VOKERA Compact HE, Compact 25 HE, Compact 29 HE, Compact 35 HE Installation & Servicing Instructions Manual

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Compact HE

High 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.

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Contents

Design principles and operating sequence Page

1.1 Principle components 2

1.2 Mode of operation (at rest) 2

1.3 Mode of operation (heating) 2

1.4 Mode of operation (DHW) 2

1.5 Safety devices 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

2.12 Appliance 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 8

3.A2 Location of appliance 8

3.A3 Gas supply 8

3.A4 Flue system 8

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 9

3.A6.7 Low pressure sealed system 9

3.A6.8 Frequent filling 9

3.A7 Electrical supply 9

3.A8 Showers 9

3.A9 Mounting on a combustible surface 9

3.A10 Timber framed building 9

3.A11 Inhibitors 9

3.A12 Declaration of conformity 9

Installation Page

4.1 Delivery 10

4.2 Contents 10

4.3 Unpacking 10

4.4 Preparation for mounting the appliance 10

4.5 Fitting the flue 10

4.5.1 Concentric horizontal flue 10

4.5.2 Concentric vertical flue 11

4.5.3 Twin flue system 12

4.6 Connecting the gas and water 14

4.6.1 Gas 14

4.6.2 Flow and return 14

4.6.3 Cold water inlet 14

4.6.4 Hot water outlet 1 4

4.6.5 Safety valve 14

4.6.6 Condense pipe 14

4.7 Electrical connections 14

4.7.1 Casing removal 1 5

4.7.2 Appliance terminal block 15

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

5.7.1 Checking burner pressures 16

5.8 Final flushing of the heating system 16

5.8.1 Inhibtors 16

5.9 Setting the boiler operating temperature 16

5.9.1 Setting the DHW temperature 17

5.10 Setting the system design pressure 17

5.11 Regulating the hot water 17

5.11.1 Changing the flow restrictor 17

5.11.2 Regulating the central heating system 17

5.12 Final checks 17

5.13 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 Component removal procedure 18

6.5 Pump assembly 18

6.6 Safety valve 18

6.7 Automatic air release valve 19

6.8 Water pressure switch 19

6.9 Pressure gauge 19

6.10 Primary thermistor 19

6.11 High limit thermostat 1 9

6.12 PCB 19

6.13 Gas valve 19

6.14 Integral time switch 20

6.15 Electrode, burner thermostat, burner & injectors 20

6.16 Flue fan 21

6.17 Main heat exchanger 21

6.18 Air pressure switch 21

6.19 Flow restrictor 21

6.20 DHW flow switch 22

6.21 DHW heat exchanger 22

6.22 Valve actuator 2 2

6.23 Divertor valve cartridge 22

6.24 DHW thermistor 22

6.25 Automatic by-pass 2 2

6.26 DHW non-return valve 22

6.27 Expansion vessel 22

6.27.1 Expansion vessel removal (with sufficient clearance above) 22

6.27.2 Expansion vessel removal (with insufficient clearance above) 23

6.28.1 Latent heat collector 23

6.28.2 Dismantling the latent heat collector 23

6.28.3 Retarder 23

6.29 Condense trap removal 24

Checks, adjustments and fault finding page

7.1 Checking appliance operation 2 4

7.2 Appliance mode of operation 24

7.2.1 Selector switch in the OFF position 24

7.2.2 Selector switch in the hot water only position 24

7.2.3 Selector switch in the heating & hot water position 24

7.2.4 Appliance functions 24

7.2.5 DHW mode 24

7.2.6 Heating mode 25

7.3 Checking & adjusting burner pressure 2 6

7.3.1 Setting the maximum burner pressure 26

7.3.2 Setting the minimum burner pressure 26

7.3.3 Setting the minimum CH output 26

7.4 Combustion analysis test 26

7.5 Checking the expansion vessel 27

7.6 External faults 27

7.6.1 Installation faults 27

7.7 Electrical checks 27

7.7.1 Earth continuity test 27

7.7.2 Short circuit check 27

7.7.3 Polarity check 27

7.7.4 Reversed polarity or supply fault 28

7.7.5 Resistance to earth check 28

7.8 Fault finding 28

7.8.1 Replacing the main PCB 28

7.9 Fault codes 28

7.10 Fault finding 29-34

Wiring diagrams Page

8.1 External wiring 35

8.2 Typical control applications 35

8.3 Vokera remote control 35

8.4 Room thermostat 35

8.5 Other controls 35 Functional diagram 36

Exploded diagrams Page

Table 1-5 37-41

L.P.G. instructions Page

10.1 Related documents 42

10.2 Technical data 4 2

10.3 Converting the appliance gas supply 42

10.4 Gas supply 4 2

10.5 Gas supply installation 42

10.6 Checking & adjusting burner pressure 4 2

10.6.1 Setting the maximum burner pressure 42

10.6.2 Setting the minimum burner pressure 42

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INTRODUCTION

The Compact HE range of appliances is comprised of 2 models of high-efficiency combination boiler with inputs to heating & DHW of 25, 29 & 35kW respectively. Each appliance - by design - incorporates electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge, and automatic by-pass.

The Compact HE range is produced as room sealed, category II2H3P appliances, suitable for internal wall mounting applications only. They are provided with a fan

powered flue outlet with an annular coaxial combustion air intake that can be rotated - horizontally - through 360 degrees for various horizontal or vertical applications. The Compact HE range can also be used with the Vokera twin flue system. The Compact HE range is approved for use with C12 & C32 type flue applications. These appliances are designed for use with a sealed system only; consequently they are not intended for use on open vented systems

Fig.1 General Layout

1 Diverter valve motor 2 Discharge valve 3 Domestic hot water heat exchanger 4 Safety valve 5 Pump 6 Pressure switch 7 Auto air vent (AAV) 8 Electrode 9 Main burner 10 Main heat exchanger 11 Latent heat collector 12 Flue gas analysis test point 13 Flue outlet 14 Air intake 15 Differential pressure switch 16 Silicone pressure tube (-) 17 Silicone pressure tube (+) 18 Fan assembly 19 CH NTC sensor 20 Combustion chamber 21 High limit thermostat 22 Expansion vessel 23 Condensate pressure switch 24 Ignition transformer 25 Condense trap 26 Modulator coil 27 Gas valve 28 DHW flow switch

Fig. 1

29 30 31 32 33 34

29 Pressure gauge 30 DHW temperature selector 31 Mode selector switch 32 Status fault/indicator led 33 CH temperature selector 34 Timeclock

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SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS

● A fully integrated electronic control board fea-

turing electronic temperature control, anti-cycle control, pump over-run, LED fault indicator, full gas modulation.

● Low-water-content, copper heat exchanger.

● Electronic ignition with flame supervision.

● Integral high-head pump.

● Fan.

● Air pressure switch.

● Expansion vessel.

● Water pressure switch.

● Two-stage gas valve.

● Pressure gauge.

● Safety valve.

● Condense switch.

1.2 MODE OF OPERATION (at rest)

When the appliance is at rest and there are no requests for heating or DHW, the following functions are active:

● Frost-protection system - the frost-protection

system protects the appliance against the risk of frost damage. Should the temperature of the appliance fall to 5 °C, the boiler will function in the heating mode at minimum power until it reaches 35 °C.

● Anti-block function - the anti-block function

enables the pump and divertor valve actuator, to be energised for short periods, when the appliance has been inactive for more than 19hours.

expansion

vessel

AAV

valve motor

safety valve

Fig. 2

pump

diverter

automatic

by-pass

latent heat

collector

return

flow

flue

outlet

DHW heat exchanger

intake

gas valve

DHW outlet

air

pressure

switch

main heat

exchanger

CH NTC

sensor main

burner

DHW tempera-

ture sensor

DHW non

return valve

flow switch

Domestic cold water inlet

water

pressure

switch

DHW

1.3 MODE OF OPERATION (Heating)

When there is a request for heat via the time clock and/or any external control, the pump and fan are started, the fan will then prove the air pressure switch. At this point an ignition sequence is enabled.

Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry increases the gas rate to 75% for a period of 15 minutes. Thereafter, the boiler’s output will either be increase to maximum or modulate to suit the set requirement.

When the appliance reaches the desired temperature the burner will shut down and the boiler will perform a three-minute anti-cycle (timer delay).

When the request for heat has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

1.4 MODE OF OPERATION (DHW)

When there is a request for DHW via a hot water outlet or tap, the pump and fan are started, the fan will then prove the air pressure switch. At this point an ignition sequence is enabled.

Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry increases the gas rate to maximum or will modulate output to stabilise the temperature.

In the event of the appliance exceeding the desired temperature the burner will shut down until the temperature drops.

When the request for DHW has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

1.5 SAFETY DEVICES

When the appliance is in use, safe operation is ensured by:

● A water pressure switch that monitors system

water pressure and will de-activate the pump, fan and burner should the system water pressure drop below the rated tolerance.

● A high limit thermostat that over-rides the tem-

perature control circuit to prevent or interrupt the operation of the burner.

● An air pressure switch that requires the fan to

prove operation before the gas valve is energised.

● A pressure switch that interrupts the operation

of the appliance if the condense pipe becomes blocked.

● A safety valve which releases excess pressure

from the primary circuit.

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SECTION 2 TECHNICAL DATA

25 29

2.1 Central heating

Heat input (kW) 25.0 29.0 34.8 Maximum heat output@ 80/60 °C (kW) 24.3 28.1 33.8 Minimum heat output@ 80/60 °C (kW) 14.2 14.2 13.9 Maximum heat output@ 50/30 °C (kW) 25.9 30.2 36.1 Minimum heat output@ 50/30 °C (kW) 14.9 14.8 14.4 Minimum working pressure 0.5 bar 0.5 bar 0.5 bar Maximum working pressure 3.0 bar 3.0 bar 3.0 bar Minimum flow rate 350 l/h 350 l/h 350 l/h

2.2 Domestic hot water

Maximum output (kW) 25.0 29.0 34.8 Minimum output (kW) 9.5 9.9 9.9 Flow rate (35 °C rise) 10.2 l/min 11.9 l/min 14.3 l/min Maximum inlet pressure 6.0 bar 6.0 bar 6.0 bar Minimum inlet working pressure 0.15 bar 0.15 bar 0.15 bar Minimum flow rate 2 l/min. 2 l/min. 2 l/min.

2.3 Gas pressures

Inlet pressure G20 20.0 mbar 20.0 mbar 20.0 mbar Maximum burner pressure 9.40 mbar 9.20 mbar 10.1 mbar Minimum burner pressure (central heating) 3.50 mbar 2.70 mbar 2.10 mbar Minimum burner pressure (domestic hot water) 1.50 mbar 1.20 mbar 1.00 mbar Gross rate (central haeting, max - min) 2.64 - 1.59 m3/h 3.07 - 1.59 m3/h 3.68 - 1.59 m3/h Injectors size 12 x 1.35 mm 14 x 1.35 mm 16 x 1.35 mm

2.4 Expansion vessel

Capacity 8 litres 10 litres 10 litres Maximum system volume 76 litres 76 litres 76 litres Pre-charge pressure 1.0 bar 1.0 bar 1.0 bar

2.5 Dimensions

Height 780 mm 780 mm 780 mm Width 400 mm 450 mm 500 mm Depth 332 mm 332 mm 332 mm Dry weight 40 kg 44 kg 48 kg

2.6 Clearances

Sides 12 mm 12 mm 12 mm Top 150 mm from casing or 25 mm above flue elbow, whichever is applicable Bottom 150 mm 150 mm 150 mm Front 600 mm 600 mm 600 mm

2.7 Connections

Flow & return 22 mm 22 mm 22 mm Hot & cold water connections 15 mm 15 mm 15 mm Gas 15 mm 15 mm 15 mm Safety valve 15 mm 15 mm 15 mm Condense 21 mm 21 mm 21 mm

2.8 Electrical

Voltage 230V/~ 50Hz 230V/~ 50Hz 230V/~ 50Hz Power consumption 153 W 153 W 153 W Internal fuse 2 A 2 A 2 A External fuse 3 A 3 A 3 A

2.9 Flue details (concentric)

Maximum horizontal flue length (60/100mm) 4.5 m 4.0 m 1.85 m Maximum vertical flue length (60/100mm) 5.5 m 5.0 m 2.85 m Maximum horizontal flue length (80/125mm) 11.0 m 9.0 m 6.8 m Maximum vertical flue length (80/125mm) 12.0 m 10.0 m 7.8 m

2.9 Flue details (twin pipe)

Maximum horizontal flue length (80mm + 80mm) 20 m + 20 m 12 m + 12 m 10 m + 10 m Maximum vertical flue length (80mm + 80mm) 20 m + 20 m 12 m + 12 m 10 m + 10 m

2.10 Efficiency

SEDBUK 86.9 Band “B” 87.1 Band “B” 86.65 Band “B”

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

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2.11 PUMP DUTY

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

25 - 29

5,0

4,5

4,0

3,5

3,0

2,5

2,0

1,5

1,0

0,5

0,0

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

Residual head (x 100 mbar)

first speed

second speed

Litres Per Hour (x100)

third speed

6,0

5,5

5,0

4,5

4,0

3,5

3,0

2,5

2,0

1,5

1,0

0,5

0,0

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500

Residual head (x 100 mbar)

first speed

Litres Per Hour (x100)

third speed

second speed

Fig. 3

25 29 35

2.12 Appliance

NOx 98 ppm - 172 mg/kWh 81 ppm - 142 mg/kWh 85 ppm - 149 mg/kWh CO (max-min) 80 ppm - 80 ppm 100 ppm - 60 ppm 100 ppm - 120 ppm CO2 (max-min) 6.75 - 3.90 % 7.05 - 3.40 % 6.8 - 2.7 % CO/CO2 ratio (max) 0.001 to 1 0.001 to 1 0.001 to 1 CO/CO

ratio (min) 0.002 to 1 0.001 to 1 0.004 to 1

SECTION 3 GENERAL REQUIREMENTS (UK)

Fig. 4

Key Location Minimum distance

A Below an opening (window, air-brick, etc.) 300 mm B Above an opening (window, air-brick, etc.) 300 mm C To the side of an opening (window, air-brick, etc.) 300 mm D Below gutter, drain-pipe, etc. 75 mm E Below eaves 200 mm F Below balcony, car-port roof, etc. 1200 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 1200 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 500 mm Q From the top of the vertical terminal to the roof flashing As determined by the fixed collar

of the vertical terminal

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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 (see fig. 4).

Water vapour will condense on leaving the terminal and the effect of such pluming must be considered.

BS 5440 PART 1 FLUES BS 5440 PART 2 FLUES & VENTILATION BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

(2ND FAMILY GASES) BS 6798 INSTALLATION OF 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 2m 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 a terminal is sited less than 1m below a plastic gutter, or less than 500mm below a painted surface, a suitable one metre long heat shield should be fitted.

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.

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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. However it may be necessary to fit an external bypass should the design of the heating system require such. In any case, the design of the system should be such that it prevents boiler ‘cycling’.

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.

3.6.7 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 (see 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

Non-return

valve

Stopcock

5.0 metres minimum

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 (25kW) or 10 litres (29 & 35kW) 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 6.19).

3.6.6 FILLING POINT

An approved method for initial filling of the system and replacing water lost during servicing etc. is required (see fig. 5). This method of filling must comply with the current Water Supply (Water Fittings) Regulations 1999 and Water Bylaws 2000 (Scotland).

control valve

temporary

connection

control valve

Fig. 5a

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 3mm. 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.

flow/return

pipe

Fig. 5

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.

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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 an inhibitor - suitable for use with copper and aluminium heat exchangers

- is used to protect the boiler and system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers instructions*.

*Water treatment of the complete heating system

- including the boiler - should be carried out in accordance with BS 7593 and the Domestic Water Treatment Association’s (DWTA) code of practice.

Fig. 6a

30kW

25kW

35kW

Fig. 6

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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. This appliance is not suitable for external installation.

3A.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 I.S. 813.

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.

3A.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 (refer to I.S. 813 for guidance on permitted locations and minimum distances of flue terminals).

Water vapour will condense on leaving the terminal; the effect of such pluming must be considered.

If installed less than 2m 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.

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

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

The appliance has an integral expansion vessel to accommodate the increased volume of water

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when the system is heated. It can accept up to 8 litres (25kW) or 10 litres (29 & 35kW) 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 6.19).

3A.6.6 FILLING POINT

A suitable method for initial filling of the system and replacing water lost during servicing etc. is required (see fig. 5). You should ensure this method of filling complies with the local water authority regulations.

3A.6.7 LOW PRESSURE SEALED SYSTEM

effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers’ instructions*.

*Water treatment of the complete heating system

- including the boiler - should be carried out in accordance with I.S. 813 and the Domestic Water Treatment Association’s (DWTA) code of practice.

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.

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 an inhibitor - suitable for use with copper and aluminium heat exchangers

- is used to protect the boiler and system from the

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SECTION 4 INSTALLATION

4.1 DELIVERY

Due to the weight of the appliance it may be necessary for two people to lift and attach the appliance to its mounting. The appliance is contained within 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 bracket

● appliance template

● an accessories pack containing appliance serv-

ice connections and washers

● the instruction pack containing the installation

& servicing instructions, user instructions, Benchmark logbook, guarantee registration card and a 3-amp fuse.

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.

Reduction for additional bends

Bend Reduction in maximum flue length for each bend

45º bend 0.5 metre 90º bend 1.0 metre

Horizontal flue terminals and accessories

Part No. Description Min-Max Length

0225720 Horizontal flue kit for use with 1000 mm

add. bends & extensions 0225755 Telescopic extension 350 mm – 500 mm 0225740 0.5m extension 500 mm 0225745 1.0m extension 1000 mm 0225750 2.0m extension 2000 mm 0225730 45º bend (pair) N/A 0225735 90º bend N/A 0225760 Wall bracket (5) N/A

Using the template provided, mark and drill a 115mm hole for the passage of the flue pipe. The hole should be drilled level to ensure any condense fluid that forms will drain back to 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.

4.4 PREPARATION FOR MOUNTING THE APPLIANCE

The appliance should be mounted on a smooth, vertical, non-combustible 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- mounting bracket (see fig. 6) and flue-hole (if applicable).

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).

The appliance can be used with either the Vokera condensing 60/100mm concentric flue system or the optional 80/125mm concentric flue system.

NOTE

These instructions relate only to the Vokera condensing 60/100mm concentric flue system. For specific details on the installation of the 80/125mm concentric flue system please refer to the instructions supplied with the 80/125mm terminal. 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 2.9). A reduction must also be made to the maximum length (see table below) when additional bends are used.

Push-fit connection

Terminal or

extension

outer

clamp

Fig. 7

Boiler

FITTING THE HORIZONTAL FLUE KIT

Carefully measure the distance from the centre of the appliance flue outlet to the edge of the finished outside wall (dimension X). Add 45mm to dimension X to give you Dimension Y (see fig 7A). Measure dimension Y from the terminal end of the concentric flue pipe and cut off the excess ensuring any burrs are removed. Pass the concentric flue pipe through the previously drilled hole. Fit the flue bend to the boiler flue outlet and insert the concentric flue pipe into the flue bend ensuring the correct seal is made. Using the clamp, gasket, and screws supplied, secure the flue bend to the appliance flue spigot. The 60mm M & F adaptor (supplied with the flue kit) should be discarded.

NOTE

Fit the internal (White) trim to the flue assembly prior to connecting the flue pipe to the bend. 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 (Black) can now be fitted.

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Fig. 7a

“X” + 45 mm = “Y”

FLUE RESTRICTOR RING (horizontal flue)

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 (see tables below).

Total flue length Restrictor required

Less than 1.2 metre 82.5mm diameter Less than 3.0 metres 88mm diameter Less than 4.5 metres not required

Total flue length Restrictor required

Less than 2.0 metres 84mm diameter Less than 4.0 metres not required

Total flue length Restrictor required

Less than 1.85 metres not required

4.5.1.1 EXTENDING THE FLUE

Connect the bend - supplied with the terminal kit

- to the top of the boiler using clamp (supplied) see fig. 7. The additional bends & extensions have push-fit connections, 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 (see fig. 7 & 8).

The flue pipe should have a minimum 1-degree rise from the boiler (17mm every 1.0 metre) to ensure that any condense fluid drains back to the appliance.

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (see fig. 7 & 8). Remove any burrs, and check that all seals are located properly.

125 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 satisf actory weatherproofing.

4.5.2 CONCENTRIC VERTICAL FLUE

The appliance can be used with either the Vokera condensing 60/100mm concentric flue system or the optional 80/125mm concentric flue system.

NOTE

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

Reduction for bends

Bend Reduction in maximum flue length for each bend

45º bend 0.5 metre 90º bend 1.0 metre

Ver tical flue terminal and accessor ies

Part No. Description Min-Max Length

0225725 Vertical flue terminal 1.0 metre 0225770 Pitched roof flashing plate N/A 0225765 Flat roof flashing plate N/A

0225755 350-500 telescopic extension 350 mm – 500 mm 0225740 0.5m extension 500 mm 0225745 1.0m extension 1000 mm 0225750 2.0m extension 2000 mm 0225730 45º bend (pair) N/A 0225735 90º bend N/A 0225760 Wall bracket (4) N/A

Using the dimensions given in fig. 9 as a reference, mark and cut a 107mm hole in the ceiling and/or roof.

Fig. 9

Fig. 8

145

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Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing. The fixing holes for the wall-mounting bracket 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.

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.

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

If the vertical flue requires extension/s or additional bend/s, connect the required number of flue extensions or bends (up to the maximum equivalent flue length) between the boiler and vertical flue assembly (see fig. 8).

Ensure that any horizontal sections of the flue system have a minimum 1º fall back to the boiler (17mm per 1000mm).

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (see fig. 8). Remove any burrs, and check that any seals are located properly.

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

FLUE RESTRICTOR RING (vertical flue)

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 (see tables below).

Total flue length Restrictor required

Less than 2.0 metre 82.5mm diameter Less than 4.0 metres 88mm diameter Less than 5.5 metres not required

Total flue length Restrictor required

Less than 2.8 metres 84mm diameter Less than 5.0 metres not required

Total flue length Restrictor required

Less than 2.7 metres not required

4.5.3 TWIN FLUE SYSTEM

The Vokera twin flue system enables greater flue distances to be achieved (see 4.4.2) than that of a concentric flue system. It can be used for horizontal or vertical applications, however the twin flue system must be converted to the dedicated concentric flue kit for termination. It is essential that the installation of the twin flue system be carried out in strict accordance with these instructions.

GUIDANCE NOTES ON TWIN FLUE INSTALLATION

● The flue must have a fall back of 1º back to the

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

● Ensure that the entire flue system is adequately

supported, use at least one bracket for each extension.

● The entire flue system must be adequately

insulated to maintain heat within the flue system thereby reducing the possibility of condensate production.

● As the exhaust outlet pipe can reach very high

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

● The condensate drainpipe must be connected

in accordance with local building regulations that are in force.

Reduction for bends

Bend Reduction in maximum flue length for each bend

45º bend 1.0 metre 90º bend 1.0 metre

Twin flue accessories

Part No. Description Min-Max Length

0225805 Horizontal flue terminal 1.0 metre 0225810 Vertical flue terminal 1.0 metre 430 T win adapter kit N/A 0225770 Pitched roof flashing plate N/A 0225765 Flat roof flashing plate N/A 0225815 Condensate drain kit N/A 0225820 0.25 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 br acket (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.

FLUE RESTRICTOR RING (vertical flue)

To ensure maximum efficiency of the appliance, it may be necessary to fit one of the flue restrictor rings (supplied with the twin adaptor kit) to the appliance flue outlet (see tables below).

Total flue length Restrictor required

Less than 7.0 metre 40mm diameter Less than 13.5 metres 45mm diameter Less than 19.5 metres not required

Total flue length Restrictor required

Less than 5.0 metres 45mm diameter Less than 12.0 metres not required

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Total flue length Restrictor required

Less than 5.0 metres 50mm diameter Less than 10.0 metres not required

4.5.3.1 INSTALLATION OF TWIN ADAPTOR KIT (fig. 10 & 11)

● Insert the exhaust connection manifold (A)

onto the appliance flue outlet.

● Remove the blanking plate (located to the right

of the appliance flue outlet) and – using the same screws – install the air inlet plate (B).

● Using the hole in the exhaust connection mani-

fold as a guide, drill a 3mm hole in the appliance flue spigot and secure the exhaust manifold connection to the flue spigot using the screw provided (C).

● Using the two holes in the air inlet plate as a

guide, drill a 3mm hole in each and secure the air inlet pipe/bend using the screws provided.

● The twin flue pipes extensions and accessories

can now be installed by pushing together (the plain end of each extension or bend should be pushed approximately 50mm into the female socket of the previous piece).

Fig. 12

Fig. 10

Fig. 11

4.5.3.2 HORIZONTAL TERMINATION (see fig. 12)

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 130mm hole is required for the passage of

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

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

Push-fit the twin flue pipes onto the concentric to twin converter 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.

Fig. 13

NOTE

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

NOTE

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

4.5.3.3 VERTICAL TERMINATION (see fig. 13)

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 130mm hole is required for the passage of

the concentric terminal through the ceiling and/ or roof.

+ 33 hidden pages

VOKERA Compact HE, Compact 25 HE, Compact 29 HE, Compact 35 HE Installation & Servicing Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual