vokera Compact 24 User guide

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Page 1

Compact

Standard efficiency combi boiler

Installation

& Servicing

Instructions

THESE INSTRUCTIONS TO BE RETAINED BY USER

Vokèra is a licensed member of the Benchmark scheme which aims to improve the standards of installation and commissioning of domestic hot water systems in the UK.

Page 2

Contents

Design principles and operating sequence Page

1.1 Principle components 2

1.2 Central heating mode 2

1.3 Hot water mode 2

1.4 Safety devices 2

1.5 Frost protection 2

Technical data Page

2.1 Central heating 3

2.2 Domestic hot water 3

2.3 Gas pressure 3

2.4 Expansion vessel 3

2.5 Dimensions 3

2.6 Clearances 3

2.7 Connections 3

2.8 Electrical 3

2.9 Flue details 3

2.10 Efficiency 3

2.11 Pump duty 4

General requirements (UK) Page

3.1 Related documents 5

3.2 Location of appliance 5

3.3 Gas supply 5

3.4 Flue system 5

3.5 Air supply 5

3.6 Water circulation 5

3.6.1 Pipework 6

3.6.2 Automatic by-pass 6

3.6.3 Drain cocks 6

3.6.4 Air release points 6

3.6.5 Expansion vessel 6

3.6.6 Filling point 6

3.6.7 Low pressure sealed system 6

3.6.8 Frequent filling 6

3.7 Electrical supply 6

3.8 Showers 6

3.9 Mounting on a combustible surface 7

3.10 Timber framed building 7

3.11 Inhibitors 7

General requirements (EIRE) Page

3.A1 Related documents 7

3.A2 Location of appliance 7

3.A3 Gas supply 7

3.A4 Flue system 7

3.A5 Air supply 8

3.A6 Water circulation 8

3.A6.1 Pipework 8

3.A6.2 Automatic by-pass 8

3.A6.3 Drain cocks 8

3.A6.4 Air release points 8

3.A6.5 Expansion vessel 8

3.A6.6 Filling point 8

3.A6.7 Low pressure sealed system 8

3.A6.8 Frequent filling 8

3.A7 Electrical supply 8

3.A8 Showers 8

3.A9 Mounting on a combustible surface 8

3.A10 Timber framed building 8

3.A11 Inhibitors 8

3.A12 Declaration of conformity 8

Installation Page

4.1 Delivery 9

4.2 Contents 9

4.3 Unpacking 9

4.4 Preparation for mounting the appliance 9

4.4.1 Important 9

4.4.2 Flue restrictor ring 9

4.5 Fitting the flue 9

4.5.1 Concentric horizontal flue 9

4.5.2 Concentric vertical flue 11

4.5.3 Twin flue system 11

4.6 Connecting the gas and water 13

4.6.1 Gas 13

4.6.2 Flow and return 14

4.6.3 Safety valve 14

4.6.4 Cold water inlet 14

4.6.5 Hot water outlet 14

4.7 Electrical connections 14

4.7.1 Casing removal 14

4.7.2 Electrical connection 14

4.7.3 Connecting the mains (230V) input 15

Commissioning Page

5.1 Gas supply installation 16

5.2 The heating system 16

5.3 Initial filling of the system 16

5.4 Initial flushing 16

5.5 Filling the hot water system 16

5.6 Pre-operation checks 16

5.7 Initial lighting 16

5.8 Checking burner pressures 16

5.9 Final flushing of the heating system 17

5.9.1 Inhibtors 17

5.10 Setting the flow temperature 17

5.11 Setting the system design pressure 17

5.12 Regulating the central heating system 17

5.13 Regulating the domestic hot water 17

5.14 Final checks 17

5.15 Instructing the user 17

Servicing instructions Page

6.1 General 18

6.2 Routine annual servicing 18

6.3 Replacement of components 18

6.4 De-scaling main heat exchanger 18

6.5 Component removal procedure 18

6.6 Pump head 18

6.7 Safety valve 18

6.8 Automatic air release valve 19

6.9 Water pressure switch 19

6.10 Domestic water flow switch 19

6.11 Pressure gauge 19

6.12 Primary and secondary thermistors 19

6.13 High limit thermostat 19

6.14 PCB 20

6.15 Integral time switch 20

6.16 Gas valve 20

6.17 Burner, injectors and spark/sense electrode 20

6.18 Flue fan 21

6.19 Heat exchanger 21

6.20 Air pressure switch 21

6.21 Expansion vessel 21

6.22 Expansion vessel (removal) 21

Checks, adjustments and fault finding page

7.1 Checking appliance operation 22

7.2 At rest mode 22

7.3 Hot water mode 22

7.4 Heating mode 22

7.5 Frost protection mode 22

7.6 Burner pressure settings 22

7.6.1 Setting the maximum DHW gas pressure 23

7.6.2 Setting the minimum DHW gas pressure 23

7.6.3 Setting the max & min CH burner pressures 23

7.7 Combustion analysis test 23

7.8 Checking the expansion vessel 23

7.9 Electro-mechanical faults 23

7.10 Possible installation faults 24

7.11 Electrical checks 24

7.11.1 Earth continuity test 24

7.11.2 Short circuit test 24

7.11.3 Polarity check 24

7.11.4 Reversed polarity or supply fault 24

7.11.5 Resistance to earth check 24

7.11.6 Fuses 24

7.12 Fault finding 24-31

Wiring diagrams Page

8.1 Connection of a room thermostat 32

8.2 Connection of an external time clock 32 Functional flow diagram 33-34

Exploded diagrams Page

Table 1 35 Table 2 36 Table 3 37 Table 4 38 Table 5 39

L.P.G. instructions Page

10.1 Technical data 40

10.2 Related documents 40

10.3 Gas supply 40

10.4 Gas supply installation 40

10.5 Burner pressures 40

10.5.1 Setting the maximum DHW gas pressure 40

10.5.2 Setting the minimum DHW gas pressure 40

10.5.3 Setting the max & min CH burner pressures 40

REAR FLUE Page

11.1 Fitting the flue 41

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INTRODUCTION

The Vokera Compact range of appliances are combined central heating and domestic hot water boilers, which – by design – incorporates full sequence electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge, automatic by-pass, and mechanical time clock.

Compact is produced as a room sealed appliance, suitable for wall mounting applications only. Compact is provided

24 23

150

with a fan powered flue outlet with an annular co-axial combustion air intake that can be rotated – horizontally – through 360 degrees for various horizontal or vertical applications, and can also be converted for use with a rear flue outlet. Compact can also be used with the Vokera twin flue system.

This appliance is designed primarily for use with sealed systems; consequently it is not intended for use on an open vented system.

Fig.1 General Layout

1 Flue Analysis Test Point 2 Pressure Tube Negative 3 Fan Assembly 4 Heat Exchanger 5 Secondary thermistor 6 Combustion chamber 7 Burner 8 Expansion vessel 9 Water pressure switch 10 Domestic Hot Water Flow Switch 11 Gas Valve 12 Timeclock 13 CH position 14 Fault indicator led 15 Mode selector switch 16 DHW position 17 Pressure gauge 18 Safety valve 19 Pump 20 Auto air vent 21 Electrode 22 High limit thermistor 23 Primary thermistor 24 Air chamber (with cover removed) 25 Air pressure switch 26 Auto by pass (fig. 2) 27 Water flow restrictor (fig. 2)

Fig. 1

Compact

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SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS

● A fully integrated, electronic control board fea-

turing mode selection switch, full sequenceelectronic ignition, temperature control system, and appliance status indicator.

● A BI-thermal gas to water heat exchanger.

● A multi-functional gas valve.

● Two-stage, primary water pressure switch.

Integral pump, expansion vessel, pressure relief valve, pressure gauge, domestic water flow switch, fan, differential air pressure switch, and time clock.

MODES OF OPERATION

1.2 CENTRAL HEATING MODE

When there is a request for central heating via the time-clock and/or any external controls, the pump and fan are started, the fan proves the differential air pressure switch which in-turn, allows an ignition sequence to begin. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved the appliance operates al 75% of maximum for a fifteen-minute period, and thereafter the appliance operates on maximum output until the desired temperature setting is reached.

1.3 HOT WATER MODE

1.4 SAFETY DEVICES

Once the desired temperature is reached, the burner will modulate to maintain that temperature, however should the temperature within the appliance continue to rise, the burner will shut down and the boiler will perform a three-minute anti-cycle (timer delay).

When there is a demand for domestic hot water the domestic hot water flow switch is proved by the flow of water through the appliance, this allows the fan to run, the fan proves the differential air pressure switch which in-turn, allows an ignition sequence to begin.

Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved the appliance will modulate burner gas pressure to maintain the desired water temperature, should the temperature of the domestic hot water exceed the temperature setting by 5 ºC the burner will shut down until the water temperature drops below the required setting.

In both central heating and domestic hot water modes, safe operation is ensured by.

● A water pressure switch that monitors the sys-

tem pressure and will deactivate the pump and prevent burner ignition should the pressure or primary flow rate fall below the rated tolerance.

● Differential air pressure switch that checks the

correct operation of the fan and flue thereby preventing or interrupting burner operation.

● A high limit thermostat that overrides the con-

trol circuit to prevent or interrupt burner ignition.

● A safety valve which releases excess pressure

from the primary circuit.

20 19

18 26

1.5 FROST PROTECTION

The appliance has built-in frost protection that allows the pump to operate if the appliance temperature drops to 7 ºC, should the temperature continue to drop the burner will light until the primary circuit temperature exceeds 30 ºC.

return flow

outlet

Fig. 2

cold inlet

Compact

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SECTION 2 TECHNICAL DATA

Compact 24 Compact 28

2.1 Central heating

Heat input (kW) 26.3 31.0 Heat output (maximum) kW 24.0 28.0 Heat output (minimum) kW 9.4 10.5 Minimum working pressure 0,5 bar 0,5 bar Maximum working pressure 3.0 bar 3.0 bar Minimum flow rate 350 l/h 350 l/h

2.2 Domestic hot water

Heat input (kW) 26.3 31.0 Heat output (maximum) kW 24.0 28.0 Heat output (minimum) kW 8.2 8.7 Flow rate (35 °C rise) 9.8 l/min 11.5 l/min Maximum inlet pressure 6.0 bar 6.0 bar Minimum inlet working pressure 0.15 bar 0.15 bar Minimum flow rate 2 l/min. 2 l/min.

2.3 Gas pressures

Inlet pressure G20 20.0 mbar 20.0 mbar Maximum burner pressure 10.1 mbar 10.2 mbar Minimum burner pressure (central heating) 1.9 mbar 1.9 mbar Minimum burner pressure (domestic hot water) 1.5 mbar 1.3 mbar Gross rate (maximum) 2.78 m3/h 3.28 m3/h Injectors size 12 x 1.35 mm 14 x 1.35 mm

2.4 Expansion vessel

Capacity 8 litres 8 litres Maximum system volume 76 litres 76 litres Pre-charge pressure 1.0 bar 1.0 bar

2.5 Dimensions

Height 740 mm 740 mm Width 400 mm 450 mm Depth 328 mm 328 mm Dry weight 32 kg 34 kg

2.6 Clearances

Left side 50 mm 50 mm Right side 12 mm 12 mm Top 150 mm from casing or 25 mm above flue elbow, whichever is applicable Bottom 150 mm 150 mm Front 600 mm 600 mm

2.7 Connections

Flow & return 22 mm 22 mm Hot & cold water connections 15 mm 15 mm Gas 15 mm 15 mm Safety valve 15 mm 15 mm

2.8 Electrical

Voltage 230V/~ 50hz 230V/~ 50hz Power consumption 125 W 125 W Internal fuse 2 A 2 A PCB fuse 2 AF 2 AF External fuse 3 A 3 A

2.9 Flue details

Maximum horizontal flue length (concentric) 4.25 m 3.4 m Maximum vertical flue length (concentric) 5 m 4.2 m Maximum twin flue length (horizontal or vertical) 14 m + 14 m 14 m + 14 m Maximum rear flue length (see section 11) 1.0 m 1.0 m

2.10 Efficiency

SEDBUK Band “D” Band “D”

Ref. Condition 15 °C , 1013,25 mbar, dry gas NOTE: L.P .G. data refer to section 10

Compact

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2.11 PUMP DUTY

Fig. 3 shows the flow rate available – after allowing for pressure loss through the appliance – against system pressure loss. When using this graph apply only the pressure loss of the system. The graph is based on a 20 ºC temperature differential.

600

500

400

300

200

Water pressure (mbar)

100

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

Fig. 3

SECTION 3 GENERAL REQUIREMENTS (UK)

Litres Per Hour (x100)

Key Location Minimum distance

A Below an opening (window, air-brik, etc.) 300 mm

B Above an opening (window, air-brik, etc.) 300 mm C To the side of an opening (window, air-brik, etc.) 300 mm D Below gutter, drain-pipe, etc. 75 mm

E Below eaves 200 mm

F Below balcony, car-port roof, etc. 200 mm G To the side of a soil/drain-pipe, etc. 150 mm H From internal/external corner or boundary 300 mm

I Above ground, roof, or balcony level 300 mm

J From a surface or boundary facing the terminal 600 mm K From a terminal facing a terminal 1200 mm L From an opening in the car-port into the building 1200 mm

M Vertically from a terminal on the same wall 1500 mm N Horizontally from a terminal on the same wall 300 mm

P From a structure to the side of the vertical terminal 300 mm

Q From the top of the vertical terminal to the roof flashing As determined by the fixed collar Fig. 4

of the vertical terminal

Compact

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

3.1 RELATED DOCUMENTS

The installation of this boiler must be in accordance with the relevant requirements of the Gas Safety (Installation & Use) Regulations, the local building regulations, the current I.E.E. wiring regulations, the bylaws of the local water undertaking, the Building Standards (Scotland) Regulation, and Building Standards (Northern Ireland) Regulations.

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.

3.2 LOCATION OF APPLIANCE

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

3.3 GAS SUPPLY

The gas meter – as supplied by the gas supplier – must be checked to ensure that it is of adequate size to deal with the maximum rated input of all the appliances that it serves. Installation pipes must be fitted in accordance with BS 6891.

Pipe work from the meter to the appliance must be of adequate size. Pipes of a smaller size than the appliance gas inlet connection must not be used. The installation must be tested for soundness in accordance with BS6891.

If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time.

3.4 FLUE SYSTEM

The terminal should be located where the dispersal of combustion products is not impeded and with due regard for the damage and discoloration that may occur to building products located nearby. The terminal must not be located in a place where it is likely to cause a nuisance (fig. 4).

In cold and/or humid weather, water vapour may condense on leaving the terminal; the effect of such pluming must be considered.

BS 5440 PART 1 FLUES BS 5440 PART 2 FLUES AND VENTILATION BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

(2ND FAMILY GASES) BS 6798 BOILERS OF RATED INPUT NOT EXCEEDING 60kW BS 6891 LOW PRESSURE INSTALLATION PIPES BS 7074 PART 1 APPLICATION, SELECTION, AND INSTALLATION OF EXPANSION VESSELS AND

ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS

When an appliance is installed in a room or internal space containing a bath or shower, the appliance or any control pertaining to it must not be within reach of a person using the bath or shower.

The location chosen for the appliance must permit the provision of a safe and 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 appliance. Where the installation of the appliance will be in an unusual location special procedures may be necessary, BS 6798 gives detailed guidance on this aspect. A compartment used to enclose the appliance must be designed and constructed specifically for this purpose. An existing compartment/ cupboard may be utilised provided that it is modified to suit.

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

3.5 AIR SUPPLY

3.6 WATER CIRCULATION

If installed less than 2 m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material. The guard must be fitted centrally over the terminal. Refer to BS 5440 Part 1, when the terminal is 0.5 metres (or less) below plastic guttering or 1 metre (or less) below painted eaves.

The following notes are intended for general guidance only.

This appliance is a room-sealed, fan-flued boiler, consequently it does not require a permanent air vent for combustion air supply.

When installed in a cupboard or compartment, ventilation for cooling purposes is also not required.

Detailed recommendations are given in BS 5449 Part 1 and BS 6798. The following notes are for general guidance only.

Compact

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3.6.1 PIPEWORK

It is recommended that copper tubing to BS 2871 Part 1 is used in conjunction with soldered capillary joints.

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

Except where providing useful heat, pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing. Particular attention should be paid to pipes passing through ventilated areas such as under floors, loft space, and void areas.

3.6.2 AUTOMATIC BY-PASS

The appliance has a built-in automatic by-pass, consequently there is no requirement for an external by-pass, however the design of the system should be such that it prevents boiler ‘cycling’.

3.6.7 LOW PRESSURE SEALED SYSTEM

An alternative method of filling the system would be from an independent make-up vessel or tank mounted in a position at least 1 metre above the highest point in the system and at least 5 metres above the boiler (fig. 5a).

The cold feed from the make-up vessel or tank must be fitted with an approved non-return valve and stopcock for isolation purposes. The feed pipe should be connected to the return pipe as close to the boiler as possible.

Make-up vessel or tank

Automatic air-vent

3.6.3 DRAIN COCKS

These must be located in accessible positions to facilitate draining of the appliance and all water pipes connected to the appliance. The drain cocks must be manufactured in accordance with BS 2879.

3.6.4 AIR RELEASE POINTS

These must be positioned at the highest points in the system where air is likely to be trapped. They should be used to expel trapped air and allow complete filling of the system.

3.6.5 EXPANSION VESSEL

The appliance has an integral expansion vessel to accommodate the increased volume of water when the system is heated. It can accept up to 8 litres of expansion from within the system, generally this is sufficient, however if the system has an unusually high water content, it may be necessary to provide additional expansion capacity (see section 6.19).

3.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. must be provided. This method of filling must comply with the current Water Supply (Water Fittings) Regulations 1999 and Water Bylaws 2000 (Scotland). Fig. 5 shows an accepted method.

control valve

temporary

connection

control valve

Stopcock

Fig. 5a

Non-return

valve

Heating return

3.6.8 FREQUENT FILLING

Frequent filling or venting of the system may be indicative of a leak. Care should be taken during the installation of the appliance to ensure all aspects of the system are capable of withstanding pressures up to at least 3 bar.

3.7 ELECTRICAL SUPPLY

The appliance is supplied for operation on 230V @ 50Hz electrical supply; it must be protected with a 3-amp fuse. The method of connection to the mains electricity supply must allow for complete isolation from the supply. The preferred method is by using a double-pole switch with a contact separation of at least 3 mm. The switch must only supply the appliance and its corresponding controls, i.e. time clock, room thermostat, etc. Alternatively an un-switched shuttered socket with a fused 3-pin plug both complying with BS 1363 is acceptable.

5.0 metres minimum

Fig. 5

flow/return

pipe

double check

valve

supply pipe

3.8 SHOWERS

If the appliance is intended for use with a shower, the shower must be thermostatically controlled and be suitable for use with a combination boiler.

Compact

Page 9

3.9 MOUNTING ON A COMBUSTIBLE SURFACE

If the appliance is to be fitted on a wall of combustible material, a sheet of fireproof material must protect the wall.

3.10 TIMBER FRAMED BUILDING

If the appliance is to be fitted in a timber framed building, it should be fitted in accordance with the Institute of Gas Engineers publication (IGE/UP/

7) ‘Guide for Gas Installations in Timber Frame Buildings’.

3.11 INHIBITORS

Vokera recommend that a neutral inhibitor is used to protect the heating system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers* instructions.

*Fernox and Sentinel manufacture products that have proved suitable for use with Vokera appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our appliances.

Fig. 6

150

SECTION 3A GENERAL REQUIREMENTS (EIRE)

This appliance must be installed by a competent person in accordance with and defined by, the Standard Specification (Domestic Gas Installations) Declaration (I.S. 813).

3A.1 RELATED DOCUMENTS

The installation of this boiler must be in accordance with the relevant requirements of the local building regulations, the current ETCI National Rules for Electrical Installations, and the bylaws of the local water undertaking.

It should be in accordance also with any relevant requirements of the local and/or district authority.

3A.2 LOCATION OF APPLIANCE

The appliance may be installed in any room or internal space, although particular attention is drawn to the requirements of the current ETCI National Rules for Electrical Installations, and I.S. 813, Annex K.

When an appliance is installed in a room or internal space containing a bath or shower, the appliance or any control pertaining to it must not be within reach of a person using the bath or shower. The location chosen for the appliance must permit the provision of a safe and 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 appliance. Where the installation of the appliance will be in an unusual location special procedures may be necessary, refer to I.S. 813 for detailed guidance on this aspect. A compartment used to enclose the appliance must be designed and constructed specifically for this purpose. An existing compartment/cupboard may be utilised provided that it is modified to suit.

3A.3 GAS SUPPLY

3A.4 FLUE SYSTEM

This appliance is not suitable for external installation.

If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time.

In cold and/or humid weather, water vapour may condense on leaving the terminal; the effect of such pluming must be considered.

If installed less than 2 m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material. The guard must be fitted centrally over the terminal. Refer to I.S. 813, when the terminal is 0.5 metres (or less) below plastic guttering or 1 metre (or less) below painted eaves.

Compact

Page 10

3A.5 AIR SUPPLY

The following notes are intended for general guidance only. This appliance is a room-sealed, fan-flued boiler, consequently it does not require a permanent air vent for combustion air supply.

When installed in a cupboard or compartment, ventilation for cooling purposes is also not required.

3A.6 WATER CIRCULATION

Specific recommendations are given in I.S. 813. The following notes are for general guidance only.

3A.6.1 PIPEWORK

It is recommended that copper tubing be used in conjunction with soldered capillary joints.

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

3A.6.2 AUTOMATIC BY-PASS

The appliance has a built-in automatic by-pass, consequently there is no requirement for an external by-pass, however the design of the system should be such that it prevents boiler ‘cycling’.

3A.6.3 DRAIN COCKS

These must be located in accessible positions to facilitate draining of the appliance and all water pipes connected to the appliance.

3A.6.4 AIR RELEASE POINTS

These must be positioned at the highest points in the system where air is likely to be trapped. They should be used to expel trapped air and allow complete filling of the system.

3A.6.5 EXPANSION VESSEL

3A.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. has been provided. You should ensure this method of filling complies with the local water authority regulations.

3A.6.7 LOW PRESSURE SEALED SYSTEM

3A.6.8 FREQUENT FILLING

3A.7 ELECTRICAL SUPPLY

3A.8 SHOWERS

If the appliance is intended for use with a shower, the shower must be thermostatically controlled and be suitable for use with a combination boiler.

3A.9 MOUNTING ON A COMBUSTIBLE SURFACE

If the appliance is to be fitted on a wall of combustible material, a sheet of fireproof material must protect the wall.

3A.10 TIMBER FRAMED BUILDINGS

If the appliance is to be fitted in a timber framed building, it should be fitted in accordance with I.S. 813 and local Building Regulations.

The Institute of Gas Engineers publication (IGE/ UP/7) ‘Guide for Gas Installations in Timber Frame Buildings’ gives specific advice on this type of installation.

3A.11 INHIBITORS

Vokera recommend that a neutral inhibitor is used to protect the heating system from the effects of corrosion and/or electrolytic action.The inhibitor must be administered in strict accordance with the manufacturers* instructions.

*Fernox and Sentinel manufacture products that have proved suitable for use with Vokera appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our appliances.

3A.12 DECLARATION OF CONFORMITY

A Declaration of Conformity (as defined in I.S.

813) must be provided on completion of the installation.

A copy of the declaration must be given to the responsible person and also to the gas supplier if required.

Compact

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SECTION 4 INSTALLATION

4.1 DELIVERY

The appliance is delivered in a heavy-duty cardboard carton. Lay the carton on the floor with the writing the correct way up.

4.2 CONTENTS

Contained within the carton is:

● the boiler

● the wall mounting bracket

● an accessories pack containing service valves

and sealing washers

● the instructions pack containing installation &

servicing instructions, appliance logbook, user instructions, guarantee registration card, 3 amp fuse and flue restrictor ring.

4.3 UNPACKING

At the top of the carton pull both sides open – do not use a knife – unfold the rest of the carton from around the appliance, carefully remove all protective packaging from the appliance, and lay the accessories etc. to one side. Protective gloves should be used to lift the appliance, the appliance back-frame should be used for lifting points.

4.4 PREPARATION FOR MOUNTING THE APPLIANCE

The appliance should be mounted on a smooth, non-combustible, 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 wall bracket (fig. 7) and flue-hole (if applicable).

4.4.1 IMPORTANT There are three hole types set out on the appliance template:

● type 1 should be used in conjunction with

the telescopic flue kits (part no. 0225705 &

0225710)

● type 2 should be used in conjunction with

standard horizontal flue kit (part no.

2359029)

● type 3 should be used in conjunction with

the telescopic rear flue kits (part no. 0225905 & 0225910).

4.4.2 FLUE RESTRICTOR RING

To ensure maximum efficiency of the appliance, it may be necessary to fit one of the supplied flue restrictor rings to the appliance flue outlet.

4.5 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.

4.5.1 CONCENTRIC HORIZONTAL FLUE

(For concentric vertical flue, see section 4.5.2). (For twin flue applications, see section 4.5.3).

Compact 24

Total flue length Restrictor required

Less than 0.85 metre Less than 2 metre Less than 3 metre Less than 4.25 metre

42 mm diameter 44 mm diameter 46 mm diameter Not installed

Compact 28

Total flue length Restrictor required

Less than 0.85 metre Less than 1.70 metre Less than 2.70 metre Less than 3.40 metre

45 mm diameter 47 mm diameter 49 mm diameter Not installed

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 section 4.4.2), 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.

Bend Reduction in maximum flue length for each bend

45º bend 0.5 metre 90º bend 0.85 metre

Horizontal flue terminals and accessories

Part No. Description Min-Max Length

0225705 Standard telescopic flue 380 mm – 600 mm

(Dimension ‘X’)

0225710 Extended telescopic flue 600 mm – 920 mm

(Dimension ‘X’)

2359029 Horizontal flue kit

For use with add. Bends 833 mm

& extensions (dimension ‘X’) 2359069 750 mm extension 750 mm 2359079 1500 mm extension 1500 mm 2359049 45º bend (pair) N/A 2359059 90º bend N/A 0225760 Wall bracket (5) N/A

Using the template provided (see section 4.4.1), mark and drill a 125 mm 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 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.

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type 1= centre of rear flue hole

using only 0225705 or 0225710 flue

type 2= centre of rear flue hole

for use with 2359029

type 3= for rear flue only

Fig. 7

FITTING THE TELESCOPIC FLUE KIT (0225705 & 0225710)

Total flue length Restrictor required

Compact 24 Compact 28

Less than 1 metre

40 mm diameter 42 mm diameter

Carefully measure the distance from the centre of the appliance flue outlet to the face of the outside wall (dimension ‘X’, fig. 8). Add 50 mm 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 restrictor ring (supplied in the instruction pack) into the appliance flue gas outlet. Slide 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 (115 mm).

115 mm

FITTING THE STANDARD (2359029) HORIZONTAL FLUE KIT (see section 4.4.1)

Carefully measure the distance from the centre of the appliance flue outlet to the face of the outside wall (dimension ‘X’, fig. 8A). Ensure the inner (60 mm) pipe is fully inserted into the outer (100 mm) pipe (when the inner pipe is fully inserted, it stands proud of the outer pipe by 7.5 mm). Add 32 mm to dimension ‘X’ to give the overall flue length (dimension ‘Y’). The standard horizontal flue kit (part no. 2359029) is suitable for a distance (dimension ‘Y’) of up to 865 mm.

NOTE

Dimension ‘Y’ is measured from the end of the terminal to the end of the outer (100 mm) pipe. The internal trim should be fitted to the flue pipe before connection of the 90º bend. Insert the flue restrictor ring (supplied with instruction pack) into the appliance flue gas outlet if the total flue length is less than 1.0 metre. If the horizontal flue kit (2359029) requires to be cut to the correct size (dimension ‘Y’), you must ensure that the inner (60 mm) pipe stands proud of the outer (100 mm) pipe by 7.5 mm (fig. 8B). Ensure any burrs are filed or removed and that any seals are located properly before assembly.

Connect the inner (60 mm) 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 (135 mm).

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 exterior trim can now be fitted.

Dimension “Y”

110

7,5

Max 833 mm

Dimension “X”

135 mm

Fig. 8A

“X” + 50 mm = “Y”

Fig. 8

NOTE

EXTENDING THE HORIZONTAL FLUE

If the horizontal flue requires extension/s or additional bend/s, the standard horizontal flue terminal (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 (fig. 8A & 8B).

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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 (60 mm) pipe is 7.5 mm longer than outer (100 mm) pipe (fig. 8A & 8B). 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.

Push-fit connection

Extension

7,5 mm

Boiler

4.5.2 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 section 4.4.2), however if additional bends are fitted, a reduction must be made to the maximum flue length (see table below).

Compact 24

Total flue length Restrictor required

Less than 1.5 metre Less than 2.5 metre Less than 3.5 metre Less than 5 metre

42 mm diameter 44 mm diameter 46 mm diameter Not installed

Fig. 8B

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.

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. Insert the flue restrictor ring into the appliance flue outlet, in accordance with the table in section 4.4.2.

Connect the vertical flue assembly to the boiler flue spigot using the 60 mm & 100 mm 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 (fig. 8B).

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 (60 mm) pipe is 7.5 mm longer than outer (100 mm) pipe (fig. 8B). Remove any burrs, and check that any seals are located properly.

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

300 mm

min.

465 mm

Compact 28

Total flue length Restrictor required

Less than 1.5 metre Less than 2.4 metre Less than 3.4 metre Less than 4.2 metre

Bend Reduction in maximum flue length for each bend

45º bend 0.5 metre 90º bend 0.85 metre

Vertical flue terminal and accessories

Part No. Description Length

2359039 Vertical flue terminal 1.0 metre 0225770 Pitched roof flashing plate N/A 0225765 Flat roof flashing plate N/A 2359069 750 mm extension 750 mm 2359079 1500 mm extension 1500 mm 2359049 45º bend (pair) N/A 2359059 90º bend N/A 0225760 Wall bracket (5) N/A

45 mm diameter 47 mm diameter 49 mm diameter Not installed

Using the dimensions given in fig. 9 as a reference, mark and cut a 105 mm hole in the ceiling and/or roof.

Fig. 9

150 mm

4.5.3 TWIN FLUE SYSTEM

Compact 24

Total flue length (air = fumes) Restrictor required

Less than 4.5 + 4.5 Less than 10.5 + 10.5 Less than 14 + 14

42 mm diameter 44 mm diameter 46 mm diameter

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Compact 28

Total flue length Restrictor required

Less than 4 + 4 Less than 8 + 8 Less than 12.5 + 12.5 Less than 14 + 14

45 mm diameter 47 mm diameter 49 mm diameter Not required

Compact 24

restrictor ring

The Vokera twin flue system enables greater flue distances to be achieved (see section 2.8) 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 forms in the flue system to 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.

● Extreme care must be taken to ensure that no

debris is allowed to enter the flue system at any time.

● As the exhaust outlet pipe can reach very high

temperatures it must be protected to prevent persons touching the hot surface.

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 for Compact 24 N/A 2359249 Twin adapter kit for Compact 28 N/A 0225770 Pitched roof flashing plate N/A 0225765 Flat roof flashing plate N/A 0225815 Condensate drain kit N/A 0225820 0.25 m extension (pair) 250 mm 0225825 0.5 m extension (pair) 500 mm 0225830 1.0 m extension (pair) 1000 mm 0225835 2.0 m extension (pair) 2000 mm 0225840 45º bend (pair) N/A 0225845 90º bend (pair) N/A 0225850 Twin bracket (5) N/A 0225855 Single bracket (5) N/A

MOUNTING THE BOILER

The fixing holes for the wall-mounting bracket 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.

4.5.3.1 INSTALLATION OF TWIN ADAPTOR KIT (fig. 10 &

10A)

● Insert the exhaust connection manifold (B) onto

the appliance flue outlet and secure to the flue spigot using the screws provided.

● Insert the silicone seal into the exhaust outlet.

● Remove the blanking plates (located to the left

of the appliance flue outlet) and – using the same screws – install the air baffle (A).

flue outlet

air inlet

Fig. 10

Compact 28

restrictor ring

flue outlet

air inlet

Fig. 10A

4.5.3.2 INST ALLA TION OF CONDENSA TE DRAIN KIT (fig. 10B)

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 3 mm 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 50 mm 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.

Condensate drain kit

Fig. 10B

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4.5.3.3 HORIZONTAL TERMINATION (fig. 11)

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.

● A 130 mm 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. Mark and drill a 130 mm hole for the passage of the horizontal flue terminal, ensuring that there is a 1º fall back to the boiler (17 mm per 1000 mm). Insert the terminal assembly into the flue hole. Push-fit the twin flue pipes onto the concentric to twin converter box 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.

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 sockets of the concentric to twin converter.

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.

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 50 mm onto the male spigots of the concentric to twin converter.

• 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 (17 mm per 1000 mm).

• 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.

convertor box

condensate trap

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.

4.5.3.4 VERTICAL TERMINATION (fig. 12)

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

● The vertical terminal is supplied with a built-in

converter box and cannot be shortened.

● A 130 mm 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. Push-fit the twin flue pipes onto the concentric to twin converter ensuring that the exhaust pipe

convertor box

Fig. 11

condensate trap

Fig. 12

4.6 CONNECTING THE GAS AND WATER

The appliance is supplied with an accessories pack that contains large and small sealing washers, service valves, and pipe connections. The service valves are of the compression type, the pipe connections have plain copper ends. When connecting pipework to the valves or connections, tighten the compression end first, then insert the sealing washers before tightening the valve or connection to the appliance. It will be necessary to hold the valve or connection with one spanner whilst tightening with another.

4.6.1 GAS (fig. 6)

The appliance is supplied with a 15 mm service valve, connect a 15 mm pipe to the inlet of the valve, and tighten both nuts.

NOTE

It will be necessary to calculate the diameter of the gas pipe to ensure the appliance has an adequate supply of gas.

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4.6.2 FLOW & RETURN (fig. 6)

The appliance is supplied with 22 mm service valves for the heating connections, connect 22 mm pipe to the inlet of each valve and tighten both nuts.

4.6.3 SAFETY VALVE (fig. 6)

The appliance is supplied with a 15 mm compression coupling. Connect a 15 mm pipe to the coupling and tighten. It may be necessary to fit a non-return valve if the installation is subject to mains knock, in order to eliminate false activation of the domestic hot water flow switch.

4.6.4 COLD WATER INLET (fig. 6)

The appliance is supplied with a 15mm stopcock, connect a 15mm service pipe to the inlet of the service valve and tighten both nuts. It may be necessary to fit a pressure reducing valve if the installation is subject high-pressure fluctuations or high pressure surges.

4.6.5 HOT WATER OUTLET (fig. 6)

The appliance is supplied with a 15 mm copper tail, connect a 15 mm pipe and suitable coupling to the tail and tighten. The discharge pipe must have a continuos fall away from the boiler to outside and allow any water to drain away thereby eliminating the possibility of freezing. The discharge pipe must terminate in a position where any water – possibly boiling – discharges safely without causing damage or injury, but is still visible.

4.7 ELECTRICAL CONNECTIONS

The electrical supply must be as specified in 3.7/

3.7A. the appliance is supplied, pre-wired with a

1.0 metre length of flex, connect the wires as follows:

● connect the Brown wire to the L (Live) terminal

of the plug or fused isolator

● connect the Blue wire to the N (Neutral) terminal

of the plug or fused isolator

● connect the Green/Yellow wire to the E (Earth)

terminal of the plug or isolator

● ensure the plug or fused isolator is fitted with a

3 amp fuse.

If this method of connection is unsuitable, please refer to section 8. A qualified electrician should connect the electrical supply to the appliance. The electrical supply must be as specified in section 3.7/3.7A. A qualified electrician should connect the electrical supply to the appliance. If controls – external to the appliance – are required, a competent person must undertake the design of any external electrical circuits, please refer to section 8 for detailed instructions. ANY EXTERNAL CONTROL OR WIRING MUST BE SERVED FROM THE SAME ISOLATOR AS THAT OF THE APPLIANCE. The supply cable from the isolator to the appliance must be 3-core flexible sized 0.75mm to BS 6500. Wiring to the appliance must be rated for operation in contact with surfaces up to 90 ºC.

4.7.1 CASING REMOV AL

To gain access to the appliance electrical connections you must first remove the casing, proceed as follows:

● Locate and remove the 3 screws that secure

the outer casing to the appliance (fig 13).

● Gently pull one side of the casing then the other

to disengage it from the retaining clips.

● Lift the casing upward to disengage it from the

top locating hooks and then remove.

● Store the casing and screws safely until

required. Re-fit in the reverse order.

Control panel screws and casing screws

Fig. 13

4.7.2 ELECTRICAL CONNECTION

The appliance terminal strip is located behind the control fascia (fig. 14).

NOTE

If it is anticipated that external controls will be required please refer to the wiring diagrams in section 8 for more detailed information.

Fig. 14

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4.7.3 CONNECTING THE MAINS (230V) INPUT (fig.

14)

The appliance comes with a factory fitted main electrical supply cable. If it’s necessary to change the main electrical cable, proceed as follow.

Open the terminal strip cover. Pass the cable through the cable anchorage. Connect the supply cable wires (earth, live, and neutral) to their corresponding terminals on the terminal strip. Ensure that the EARTH wire is left slightly longer that the others, this will prevent strain on the EARTH wire should the cable become taut.

The securing screw on the cable anchorage should now be tightened. This must be done before the control fascia is re-fitted in the upright position. The terminal strip cover can now be refitted.

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SECTION 5 COMMISSIONING

5.1 GAS SUPPLY INSTALLATION

Inspect the entire installation including the gas meter, test for soundness and purge.

5.2 THE HEATING SYSTEM

The appliance contains components that may become damaged or rendered inoperable by oils and/or debris that are residual from the installation of the system, consequently it is essential that the appliance is flushed in accordance with the following instructions.

5.3 INITIAL FILLING OF THE SYSTEM

Ensure both flow and return service valves are open, remove appliance casing as described in section 4.7.1, identify the automatic air release valve, and loosen the dust cap by turning cap anti-clockwise one full turn. IMPORTANT, THERE ARE NO MANUAL AIR RELEASE VALVES LOCATED ON THE APPLIANCE. Ensure all manual air release valves located on the heating system are closed. Using the method of filling as described in fig. 5, slowly proceed to fill the system, as water enters the system the pressure gauge will begin to rise, once the gauge has reached 1 bar close the filling valve and begin venting all manual air release valves, starting at the lowest first. It may be necessary to go back and top-up the pressure until the entire system has been filled. Inspect the system for water soundness, rectifying any leaks.

5.4 INITIAL FLUSHING

The whole of the heating system must be flushed both cold and hot as detailed in section 5.9. 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 section 5.3.

5.5 FILLING THE HOT WATER SYSTEM

Close all hot water outlets, turn appliance stopcock on (anti-clockwise), slowly open each outlet until all air has been expelled and clear water is discharged. Check pipe-work etc. for water soundness.

5.6 PRE-OPERATION CHECKS

Before attempting the initial lighting of the appliance, the following checks must be carried out:

● Ensure all gas service valves from the meter to

the appliance are open and the supply pipe has been properly purged.

● Ensure the proper electrical checks have been

carried out (section 7.11), particularly continuity, polarity and resistance to earth.

● Ensure the 3-amp fuse – supplied with the

appliance – has been fitted.

● Ensure the system has been filled, aired, and

the pressure set to 1bar.

● Ensure the flue has been fitted properly and in

accordance with the instructions.

● Ensure all appliance service valves are open.

5.7 INITIAL LIGHTING

Ensure the electrical supply to the appliance is switched on. Switch the time clock or programmer to an ‘on’ position and ensure all external controls are also calling for heat. The appliance will now operate in as described in section 1.2. Should the appliance fail to ignite, refer to section 5.6 and/or section 7 (fault finding).

5.8 CHECKING BURNER PRESSURES

Although burner pressures are set at the factory, it is necessary to check them during the commissioning procedure. Isolate the appliance from the electrical supply and remove the casing as described in section 4.7.1. After attaching a manometer to the outlet test point of the gas valve (fig. 23), restore the electrical supply to the appliance, turn the selector to hot water only (summer position), and rotate the DHW temperature selector to maximum.

Maximum burner pressure

Fully open a hot water outlet – preferably the bath tap – and check that reading on the manometer corresponds to the data given in section 2.3.

Minimum burner pressure

After checking the maximum burner pressure, remove one of the black wires from the modulating coil on the gas valve. The burner pressure will drop to the minimum setting. Check that the reading on the manometer corresponds with the data given in section 2.3. Once the gas pressures have been checked:

●

isolate the appliance from the electrical supply

●

close the hot water outlet

●

remove the manometer from the outlet test point and tighten the test point screw

●

refit the appliance casing.

Should either the maximum or minimum burner pressure require to be adjusted, refer to section

7.6 for the correct adjustment procedure.

Fig. 15

Maximum pressure adjustment screw (a)

Gas pressure adjustment protective cover

Minimum pressure adjustment screw (b)

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5.9 FINAL FLUSHING OF THE HEATING SYSTEM

The system shall be flushed in accordance with BS 7593. If a cleanser is to be used, it shall be from a reputable manufacturer* and shall be administered in strict accordance with the manufacturers instructions. *Both Sentinel and Fernox manufacture products that have proved suitable for use with Vokera appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our appliances.

5.9.1 INHIBITORS

See section 3 “General requirements”.

5.10 SETTING THE FLOW TEMPERATURE

The heating flow temperature selector can be adjusted from a minimum of 40 °C, to a maximum of 82 °C. In addition, when the selector is rotated to the Auto position, the appliance will automatically adjust the outlet flow temperature to compensate for inclement weather

Flow temperature selection Sector Range

Low sector Auto sector High sector

*When the selector is left within this range, the appliance will automatically raise the outlet temperature during cold or inclement weather conditions

40° - 50°C 55° - 65°C* 65° - 82°C

5.11 SETTING THE SYSTEM DESIGN PRESSURE

The design pressure should be I minimum of 1 bar and a maximum of 1.5 bar. The actual reading should ideally be 1 bar plus the equivalent height in metres to the highest point in 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 3 bar/ 30m/ 45psig. To lower the system pressure to the required value, pull lever on head of safety valve to release water until the required figure registers on the pressure gauge (fig.1).

5.12 REGULATING THE CENTRAL HEATING SYSTEM

Fully open all radiator and circuit valves and run the appliance in the central heating mode until heated water is circulating. If conditions are warm remove any thermostatic valve heads. Adjust radiator return valves and any branch circuit return valves until the individual return temperatures are correct and are approximately equal.

stopcock should be used to limit the available flow rate at the outlet. Slowly turn the adjustable stopcock clockwise until a satisfactory temperature is obtained. Please note that it’s prudent to set the domestic hot water outlet temperature at the lowest acceptable temperature, as higher temperatures can be realised by reducing the flow rate at the individual hot water outlets.

NOTE

The appliance will light to provide hot water when the domestic hot water flow switch senses a flow rate of 2.0 litres –per minute – or more.

5.14 FINAL CHECKS

● ENSURE ALL TEST NIPPLES ON THE

APPLIANCE GAS VALVE ARE TIGHT AND HAVE BEEN CHECKED FOR SOUNDNESS.

● ENSURE THE APPLIANCE FLUE SYSTEM IS

FITTED CORRECTLY AND IS PROPERLY SECURED.

● ENSURE ALL PIPE WORK IS RE-CHECKED

FOR SOUNDNESS.

● RE-FIT APPLIANCE CASING.

● COMPLETE APPLIANCE LOGBOOK.

Complete details of the boiler, controls, installation, and commissioning in the logbook supplied with the boiler. This is an important document, which must be correctly completed and handed to the user. Failure to install and commission the appliance to the manufacturers instructions may invalidate the warranty.

5.15 INSTRUCTING THE USER

Hand over all documentation supplied with this appliance – including these instructions – and explain the importance of keeping them in a safe place.

Explain to the user how to isolate the appliance from the gas, water, and electricity supplies, and the locations of all drain points.

Show the user how to operate the appliance and Show the user the position of the filling valve and

how to top-up the system pressure correctly, and show the location of all manual air release points.

Explain to the user how to turn off the appliance for both long and short periods, and advise on the necessary precautions to prevent frost damage.

Explain to the user that for continued safe and efficient operation, the appliance must be serviced annually by a competent person.

5.13 REGULATING THE DOMESTIC HOT WATER

The appliance is supplied with a built-in flow restrictor that limits the amount of water passing through the heat exchanger, thereby ensuring a reasonable temperature at the outlet. The outlet temperature can also be adjusted via the DHW temperature selector. If the required outlet temperature cannot be obtained by rotating the DHW temperature selector to its maximum setting, the adjustable

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SECTION 6 SERVICING INSTRUCTIONS

6.1 GENERAL

To ensure the continued safe and efficient operation of the appliance, it is recommended that it is checked and serviced at regular intervals.

The frequency of servicing will depend upon the particular installation conditions, but in general, once per year should be adequate.

It is the law that any servicing work is carried out by competent person such as a Vokera engineer, an approved service agent, British Gas, or other CORGI registered personnel.

The following instructions apply to the appliance and its controls, but it should be remembered that the central heating system will also require attention from time to time.

Always use genuine Vokera spare parts

6.2 ROUTINE ANNUAL SERVICING

Check the operation of the appliance in both ‘hot water only’ and ‘heating and hot water’ modes. Ensure the appliance functions as described in section 7. Compare the performance of the appliance with its design specification. The cause of any noticeable deterioration should be identified and rectified without delay.

Thoroughly inspect the appliance for signs of damage or deterioration especially the flue system and the electrical apparatus.

Check and adjust – if necessary – all burner pressure settings (see section 7.6).

Check and adjust – if necessary – the system design pressure (see section 5.11).

Carry out an analysis of the flue gases (see section 7.7), and visually check the condition of the entire flue assembly. Compare the results with the appliance design specification. Any deterioration in performance must be identified and rectified without delay.

Ensure both flue venturis are clean and free from any debris or obstruction.

Ensure both the burner and heat exchanger are clean and free from any debris or obstruction.

Inspect all joints for signs of leakage and repair if necessary.

Refer to the commissioning section and/or replacement of parts section for detailed instruction if required.

6.3 REPLACEMENT OF COMPONENTS

Although it is anticipated that this appliance will give years of reliable, trouble free service, the life span of components will be determined by factors such as operating conditions and usage. Should the appliance develop a fault, the fault finding section will assist in determining which component is malfunctioning.

the hot water performance. The heat exchanger can be de-scaled using a proprietary de-scalant without having to remove it from the appliance. However the appliance must be disconnected from the hot and cold service pipes, the descalant should be administered with strict adherence to the manufacturers instructions. Reconnect the hot and cold services only after thorough flushing with clean water has taken place.

6.5 COMPONENT REMOVAL PROCEDURE

To remove a component, access to the interior of the appliance is essential. Isolate the appliance from the electrical supply and remove the fuse. And when necessary, close all service valves on the appliance, remove the appliance casing as described in section 4.7.1, drain the primary water content from the appliance via the safety valve, and drain off secondary water content from the appliance via a hot water outlet. Ensure some water absorbent cloths are available to catch any residual water that may drip from the appliance or removed component. Undertake a complete commissioning check as detailed in section 5, after replacing any component. ALWAYS TEST FOR GAS SOUNDNESS IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED OR DISTURBED.

6.6 PUMP HEAD fig. 16

Carry out component removal procedure as described in section 6.5. Using a 4 mm Allen key or ‘T’ bar, unscrew and remove the four Allen screws that hold the pump in position, pull firmly on the pump head to release it from the base. Disconnect the electrical leads. Replace in the reverse order.

6.7 SAFETY VALVE fig. 16

Carry out component removal procedure as described in 6.5. Disconnect the outlet pipe from the safety valve, unscrew and remove the hex bush from the safety valve outlet, remove safety valve locking pin from appliance manifold. Replace in the reverse order

Pump

6.4 MAIN HEAT EXCHANGER (de-scaling)

The main heat exchanger may – when operating under certain conditions – become affected by scaling. Evidence of this will be a deterioration of

Safety valve

Fig. 16

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6.8 AUTOMATIC AIR RELEASE VALVE (AAV, fig.

17)

Carry out component removal procedure as described in 6.5. Remove the locking pins at the pump outlet, and the flow & return connection of the heat exchanger, disconnect both pipes from the heat exchanger, and remove the return pipe from the pump outlet. Remove the locking pin and expansion pipe from the pump base. Using a suitable pair of pliers, unscrew the AAV from the pump base. Replace in the reverse order.

AAV

Fig. 17

6.9 WATER PRESSURE SWITCH fig. 18

Carry out component removal procedure as described in 6.5. Remove locking pin from heating flow pipe at the heating manifold and withdraw the pipe from the manifold. Remove locking pin and the water pressure switch from the heating manifold, pull back protective cover – and after taking note of the electrical connections – disconnect the wiring. Replace in the reverse order.

Fig. 19

6.11 PRESSURE GAUGE (fig. 1)

Carry out component removal procedure as described in 6.5. Remove pressure gauge locking pin, located on pump base, and withdraw the pressure gauge pipe, locate the spring tabs on the pressure gauge body, push and hold tabs in, to enable extraction of the gauge from its location. Replace in the reverse order.

6.12 PRIMARY AND SECONDARY THERMISTORS (fig. 20-21)

Carry out component removal procedure as described in 6.5. Pull back protective rubber cover from the thermistor, disconnect thermistor electrical plug, using a 13 mm spanner slacken and remove the thermistor and sealing washer. Replace in the reverse order.

primary thermistor

WATER PRESSURE

SWITCH

Fig. 18

6.10 DOMESTIC WATER FLOW SWITCH fig. 19

Carry out component removal procedure as described in 6.5. Remove black electrical plug from the domestic water flow switch, disconnect and remove inlet pipe between the domestic water flow switch and the heat exchanger, remove locking pin from the domestic water flow switch, the switch can now be removed from the appliance. Replace in the reverse order.

high limit thermostat

Fig. 20

6.13 HIGH LIMIT THERMOSTAT fig. 20

Carry out component removal procedure as described in 6.5. Pull off electrical plug from the high limit thermostat, slacken and remove retaining screws. Replace in reverse order.

secondary thermistor

Fig. 21

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Page 22

6.14 PRINTED CIRCUIT BOARD (PCB, fig. 22)

Carry out component removal procedure as described in section 6.5. Remove the PCB cover, after carefully taking note off all wiring connections, disconnect all wiring from the PCB, locate and remove the PCB securing screws, remove PCB. Replace in the reverse order.

Fig. 22

6.15 INTEGRAL TIME SWITCH (fig. 22A)

Carry out component removal procedure as described in 6.5. Remove the PCB cover, locate and remove the time clock retaining screws, remove time clock after carefully taking note off all wiring connections. Replace in the reverse order.

CLK-1 CLK-4

Fig. 23

6.17 BURNER, INJECTORS AND SPARK/SENSE ELECTRODE (fig. 24 & 25)

Carry out component removal procedure as described in 6.5. Remove outer combustion cover by un-clipping the two retaining clips located at the base of the combustion cover, gently pull the cover towards you before lifting and disengaging it from the top retaining lugs. Locate and remove the two screws at the base of the inner combustion cover, pull the cover towards you before lifting and disengaging it from the top retaining lugs. Disconnect both the electrode lead from its connector at the top of the control fascia, and the electrode earth lead from the spade connector on the appliance frame. Locate and remove the four screws which secure the burner in position, gently ease the burner out of its location whilst also easing the electrode sealing grommet from its location. Once the burner has been removed, locate the burner injectors – located to the rear of the combustion chamber – and remove. Replace in the reverse order. Please note, the injector sealing washers must be replaced if the injectors have been removed, ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.16 GAS VALVE fig. 23

Carry out component removal procedure as described in section 6.5. The gas valve must be changed as complete unit. Disconnect both electrical plugs from the gas valve, disconnect silicone tube from gas valve regulator, slacken and unscrew gas valve inlet and outlet connections, please note, the sealing washers must be discarded and replaced with new sealing washers, locate and remove gas valve retaining screws on the underside of the boiler, the gas valve can now be removed. Replace in the reverse order. Check and adjust burner pressure settings. WARNING, A GAS SOUNDNESS CHECK MUST BE CARRIED OUT.

Fig. 22A

Fig. 24

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Page 23

Fig. 25

Fig. 26

Fig. 27

6.18 FLUE FAN (fig. 24 & 28)

Carry out component removal procedure as described in section 6.5. Remove outer combustion cover by un-clipping the two retaining clips located at the base of the combustion cover, gently pull the cover towards you before lifting and disengaging it from the top retaining lugs. Disconnect the electrical connections and silicone tubes attached to the fan, noting their positions. Locate and remove the combustion test point screws and the cross head screw which retains the combustion analysis test point assembly, push the test point into the fan housing, locate and remove the three screws which secure the fan to the flue hood, ease the fan from its location. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

Fig. 28

6.19 HEAT EXCHANGER fig. 24 & 26

Carry out component removal procedure as described in 6.5. Remove outer combustion cover by un-clipping the two retaining clips located at the base of the combustion cover, gently pull the cover towards you before lifting and disengaging it from the top retaining lugs. Locate and remove the two screws at the base of the inner combustion cover, pull the cover towards you before lifting and disengaging it from the top retaining lugs. Remove locking pins and disconnect the hoses, from the flow and return connections on the heat exchanger. Disconnect the hot and cold connections on the heat exchanger. Disconnect the electrical plugs from the primary thermistor and high limit thermostat at the heat exchanger, the heat exchanger can now be withdrawn from the appliance. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.20 AIR PRESSURE SWITCH (fig. 1, 24 & 28)

Carry out component removal procedure as described in section 6.5. Remove outer combustion cover by un-clipping the two retaining clips located at the base of the combustion cover, gently pull the cover towards you before lifting and disengaging it from the top retaining lugs. Locate and remove the two screws holding the air pressure switch to the combustion chamber. Disconnect the electrical connections and silicone tubes attached to the air pressure switch, noting their positions. Take-away the wires belt. Replace in the reverse order. Replace with a new belt. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.21 EXPANSION VESSEL

Due to the compact design of this appliance, removal and/or replacement of the expansion vessel requires the appliance to be removed from the wall, if this is deemed impractical, an external expansion vessel may be fitted to the return pipe as close to the appliance as possible.

6.22 EXPANSION VESSEL (removal) fig. 1

Carry out component removal procedure as described in 6.5. Isolate gas, water and electrical supplies from the appliance. Disconnect and remove the electrical supply cable from the appliance. Disconnect all service valves and connections from the appliance. Disconnect the flue from the appliance. The appliance can now be lifted from its mounting bracket. Lay the appliance on its side and disconnect the expansion pipe from the vessel, slacken and remove the locknut that secures the lower part of the vessel to the appliance frame. Locate and remove the six screws that secure the vessel top holding plate, remove the plate. The expansion vessel can now be removed. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly. GAS AND WATER SOUNDNESS CHECKS MUST BE CARRIED OUT.

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Page 24

SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING

7.1 CHECKING APPLIANCE OPERATION

When carrying out any repairs or servicing to the appliance the relevant commissioning procedure must be undertaken to ensure the continued safe operation of the appliance. Particular attention should be made to ensure gas soundness, water soundness, and the electrical integrity of the appliance.

7.2 AT REST MODE

When the appliance is at rest, (no demand for heat or water) the green LED will be illuminated to indicate there are no faults, if the appliance has been inactive for aproximately 24 hours, it will energise the pump for a short period to ensure the pump does not seize due to inactivity. The appliance also has built-in frost protection, which will operate even if the mode selector switch is in the ‘off’ position.

7.3 HOT WATER MODE

Opening a hot water outlet and enabling a flow rate of 2 litres or more, causes the domestic water flow switch to activate. Activation of the domestic hot water flow switch allows the fan to run. When the fan is running it proves (switches) the air pressure switch. The air pressure switch delivers current to the PCB and enables an ignition sequence to begin. The ignition sequence begins with the energising of the gas valve and a simultaneous sparking at the spark/sense electrode. This will continue for aproximately 10 seconds or until successful ignition has been established. (If no ignition has been established within the ten seconds, the ignition attempt will be terminated and the appliance will go to lockout). When ignition has been established, the appliance will quickly achieve and maintain the desired hot water temperature (see 5.13). The appliance monitors the setting of the hot water potentiometer against the temperature of the secondary thermistor, and increases or decreases current to the modulating coil, this in turn adjusts the burner pressure, thus enabling the temperature to be maintained to within a few degrees. When the temperature of the secondary thermistor exceeds the setting of the hot water potentiometer, ignition will be terminated until the temperature drops.

NOTE

The primary thermistor will overide the secondary thermistor if the temperature of the primary thermistor exceeds 80 ºC. When the mode selector switch is set to heating and hot water, the pump will over-run for 30 seconds after any demand for heating or water has been satisfied. When the mode selector switch is set to hot water only, the fan will over-run for one minute if the temperature of the primary thermistor exceeds 55 ºC.

7.4 HEATING MODE

With all controls calling for heat, the pump and fan will run. When the fan runs it proves the air

pressure switch. The air pressure switch delivers current to the PCB and enables an ignition sequence to begin. The ignition sequence begins with the energising of the gas valve and a simultaneous sparking at the spark/sense electrode. This will continue for approximately 10 seconds or until successful ignition has been established. (If no ignition has been established within the ten seconds, the ignition attempt will be terminated and the appliance will go to lockout). The appliance monitors the setting of the heating potentiometer against the temperature of the primary thermistor, and increases or decreases current to the modulating coil, this in turn adjusts the burner pressure, thus enabling the temperature to be maintained to within a few degrees (see section 5.10). When the temperature of the primary thermistor exceeds the setting of the heating potentiometer, ignition will be terminated and the appliance will anti-cycle for three minutes (timer delay). When a new ignition sequence begins the output of the appliance is set at minimum for two minutes.

NOTE

Any demand for hot water has the priority. If there is a demand for hot water whilst the appliance is anti-cycling, the timing will be cancelled once the demand for hot water has been satisfied.

7.5 FROST PROTECTION MODE

The built-in frost protection system will operate the appliance in the OFF, HOT WATER ONLY MODE, AND HEATING AND HOT WATER MODE. Should the temperature of the appliance fall to 7 ºC. the pump will run for fifteen minutes, this will be repeated every two hours. Should the temperature rise above 10 ºC. the fifteen minutes will be cancelled. Should the temperature fall below 5 ºC. the boiler will fire at minimum output until the temperature of the appliance exceeds 30 ºC.

NOTE

If the appliance is at lockout the frost protection mode is disabled. Although the frost protection mode is active even when the appliance is switched off. The electrical supply to the appliance must be maintained for it to function. Any demand for hot water or heating will reset any frost protection settings.

7.6 BURNER PRESSURE SETTINGS

Burner pressure settings should be checked and/ or adjusted whenever the appliance is being serviced, commissioned, or the gas valve/control PCB have been replaced. The procedure for setting or adjusting must be carried out in the following order:

● set the maximum DHW gas pressure

● set the minimum DHW gas pressure

● set the maximum heating gas pressure

● set the minimum heating gas pressure.

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Page 25

7.6.1 SETTING THE MAXIMUM DHW GAS PRESSURE (fig. 15 & 23)

Isolate the appliance from the electrical supply, remove the appliance casing as described in section 4.7.1.

● Attach a manometer to the outlet test point of

the gas valve.

● Remove the protective cover from the gas

valve modulator, and disconnect the compensation tube from the gas valve.

● Fully open a hot water outlet (preferably the

bath tap).

● Rotate the DHW temperature selector to

maximum.

● Restore the electrical supply to the appliance.

● The appliance will now light and after 7-10

seconds, the burner will be at full power.

● Observe the manometer, the reading for

Compact 24 should be 10.1 mbar, for Compact 28 the reading should be 10.2 mbar.

● If the reading is correct, proceed to section

7.6.2

● If the reading is incorrect, turn the maximum

adjustment screw (fig. 15) clockwise to increase the pressure, or anti-clockwise to reduce the pressure.

● Proceed to section 7.6.2

7.6.2 SETTING THE MINIMUM DHW GAS PRESSURE (fig. 15 & 23)

● After carrying out section7.6.1, disconnect one of

the black wires attached to the modulator coil.

● The burner will now operate at minimum power.

● Observe the manometer, the reading for

Compact 24 should be 1.5 mbar, for Compact 28 the reading should be 1.3 mbar.

● If the reading is correct, proceed to section 7.6.3.

● If the reading is incorrect, turn the minimum

adjustment screw (fig. 15) clockwise to increase the pressure, or anti-clockwise to reduce the pressure.

● Proceed to section 7.6.3

7.6.3 SETTING THE MAXIMUM AND THE MINIMUM CENTRAL HEATING BURNER PRESSURES

● Isolate the appliance from the electrical supply.

● Close the hot water outlet.

● Re-attach the black wire to the modulator coil.

● Remove the PCB cover and temporarily attach

a jumper tag to JP2.

● Rotate the heating temperature selector to

maximum, and ensure all radiators are turned on with any thermostatic radiator valves set to maximum.

● Restore the electrical supply and ensure there

is a call for heat via the appliance time clock and/or room thermostat.

● The appliance should now be operating in the

heating mode at maximum output.

● Observe the manometer, the – maximum –

reading for Compact 24 should be 10.1 mbar, for Compact 28 the reading should be 10.2 mbar

● Using a small screwdriver, gently rotate the P5

potentiometer if adjustment is necessary.

● To check and/or adjust the minimum heating

gas pressure, slowly rotate the heating temperature selector until the burner pressure drops to minimum (should be 1.9 mbar).

● Using a small screwdriver, gently rotate the P4

potentiometer if adjustment is necessary.

● Isolate the appliance from the electrical supply,

and remove the jumper tag from JP2.

● Remove the manometer from the gas valve

and tighten the outlet test screw.

● Refit the PCB cover and appliance casing.

7.7 COMBUSTION ANALYSIS TEST

The appliance has a built-in facility which enables combustion analysis checks to be carried out. To activate the combustion analysis mode, proceed as follows. Locate and remove combustion test point screw, (fig. 1) insert flue gas analyser probe into combustion test point, remove mode selector switch and rotate selector shaft clockwise until it can go no further, wait until the yellow LED begins to flash, turn the selector shaft back to the heating position. The appliance will now enter its combustion analysis mode whereby it will fire at maximum output in the heating mode for fifteen minutes, without modulating until the maximum operating temperature is realised. To gain accurate information, ensure the flue gas analyser has been set properly, and that the analysis is carried out when the appliance is on maximum output. Once the analysis has been completed, re-fit the mode selector switch, remove the flue gas analyser probe and replace the test point screw.

7.8 CHECKING THE EXPANSION VESSEL

Carry out procedure as described in section 6.5. Using a suitable pressure gauge, remove dust cap on expansion vessel and check the charge pressure. The charge pressure should be between

0.7 – 0.8 bar. If the charge pressure is less, use a suitable pump to increase the charge. Please note, you must ensure the safety valve is in the open position whilst re-charging takes place. Replace dust cap and carry out the relevant commissioning procedures as detailed in section

6.21.

7.9 ELECTRO-MECHANICAL FAULTS

Before carrying out any fault finding or component replacement, ensure the fault is not attributable to any aspect of the installation, for example, external wiring fault, hot & cold services reversed, service valves closed, gas supply turned off, etc.

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Page 26

7.10 POSSIBLE INSTALLATION FAULTS

FAULT POSSIBLE CAUSES REMEDY

APPLIANCE FIRES THEN LOCKOUTS INCORRECT GAS PRESSURE CHECK INCOMING PRESSURE

AND/OR BURNER PRESSURES

FLUE BLOCKED OR BROKEN CHECK FLUE ASSEMBLY

APPLIANCE WON’T FIRE FOR HOT WATER HOT & COLD PIPES REVERSED CHECK EXTERNAL PLUMBING

FLOW REGULATOR BLOCKED REMOVE AND CLEAN INSUFFICIENT FLOW RATE INCREASE FLOW RATE

APPLIANCE WON’T FIRE FOR HEATING EXTERNAL CONTROL OR

WIRING FAULT CHECK EXTERNAL CONTROLS OR WIRING

APPLIANCE FIRES FOR HEATING FLOW & RETURN SERVICE BUT NO CIRCULATION AROUND SYSTEM VALVES CLOSED OPEN SERVICE VALVES

AIR IN APPLIANCE OPEN DUSTCAP ON ‘AAV’ PUMP STUCK OPEN VENT PLUG ON PUMP AND

ROTATE SHAFT

DEBRIS IN SYSTEM FLUSH SYSTEM APPLIANCE INACTIVE NO ‘LED’s ELECTRICAL SUPPLY FAULT CHECK SUPPLY TO APPLIANCE SHOWING FOR 240V BETWEEN ‘L’ & ‘N’

BLOWN FUSE CHECK AND REPLACE

7.11 ELECTRICAL CHECKS

Any electrical checks must be carried out by a suitably qualified person.

7.11.1 EARTH CONTINUITY TEST

Isolate the appliance from the electrical supply, and using a suitable multi-meter carry out a resistance test. Connect test leads between an appliance earth point and the earth wire of the appliance supply cable. The resistance should be less than 1 ohm. If the resistance is greater than 1 ohm check all earth wires and connectors for continuity and integrity.

7.11.2 SHORT CIRCUIT CHECK

Isolate the appliance from the electrical supply, and using a suitable multi-meter, carry out a short circuit test between the Live & Neutral connections at the appliance terminal strip (fig. 14).

Repeat above test on the Live & Earth connections at the appliance terminal strip (fig. 14).

NOTE

Should it be found that the fuse has failed but no fault is indicated, a detailed continuity check will be required to trace the fault. A visual inspection of components may also assist in locating the fault.

7.11.3 POLARITY CHECK

With the appliance connected to the electrical supply and using a suitable multimeter, carry out the following voltage tests. Connect test leads between the Live & Neutral connections at the appliance terminal strip (fig.14); the meter should read aproximately 230V ac. If so proceed to next stage. If not, see section 7.11.4. Connect test leads between the Neutral & Earth connections at the appliance terminal strip (fig.14); the meter should read aproximately 0 – 15Vac. If so polarity is correct. If not, see section 7.11.4

7.11.4 REVERSED POLARITY OR SUPPLY FAULT

Repeat the above tests at the appliance isolator, if testing reveals correct polarity and/or supply at

the isolator, re-check wiring and connections between the isolator and the appliance. If tests on the isolator also reveal reversed polarity or a supply fault, consult the local electricity supplier for advice.

7.11.5 RESISTANCE TO EARTH CHECK

Isolate the appliance from the electrical supply, and using a suitable multi-meter carry out a resistance test. Connect test leads between the Live & Earth connections at the appliance terminal strip (fig.14). If the meter reads other than infinity there is a fault which must be isolated, carry out a detailed continuity check to identify the location of the fault.

IMPORTANT

These series of checks must be carried out before attempting any fault finding procedures on the appliance. On completion of any task which required the disconnection and re-connection of any electrical wiring or component, these checks must be repeated.

7.11.6 FUSES

The appliance is equipped with spare fuses. These fuses are located on the cover of the main PCB. If a fuse has blown it is usually indicative of an external wiring fault or a faulty component such as the pump, fan, valve actuator, etc. Under no circumstances should a blown fuse be replaced with one of a higher rating.

7.12 FAULT FINDING

BEFORE ATTEMPTING ANY FAULT DIAGNOSIS OR REPAIR THE FOLLOWING PROCEDURE SHOULD BE CARRIED OUT:

● Carry out the relevant electrical checks as

detailed in section 7.11

● Disconnect any external wiring from the room

thermostat connections of the appliance terminal strip and replace with a solid link wire.

● Ensure the appliance is protected – externally

– by a 3 amp fuse.

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Page 27

7.12.1 FAULT FINDING TEST ‘A’: CHECKING OPERATION OF ELECTRONIC CONTROL BOARD AT START UP

START

SWITCH ON BOILER AND

SELECT MODE TO

WINTER C/H

THERMOSTAT AT MAX.

YES

REST AR T THE

TEST

THERE 24dc

BETWEEN TERMINALS

CN9.1 & CN9.2

ON PCB

YES

REPLACE

CONTROL BOARD

WATER

PRESSURE SWITCH

IS OK

CHECK WIRING AND

CONNECTIONS OR

WATER PRESSURE

SWITCH

MAINS ON

PUMP CONNECTOR

CN2.1 & CN2.2

ON PCB

LOOSE THE PUMP

ACTING WITH A

SCREWDRIVER ON

THE IMPELLER

PUMP RUNNING

BETWEEN PIN

CHECK IDRAULIC

CN1.4 & CN1.5

YES

CIRCUIT

YES

REPLACE

PUMP

MAINS

ON PCB

MADE A LINK BETWEEN BLACK &

BLACK WIRES AT BOILER

TERMINAL STRIP AND CLOSE THE

YES

MAINS

ON PUMP

REPLACE WIRING

OR CONNECTIONS

CHECK &/OR

REPLACE WIRING

AND

CONNECTIONS

YES

IS ROOM

THERMOST AT

INPUT LINKED

YES

CHECK WIRING OR

CONNECTIONS BETWEEN TERMINAL STRIP AND CONTROL

BOARD

TIMER CONTACT

PUMP

RUNNING

MAINS

YES

BETWEEN TERMINALS

CN8.3 & CN8.5

CONTROL BOARD

MADE A LINK

BETWEEN THE ROOM

THERMOSTAT INPUT

REST AR T THE

ON FAN

CONNECTOR

CN4.1 & CN4.2

ON PCB

THERE 24dc

ON PCB

REPLACE

TEST

YES

FAN RUNNING

REPLACE WIRING

OR CONNECTIONS

GREEN LED

MAINS

ON FAN

BETWEEN TERMINALS

YES

AIR FLOW

SWITCH

OFF?

YES

BLINKS

YES

REPLACE FAN

THERE 0 VCC

CN8.3 & CN8.5

ON PCB

YES

REPLACE

CONTROL BOARD

REPLACE AIR FLOW SWITCH OR CHECK FLUE GAS

TUBE

Compact

Page 28

7.12.2 FAULT FINDING TEST ‘A’

END

REPLACE SENSING/SPARK ELECTRODE AND

LEAD

THERE 0 Vdc

BETWEEN TERMINALS

CN8.7 & CN8.8

ON PCB

SPARK AT

ELECTRODE

YES

IGNITION

YES

LOCKOUT

AFTER

IGNITION

YES

CHEK

SENSING/SPARK

ELECTRODE AND

LEAD

SENSING

SPARK ELECTRODE

AND LEAD

YES

REPLACE PCB

YES

REPLACE THE

CONTROL BOARD

CHECK AND/OR

REPLACE PCB

CHECK WIRING AND

CONNECTIONS OR

THERMOSTAT

THERE 230 Vac

BETWEEN TERMINALS

CN5.1 & CN5.2

ON PCB

THERE 24 Vdc

BETWEEN TERMINALS

CN8.4 & CN8.5

ON PCB

THERE 24 Vdc

BETWEEN TERMINALS

CN8.4 & CN8.8

ON PCB

HIGH LIMIT

CHECK WIRING AND

CONNECTIONS, AIR FLOW

SWITCH AND CONTROL

YES

MAINS

ON E.V.G.

YES

CHECK AND/OR

REPLACE PCB

YES

THERE 24 Vdc

BETWEEN TERMINALS

CN8.4 & CN8.7

ON PCB

YES

BOARD

CHECK/CLEAN THE

VENTURI TUBE AND

SILICONE AIR

TUBES

YES

CHECK REPLACE

AIR FLOW SWITCH

THERE 230 Vac

BETWEEN TERMINALS

CN6.1 & CN6.2

ON PCB

CHECK

SENSING/SPARK

ELECTRODE AND

LEAD

DO THE

AIR FLOW SWTCH

TURN ON

ARE THE

VENTURI TUBE

AND THE SILICONE

AIR TUBES

CLEAN

YES

THE AIR DP >

11 mmCH2O

CHECK WIRING AND

CONNECTIONS OR

HIGH LIMIT THERMOSTAT

CHECK WIRING

AND

CONNECTIONS

REPLACE EVG

EVG OK

YES

CHECK GAS

CHECK THE FAN

AND/OR FLUE GAS

TUBE

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Page 29

7.12.3 FAULT FINDING TEST ‘A1’

YES

REPLACE CONTROL

BOARD

YES

REST AR T THE

TEST

RED LED

BLINKS

YES

SWITCH ON/OFF

SELECTOR ON OFF

POSITION

SWITCH ON/OFF

SELECTOR TO

WINTER POSITION

GREEN LED

BLINKS

RED LED

LIGHT

CHECK CH NTC

SENSOR OR WIRING

AND CONNECTIONS

PRESENT BETWEEN

YES

BLUE & BROWN WIRES AT

REPLACE WIRING OR

CONNECTIONS

TERMINAL STRIP AND

CONTROL BOARD

YES

BOILER TERMINAL

YELLOW

LED

LIGHT

YES

CHIMNEY

SWEEPER CYCLE.

RESET AND

REST AR T TEST

MAINS

STRIP

YELLOW LED

BLINKS

RECHECK SUPPLY

FUSE &

CONNECTORS TO

BOILER

TERMINALS

MAINS

PRESENT BETWEEN

TERMINALS CN1.2

&CN1.3 M2.2 ON

CONTROL

BOARD

YES

CHECK FUSE F1

ON CONTROL

BOARD

YES

THERE 24 Vdc

BETWEEN TERMINALS

CN8.4 & CN8.6

ON PCB

YES

THERE 24 Vdc

BETWEEN TERMINALS

CN8.4 & CN8.5

ON PCB

CHECK WIRING AND

CONNECTIONS OR

AIR PRESSURE SWITCH

BETWEEN TERMINALS

CONTROL BOARD

THERE 24 Vdc CN8.4 & CN8.7

ON PCB

REPLACE

YES

THERE 24 Vdc

BETWEEN TERMINALS

CN8.4 & CN8.8

ON PCB

YES

CHECK WIRING AND

CONNECTIONS OR

HIGH LIMIT THERMOSTAT

YES

REPLACE

CONTROL BOARD

THERE 0 VCC

BETWEEN TERMINALS

CN9.1 & CN9.2

ON PCB

REPLACE

CONTROL BOARD

REPLACE

CONTROL BOARD

CHECK WIRING AND

CONNECTIONS, WATER

PRESSURE SWITCH AND

HYDRAULIC CIRCUIT

YES

FUSE OK

REPLACE FUSE

REST AR T THE

TEST

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Page 30

7.12.4 FAULT FINDING TEST ‘B’: CHECK CONTROL IN DHW MODE

START

SWITCH ON BOILER AND

SELECT MODE TO

SUMMER. DHW

THERMOSTAT AT MAX.

YES

THERE A

VOLTAGE >10 VDC

BETWEEN TERMINALS

CN9.7 & CN9.8

ON PCB

IS THE

RESISTENCE OF

MODULATOR COIL

ABOUT 70/80

OHM

REPLACE

MODULATOR COIL

YES

REPLACE

CONTROL BOARD

TURN ON TAP

DOES

BURNER LIGHT

YES

VOLT AGE

ACROSS TERMINALS

OF MODULATOR

COIL > 10 VDC

YES

THERE 24 Vdc

BETWEEN TERMINALS

CN9.7 & CN9.8

ON PCB

CHECK BOILER

YES

THERE 0 Vdc

BETWEEN TERMINALS

CN9.7 & CN9.8

ON PCB

CHECK WIRING AND

CONNECTIONS OR

DHW SWITCH

STARTUP: TEST A

YES

REPLACE CONTROL

BOARD

REPLACE WIRE

AND

CONNECTIONS

WAIT D.H.W.

TEMPERATURE

>40 ˚C

D.H.W.

TEMPERATURE

>40 ˚C

YES

WAIT TILL THE

VOLTAGE BETWEEN

TERMINAL CN9.3 & CN9.4

ON PCB IS < 1.2 Vdc

IS THE

VOLTAGE BETWEEN

TERMINAL CN9.3 &

CN9.4 ON PCB IS

< 1.2 Vdc

YES

SWITCH DHW

THERMOSTAT AT MIN.

BURNER AND FAN

SWITCH OFF

YES

D.H.W.

TEMPERATURE

>60 ˚C

YES

D.H.W. NTC

REPLACE D.H.W. NTC

WAIT D.H.W.

TEMPERATURE

>60 ˚C

YES

REPLACE

CONTROL BOARD

REPLACE

CONTROL BOARD

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Page 31

7.12.5 TEST ‘B’ CONT’D

SWITCH DHW

THERMOSTAT AT MAX.

WAIT D.H.W.

TEMPERATURE

< 60 ˚C

YES

BURNER AND FAN

SWITCH ON

D.H.W.

TEMPERATURE

>60 ˚C

REPLACE

CONTROL BOARD

YES

TURN OFF TAP

BURNER, FAN AND

PUMP SWITCH

OFF

DHW FLOW

SWITCH

REPLACE DHW

FLOW SWITCH

YES

END

YES

CHECK WIRING AND

CONNECTION OR

CONTROL BOARD

Compact

Page 32

7.12.6 FAULT FINDING TEST ‘C’: CHECK CONTROL IN C/H MODE

START

SWITCH ON BOILER

AND SELECT MODE

TO WINTER C/H

THERMOSTAT AT

MAX.

MADE A LINK BETWEEN

BLACK & BLACK WIRES AT

BOILER TERMINAL

STRIP AND CLOSE THE

TIMER CONTACT

ACROSS TERMINALS OF

VOLT AGE

MODULATOR COIL

>10 VDC

CONTROL BOARD

THERE A

VOLTAGE <8 VDC

BETWEEN TERMINALS

CN9.3 & CN9.4

ON PCB

REPLACE

YES

YES NO

VOLT AGE

ACROSS TERMINALS OF

MODULATOR COIL

< 8 VDC

YES

TIMER JUMPER

YES

REMOVE JUMPER

REST AR T THE

TEST

DOES

BURNER

LIGHT

YES

ACROSS TERMINALS OF

MODULATOR COIL

YES

WAIT TILL THE

VOLTAGE BETWEEN

TERMINAL CN9.3 & CN9.4

ON PCB IS < 1.2 Vdc

CHECK BOILER

ST AR TUP TEST A

SET TIMER

JUMPER ON

VOLT AGE

>10 VDC

REPLACE

CONTROL BOARD

IS THE

RESISTENCE OF

MODULATOR COIL

ABOUT 70/80

OHM

REPLACE

MODULATOR COIL

REPLACE WIRE

AND

CONNECTIONS

YES

REPLACE

CONTROL BOARD

YES

SWITCH CH

THERMOSTAT AT MIN.

REPLACE

C.H. NTC

IS THE

VOLTAGE BETWEEN

TERMINAL CN9.3 &

CN9.4 ON PCB IS

< 1.2 Vdc

D.H.W.

TEMPERATURE

>80 ˚C

YES

C.H. NTC

WAIT D.H.W.

TEMPERATURE

>80 ˚C

YES

REPLACE

CONTROL BOARD

Compact

Page 33

7.12.7 TEST ‘C’ CONT’D

THERMOSTAT AT MAX.

BURNER AND FAN

SWITCH ON

WAIT 3 MIN.

YES

BURNER AND FAN

SWITCH ON

SWITCH CH

YES

BURNER AND FAN

SWITCH OFF

REPLACE

CONTROL BOARD

YES

REPLACE

CONTROL BOARD

YES

WAIT WATER FLOW

IS WATER FLOW TEMPERATURE

>40 ˚C

TIMER JUMPER

TEMPERATURE

< 80 ˚C

WAIT W ATER FLOW

TEMPERATURE

>40 ˚C

YES

REMOVE JUMPER

REST AR T THE

TEST

OPEN THE TIMER

CONTACT

BURNER

AND FAN

SWITCH

OFF

YES

WAIT

30 SECS.

PUMP SWITCH

OFF

YES

END

REPLACE

CONTROL BOARD

REPLACE

CONTROL BOARD

IS WATER FLOW TEMPERATURE

>80 ˚C

C.H. NTC

REPLACE C.H. NTC

YES

REPLACE

CONTROL BOARD

Compact

Page 34

SECTION 8 WIRING DIAGRAMS

8.1 CONNECTION OF A ROOM THERMOSTAT (fig. 29 & 29A)

Isolate the appliance from the electrical supply. Remove the appliance casing and PCB cover. Connect the room thermostat as shown in diagram fig. 29. A neutral supply can be taken from the appliance terminal strip if required. Carry out the electrical checks as described in section 7.11 prior to refitting the PCB cover and appliance casing.

8.2 CONNECTION OF AN EXTERNAL TIME CLOCK

Should the integral time clock be unsuitable, additional or alternative controls must be connected to the appliance terminal strip as shown in fig. 29 & 29A.

NOTE

Guidance on the recommended practice for the installation of external controls, can be found in CHeSS – HC1/HC2 (www.energyefficiency.gov.uk).

Fig. 29

Fig. 29A

Compact

Page 35

FUNCTIONAL DIAGRAM

NOTE: L-N-E CONNECTION IS ADVISABLE

Key R.T. Room thermostat

S.F.S. Domestic hot water flow switch P.S. Pressure switch P.D.S. Differential pressure switch H.L. High limit thermostat S.R. Heat thermistor S.S. Domestic hot water thermistor MOD Modulator F Fan P Pump SP/SE E. Spark\Sense electrode OPE Gas valve solenoids B.C.B. Burner control board CP08X Boiler control board JP2 Setting timer JP3 Natural gas or L.P.G. selector

Compact

Fig. 30

JP4 Jumper disable/enable DHW absolut thermostat P1 Domestic hot water temperature control P2 Central heating temperature control P3 Off/summer/winter selector P4-P5 Setting trimmer F External fuse 2 A F (on 230 V circuit) F2 (CP08X) Fuse 2 A F (on 230 V circuit) RL1 Ignition relay RL2 Fun relay RL4 Pump relay TRF1 Trasformer TRX Ignition trasformer ACF01X Ignition control board LED Led OK (green)

Led alarm (red) Combustion test (blink orange)

Page 36

FUNCTIONAL DIAGRAM

NOTE: L-N-E CONNECTION IS ADVISABLE

Fig. 31

Compact

Page 37

SECTION 9 EXPLODED DIAGRAMS

270

300

301

226

302

226

POS. DESCRIPTION 24 28

1 Frame assembly 01005259 01005260 12 Quick primer pressure gauge 10024019 10024019 13 Pin 10023044 10023044 18 Cover 10023812 10023812 19 Ignition module 10022174 10022174 20 Printed Circuit Board 10023537 10023537 21 Led Light Guide 10023816 10023816 26 Instrumental panel 10023933 10023933 27 Knob 10023937 10023937 28 Knob 10023936 10023936 31 Case 10023822 10023883 33 Plastic Trade Mark Label 1979 1979 49 Converter 10023935 10023935 76 Timer 10023938 10023938 90 3 A fuse 3478 3478

226 Edge clip 5128 5128 270 Transformer 10021272 10021272

300 Wiring harnes 10023939 10023939 301 Wiring harnes 10024067 10024067 302 Wiring harnes 10023840 10023840

Compact

Page 38

201

289

288

300

288

303

289

303

289

299

285

201

289

290

288

289

353

POS. DESCRIPTION 24 28

2 Connection 10022658 10022658 3 Pressure switch 2044 2044

7 By-pass valve 2047 2047 22 Safety valve 1806 1806 23 Connection 10022499 10022499 24 Flow governor 8009 8009 25 Pipe 10020714 10023950 26 DHW actuator 10022349 10022349 27 Heating cock 1789 1789 28 Connection 1790 1790 30 Water supplu stop cock 7099 7099 31 Venting plugs kit 01005137 01005137 36 Pipe 10020612 10023949 63 Pipe 10020898 10020898

201 Washer 5026 5026 285 NTC sensor 8484 8484 288 O ring 6898 6898 289 Clip 2223 2223 290 Clip 2165 2165 299 Washer 10022726 10022726 300 Clip 2222 2222 303 Connection 2217 2217 351 Brass nut 1823 1823 353 Ogive 1824 1824

351

Compact

Page 39

201

289

290

289

287

202

285

290

289

POS. DESCRIPTION 24 28

1 Expansion vessel 2204 2204 2 Flexible pipe 2164 2164 3 Pump 2225 2225 7 Pipe 10022000 10023947 8 Heat exchanger 10021419 10023661

9 Pipe 10022002 10023948 10 Automatic air vent bottle 0439 0439 12 Washer 2226 2226

201 Washer 5026 5026 202 Washer 5041 5041 285 NTC senspr 8484 8484 287 High limit thermostat 2258 2258 289 Clip 2223 2223 290 Clip 2165 2165

Compact

Page 40

24 CSI

200

295

200

POS. DESCRIPTION 24 28

1 Roomsealed chamber 10023931 10023945 2 Clip 0442 0442 3 Main burner injector manifold 10023799 10023902 3 Main burner injector manifold 10023800 10023903 4 Burner 10023798 10023901

5 Spark electrode 10021398 10021398 12 Pipe 10023996 10023996 13 Gas valve 10021021 10021021 15 Gas cock 10020897 10020897 16 Cover assembly 10021570 10023928 18 Glass 10021558 10021558 27 Air box hole cap 8084 10023805 52 Burner flange - 10023997 53 Nut 2233 2233

200 Washer 5023 5023 295 Silicone tube 1457 1457

- LPG conversion kit - 01005262

Compact

Page 41

212

295

300

POS. DESCRIPTION 24 28

2 Back insulating panel 2230 10023909 3 Lateral insulating panel 2231 2231

4 Front insulating panel 2232 10023910 10 Fan 10020793 10023907 12 Connection 2237 2237 20 Fumes testing connection pipe 10020627 10020627 25 Pressure diff. switch 8195 10023908 28 Stop clip 10020626 10020626

212 Screw 5080 5080 295 Silicone tube 1457 1457

300 Wiring harnes 10024067 10024067

Compact

Page 42

SECTION 10 L.P.G. INSTRUCTIONS

For details of converting appliances to LPG please refer to the instructions supplied with the relevant conversation kit.

10.1 TECHNICAL DATA

BURNER PRESSURES COMPACT 24 COMPACT 28

Inlet pressure 37 mbar 37 mbar Gas rate 2,04 Kg/h 2,41 Kg/h Injectot size 12 x 0.77 14 x 0.77 Maximum burner pressure DHW & Heating 36 mbar 36 mbar Minimum burner pressure DHW 5.1 mbar 4.8 mbar Minimum burner pressure Heating 6.5 mbar 6.5 mbar Jumper tag for LPG Inserted across JP3 Inserted across JP3

10.2 RELATED DOCUMENTS

BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60 Kw BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 5440 PART 1 FLUES BS 5482 PART 1 DOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS

10.3 GAS SUPPLY

The gas supply must be connected to the appliance by a competent L.P.G. installer and must be of sufficient size to supply the appliance at its maximum output. An existing supply must be checked to ensure that it is of adequate size to deal with the maximum rated input of this and any other appliances that it serves.

10.4 GAS SUPPLY INSTALLATION

The entire installation including the meter, must be purged and checked for gas soundness.

10.5 BURNER PRESSURES

Burner pressure settings should be checked and/or adjusted whenever the appliance is being serviced, commissioned, or the appliance gas type has changed.

NOTE

Ensure the jumper tag has been fitted to the control PCB (JP3).

The procedure for setting or adjusting must be carried out in the following order:

● set the maximum DHW gas pressure.

● set the minimum DHW gas pressure.

● set the maximum heating gas pressure.

● set the minimum heating gas pressure.

10.5.1 SETTING THE MAXIMUM DHW GAS PRESSURE (fig. 15 & 23)

Isolate the appliance from the electrical supply, remove the appliance casing as described in 4.7.1.

● Attach a manometer to the outlet test point of the

gas valve.

● Remove the protective cover from the gas valve

modulator, and disconnect the compensation tube from the gas valve.

● Fully open a hot water outlet (preferably the bath tap).

● Rotate the DHW temperature selector to

maximum.

● Restore the electrical supply to the appliance.

● The appliance will now light and after 7-10 seconds,

the burner will be at full power.

● Observe the manometer, the reading should be

36.0 mbar.

● If the reading is correct, proceed to section 10.5.2

● If the reading is incorrect, turn the maximum

adjustment screw (fig. 15) clockwise to increase the pressure, or anti-clockwise to reduce the pressure.

● Proceed to section 10.5.2.

10.5.2 SETTING THE MINIMUM DHW GAS PRESSURE (fig. 15 & 23)

● After carrying out section 10.5.1, disconnect one

of the black wires attached to the modulator coil.

● The burner will now operate at minimum power.

● Observe the manometer, the reading for Compact

24 should be 5.1 mbar, for Compact 28 the reading should be 4.8 mbar.

● If the reading is correct, proceed to section 10.5.3.

● If the reading is incorrect, turn the minimum

adjustment screw (fig. 15) clockwise to increase the pressure, or anti-clockwise to reduce the pressure.

● Proceed to section 10.5.3.

10.5.3 SETTING THE MAXIMUM AND MINIMUM CENTRAL HEATING BURNER PRESSURES

● Isolate the appliance from the electrical supply.

● Close the hot water outlet.

● Re-attach the black wire to the modulator coil.

● Remove the PCB cover and temporarily attach a

jumper tag to JP2.

● Rotate the heating temperature selector to

maximum, and ensure all radiators are turned on with any thermostatic radiator valves set to maximum.

● Restore the electrical supply and ensure there is

a call for heat via the appliance time clock and/or room thermostat.

● The appliance should now be operating in the

heating mode at maximum output.

● Observe the manometer, the – maximum – reading

should be 36.0 mbar.

● Using a small screwdriver, gently rotate the P5

potentiometer if adjustment is necessary.

● To check and/or adjust the minimum heating gas

pressure, slowly rotate the heating temperature selector until the burner pressure drops to minimum (should be 6.5 mbar).

● Using a small screwdriver, gently rotate the P4

potentiometer if adjustment is necessary.

● Isolate the appliance from the electrical supply,

and remove the jumper tag from JP2.

● Remove the manometer from the gas valve and

tighten the outlet test screw.

Refit the PCB cover and appliance casing.

Compact

Page 43

SECTION 11 REAR FLUE

11.1 FITTING THE FLUE (see fig. 33)

There are two telescopic flue kits for use with the Option boiler. The standard telescopic flue is suitable for a wall thickness of 200 mm – 425 mm. The extended telescopic flue is suitable for a wall thickness of 425 mm – 760 mm. Please ensure the flue kit you have is suitable.

Carefully open the flue pack. Contained within the pack are:

● The outer concentric flue pipe with terminal

● The inner concentric flue pipe

● Exterior trim

● Large rubber gasket

● Locking collar

● Securing screw

Carefully measure the thickness of the wall (dimension x - fig. 33). Take the outer concentric flue pipe (A) and – using a twisting action – ease it over the inner concentric flue pipe (B) (fig. 34). Add 210 mm to ‘x’ to give you dimension ‘y’. Push both the inner and outer concentric flue pipes together until the total length of the flue assembly is equal to dimension ‘y’. Secure the flue assembly in place by using the screw provided (C). T ake the large rubber gasket and secure it firmly over the appliance flue spigot (D). Pass the assembly through the wall mounting bracket and wall leaving 25 mm proud of the wall-mounting bracket. Insert the flue restrictor ring into the appliance flue outlet. The appliance can now be mounted to the wall bracket.

Pull the flue assembly firmly towards and over the appliance flue spigot (fig. 34A) and – using a twisting action – ensure the correct seal is made. Insert the locking collar (E) into the groove on the flue assembly as shown in fig. 34 a and rotate to conceal. Seal the flue assembly to the inside wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The exterior trim can now be fitted.

Fig. 32

Fig. 33

Max Min 200

Fig. 34

Fig. 34A

Compact

Page 44

3 .dE - 30/94 - 24932001 .doC

Registered address:

Unit 7 Riverside Industrial Estate

enquiries@vokera.co.uk

www.vokera.co.uk

Sales, General Enquires

Vokèra Limited reserve the right to change

specification without prior notice

Consumers statutory rights are not affected.

A Riello Group Company.

Company Reg No: 1047779

Vokèra Ltd

Borderlake House

London Colney Herts AL2 1HG

www.vokera.ie

T 0844 391 099

F 0844 391 0998

Vokèra Ireland

West Court, Callan

Co Kilkenny

T 056 7755057 F 056 7755060

vokera Compact 24 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual