the meter. Test for soundness and purge, all as described in BS6891:1988.

6.3 Central Heating Systems

6.3.1 IMPORTANT DO NOT RELEASE AIR FROM

THE RED SEALED EXPANSION TANK. It is charged with air at the factory from .75 - .80 bar (11 - 12psig)

6.3.2 Initial filling of the System

6.3.2.1 See 3.4.3.

6.3.2.2 Open central heating flow and return valves.

Unscrew black cap on automatic air release valve (18) one full turn. (Leave open permanently).

6.3.2.3 Close all air release taps on the central heating system.

6.3.2.4 Identify the filling/inlet valve found at the base of the appliance. See fig.6. The filling loop may have been disconnected from the filling/inlet valve and heating flow valve. If so reconnect unscrewing the caps as necessary. The filling/inlet valve has 3 positions. (Fig. 20) i) Vertically up - normal operating position. ii) Turn to the left to horizontal - closed posi-

tion.

iii) Vertically down - Filling position. To fill,

slowly turn the handle of the filling/inlet valve from the closed position towards the filling position. Mains water will be heard to enter the system/boiler. As the water enters the system/boiler the pressure gauge will be seen to rise. Pressurise to between 1bar & 1.5bar when the system is cold. DO NOT OVERPRESSURISE. Once the desired pressure is achieved turn the filling/inlet valve back to the closed position.

6.3.2.5 Starting with the lowest radiator open each air release tap in turn closing it only when clear water, free of bubbles, flows out. In the same way release air from any high points in the

pipework.

6.3.2.6 Continue filling the system until at least 1.0 bar registers on the gauge then turn the handle of the filling/inlet valve back to the closed position.

6.3.2.7 Inspect the system for water soundness and remedy any leaks discovered.

6.3.3 Initial flushing of Pipework

The whole of the heating system must be flushed both cold and later hot as detailed in

6.10. Open all radiator or heating valves and the appliance central heating valves. Drain the boiler and system from the lowest points. Open the drain valve full bore to remove any installation debris from the boiler prior to lighting. Refill the boiler and heating system as described in 6.3.2

6.3.4 Setting the System Design Pressure

6.3.4.1 The design pressure should be a minimum of

1 bar and maximum 1.5 bar.

6.3.4.2 The actual reading should ideally be 1 bar plus the equivalent height in metres to the highest point of the system above the base of the appliance. (Up to the maximum of 1.5 bar total).

N.B. The safety valve is set to lift at 3bar/ 30m/ 45psig.

6.3.4.3 To lower the system pressure to the required value, pull lever on head of safety valve (14) a quarter turn to release water until the required figure registers on the gauge (31).

6.3.5 Filling the Hot Water System

6.3.5.1 Close all hot water draw-off taps.

6.3.5.2 Turn filling/inlet valve to the normal operating

position (vertically up). See fig. 20

6.3.5.3 Slowly open each draw-off until clear water is discharged.

6.4 Checking Electricity Supply

6.4.1 Carry out preliminary checks for continuity,

polarity, and resistance to earth (see page

61), gaining access as required according to

5.7.2 in this manual.

6.4.2 Leave the appliance with the control fascia closed and with the mains electricity switched OFF

6.5 Lighting the Boiler

6.5.1 Ensure flow and return valves are open.

(6.3.2.1) If external and/or internal controls are fitted

(e.g Timeclock and/or Room thermostat) ensure they ‘call for heat’. The commissioning of the appliance may be easier if the external/ internal controls are disconnected and terminals TA & TA are linked. (For access procedure turn off electricity and refer to 5.7.2 for instructions).

6.5.2 Switch on the mains electricity and turn the on / off / mode switch (25) to

6.5.3 Set the c/h control knob (28) to the highest setting.

6.5.4 The appliance will go through an ignition sequence and the burner will light.

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6.5.5 If during the ignition attempt period (10 secs approx.) the boiler fails to light, the ignition control circuit will go to lockout. This is indicated by the status LED (26) flashing red accompanied by a flashing error code 01 shown in the temperature indicator (27). The gas valve is de-energised, but leaves the fan and pump running for approximately 2 minutes after lockout.

6.5.5 In the event of the boiler going to lockout turn the mode selector switch to the reset position for approximately 10 seconds, then back to the original position. The two main causes of the boiler going to lockout during commissioning are electrical supply polarity reversed, or air in the gas supply. Check polarity and that the gas supply is completely purged of air, and that gas is reaching the boiler, then repeat from

6.5.2.

6.6 Checking Burner Pressures

6.6.1 The heat inputs for high and low gas rates are

factory set to the maximum values given in section 3.6 for domestic hot water and central heating but it is necessary to check them when commissioning.

6.6.4 Turn off the main electricity supply. Gain access to the interior as instructed in 5.7.2.

6.6.5 Locate the main burner pressure test point (fig. 19) and slacken the screw half a turn in an anti clockwise direction. Attach a suitable U gauge tube between the test nipple and manometer (see fig. 22).

IMPORTANT: Before measuring gas pressures it is imperitive that the protective cover over the gas valve adjustment screw is removed (fig. 31).

Turn on electricity supply and fully open a domestic hot water tap to operate boiler in dhw mode. Adjust hot water control knob to it's maximum setting.

be:

Plus AG (N/G)

10.1 mbar (plus or minus 1mbar)

If the pressure is wrong it should be adjusted as instructed in 8.23 (N.B. Whenever the maximum rate is adjusted, check and adjust the minimum rate too).

6.6.7 Turn off the electricity supply and remove one of the grey wires connecting to the modulator coil on the front of the gas valve. Switch on the electricity supply. The boiler will now light at the minimum setting.

6.6.8 When low flame is established, the pressure reading should be:

Plus AG (N/G)

1.1 mbar (plus or minus 0.11 mbar)

If it is different adjustment should be made in accordance with the instructions in 8.23.

6.6.9 Turn off the electricity supply and replace the wire onto the modulator coil.

6.6.6 The pressure reading for maximum rate should

Gas Valve

Manometer

U Gauge Tube

Fig. 22

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