Vokera Condexa Pro 100 M LPG User guide

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CondexaPRO

Light commercial 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.

CONDEXA PRO2

MODEL FUEL CODE

CONDEXA PRO 50 M Natural gas - LPG 50-37685-12869-4 CONDEXA PRO 100 M Natural gas - LPG 50-37685-12867-0 CONDEXA PRO 100 S Natural gas - LPG 50-37685-12868-7

The

Vokera CONDEXA PRO

boilers comply with:

• Gas Appliances Directive 90/396/EEC

• Boiler Efficiency Directive 92/42/EEC

• Electromagnetic Compatibility Directive 89/336/EEC

• Low Voltage Directive 73/23/EEC.

• EN 677 standard on condensing boilers.

0085

CONFORMITY

RANGE

CONDEXA PRO 3

Dear Customer,

congratulations on your purchase of a

Vokera CONDEXA PRO

Boiler. You have chosen proven

technology based on

Vokera Ltd

experience in this field and if fully compliant with current European standards. This appliance ensures maximum comfort for an extended period, with high reliability, efficiency, quality and safety. The purpose of this manual is to provide all the information that we feel is necessary for the correct and simple installation of the boiler and must be preserved and made available as and when requested to ensure correct installation, operation and maintenance. Full warranty cover applies providing the boiler has been correctly installed, operated and commissioned by qualified personnel. The manufacturer is not liable for any damage caused by the incorrect layout or installation of the flue system.

Vokera Ltd

The Vokera CONDEXA PRO Boiler comes with a SPECIFIC WARRANTY of 24 months (parts and

labour) starting from the date of commissioning or 3 months from date of purchase which ever soo-

ner providing it has been commissioned by

Vokera or a qualified engineer and a copy of the com-

missioning certificate has been returned and filled with

Vokera Ltd.

As a result, we suggest that you contact

Vokera Service Department or a qualified engineer for

commissioning of the boiler, as described in the conditions listed on the WARRANTY CERTIFICA-

TE supplied with the boiler, which should be read with care.

WARRANTY

CONDEXA PRO4

GENERAL

General warnings page 5 Fundamental safety rules “ 5 Description of the appliance “ 6 Safety devices “ 6 Identification “ 7 Structure “ 8 Technical specifications “ 9 Accessories “ 9 Water circuit “ 10 Positioning the probes “ 11 Pumps “ 11 Wiring diagrams “ 14 Control panels “ 18 User interface “ 19

- Display mode “ 20

- Readout mode “ 20

- Setting the user parameters “ 21

- Monitor mode “ 22

- Installer programming mode “ 23

- Test mode “ 24

- Error mode “ 24

- Permanent lockout “ 24

INSTALLER

Receiving the product pag. 25 Dimensions and weight “ 25 Handling “ 26 Room where the boiler is installed “ 26 Installation in old systems or systems to be upgraded

“ 27 Installing the boiler “ 28 Water connections “ 28 Fuel connections “ 30 Flue gas outlet and combustion air intake “ 30 Electrical connections “ 33 Installing the outside probe “ 35 Filling and emptying the systems “ 36 Preparing for first start-up “ 38

TECHNICAL

Starting for the first time pag. 39 Checks during and after first start-up “ 41 Setting the functional parameters “ 45 Setting the central heating parameters “ 45 Setting the domestic hot water parameters “ 47 Setting the temperature controller “ 48 Setting the addresses for cascading configurations“54 Fault codes “ 56 List of parameters “ 58

Conversion from one type of gas to the other “ 60 Adjustments “ 62 Temporary shutdown “ 63 Shutting down for extended periods “ 63 Servicing “ 64 Cleaning the boiler and dismantling the inside components “ 64 Troubleshooting “ 69

The following symbols are used in some parts of this booklet:

bCAUTION = actions that require special care and

suitable preparation

aPROHIBITED = actions that absolutely must

NOT be carried out

This booklet, code 068464EN - Rev. 0 (09/05), contains 76 pages.

CONTENTS

CONDEXA PRO 5

aThe boiler must not be used by children or invalid

persons without supervision.

Electrical devices or appliances, such as switches, household appliances, etc. must not be used if there is the smell of gas or unburned fuel. In this case:

- ventilate the room by opening doors and windows;

- close the fuel stopcock;

- promptly contact

Vokera Ltd, your gas supplier or

other professionally qualified personnel.

aDo not touch the boiler when barefoot or with wet

parts of the body.

aNo service or cleaning operations may be perfor-

med without first having disconnected the boiler from the mains power supply, moving the main system switch to "off".

aThe safety or control devices must not be adjusted

without the authorisation and written instructions from the manufacturer of the boiler.

aThe condensate drain must not be plugged.

aDo not pull, remove or twist the electrical cables

coming out of the boiler, even if the appliance is disconnected from the mains power supply.

aThe ventilation openings in the room where the

appliance is installed must not be plugged or reduced in size and must comply with any current standards and law applicable.

aDo not expose the boiler to the elements. It is not

designed to operate outdoors and does not have sufficient frost protection systems.

aDo not switch the boiler off if the outside temperatu-

re may fall below ZERO (risk of freezing).

aDo not leave containers and flammable substances

in the room where the boiler is installed.

aThe packaging material must not be dispersed in

the environment or left within the reach of children as it is a potential source of hazard. It must be disposed of according to the legislation in force.

The use of products that operate on fuel, electricity and water requires a number of fundamental safety rules to be observed, including:

bAfter having removed the packaging, check that the

material supplied is intact and complete; if this is not the case, contact

Vokera Ltd.

bThe CONDEXA PRO Boiler must be installed by

qualified personnel as detailed under any current standards and law applicable and with the instructions provided by

Vokera in the manual supplied

with the appliance.

bThe boiler must be used for the purposes it has

been expressly manufactured.

Vokera Ltd declines

all contractual and extra-contractual liability for damage caused to persons, animals or things, due to errors in installation, control, servicing or improper use.

bIn the event of water leaks, disconnect the boiler

from the mains power supply, close the water supply and promptly notify

Vokera Ltd or other profes-

sionally qualified personnel.

bPeriodically check that the condensate drain is free

of blockages.

bPeriodically check that the operating pressure of

the water circuit when cold is

1.5 bar and less than

the maximum limit specified for the appliance. If this is not the case, contact

Vokera Ltd or other profes-

sionally qualified personnel.

bIf the boiler is not used for an extended period, the

following minimum operations must be completed:

- move the main system switch to "off"

- close the fuel cock and the water cocks on the central heating system

- empty the central heating system if there is the risk of frost.

bServicing must be performed on the boiler at least

once a year.

bThis manual is an integral part of the boiler and as a

consequence must be kept with care. If the manual is damaged or lost, contact

Vokera Ltd for another

copy.

GENERAL WARNINGS

FUNDAMENTAL SAFETY RULES

CONDEXA PRO6

The CONDEXA PRO Boiler is a wall-hung condensing boiler, for heating only, with a premix burner, made up of one or two heating units, depending on the model. The

CONDEXA PRO Boiler can be combined in a casca-

ding configuration with other heat generators to create modular heating plants made up of boilers connected to the same water circuit and with electronic controllers communicating via bus. The heat output of each heating unit reaches 48.50 kW (100%, 50°C-30°C) and can be modulated from 30% to 100%. The efficiency reaches

108.7% and the low flue gas outlet temperature allows the use of a flame-retardant polypropylene flue (class B1), with a diameter of just 50 mm and a total equivalent height of 30 metres. The versatility of the electronic board makes quick connection possible to all types of central heating and domestic hot water production systems with storage, managing three circuits operating with three different temperatures at the same time. The individual heating units in cascading configuration can be activated, as well as by simple rotation, in such a way that when a certain percentage of output is reached by the first unit, the other units start automatically, all with the same load factor. Specific accessories are available for the boiler, such as two-way valves or pumps, or devices for taking in the combustion air. These ensure adaptability to a vast range of system configurations. Other accessories include water headers and the flue gas header for cascading installations.

The

CONDEXA PRO Boiler is fitted with the following safety devices, installed on each heating unit:

Safety thermostat with automatic reset, activated if the

outlet temperature exceeds 90°C, shutting down the burner. Diagnosis in the water circuit, the minimum flow-rate of the heat exchange fluid in each heating unit is controlled by a water differential pressure switch and an electronic safety system, using an outlet probe and a return probe. The appliance goes into safety mode if there is insufficient water or circulation. Flue gas outlet safety device: the flue gas probe, located at the bottom of the exchanger, sets off an alarm in the event of high flue gas temperatures (> 80°C). In addition, the float in the drain trap prevents the flue gas from passing through the condensate drain. Fan safety device: a Hall-effect sensor constantly monitors the rotation speed of the fan.

The CONDEXA PRO

Boilers are designed for cascading connection, which allows the creation of compact and very flexible heating plants, due to the high degree of modulation.

bThe activation of the safety devices indicates a

potentially dangerous malfunction on the boiler; immediately contact

Vokera Ltd or other professio-

nally qualified personnel.

After a short wait, try restarting the boiler (see chapter on starting for the first time).

aThe boiler must never be started, even temporarily,

with the safety devices not working or having been tampered with.

bThe safety devices must be replaced by the only

using the original components supplied by the manufacturer. See the spare parts catalogue supplied with the boiler.

After having performed the repairs or replacements, check the correct operation of the boiler.

The main features of the

CONDEXA PRO Boiler are:

- premix jet burner with constant air-gas ratio

- output from 16.3 to 100 kW (models 100 M and 100 S)

- heat output up to 450 kW, by connecting up to 9 heating units in a cascading configuration, using the waterconnection kit (code 5037685135029), available separately

- maximum flue gas outlet temperature 80°C

- total flue gas outlet and combustion air intake length up to 30 m, Ø 50 mm

- quick connection of the water and gas headers (optional), with outlet on the right or left

- microprocessor control with self-diagnosis, shown on LEDs and the display

- the electronic controller can manage up to 60 heating units in cascading

- frost protection function activated according to the outside temperature and/or the temperature of the boiler

- fitted for room thermostat in the high and low temperature zones

- outside probe to enable the climate control function

- post-circulation function for the central heating and DHW circuits

- priority settable on the DHW, high or low temperature circuit

- possibility to manage two circuits with fixed set point or with climate control using two separate curves

- automatic reversal of the burner ignition order

- emergency function, which in the event of faults on the Master board still allows the Slave boards to be controlled.

DESCRIPTION OF THE APPLIANCE

SAFETY DEVICES

CONDEXA PRO 7

Models

50 M - 100 M

Models

100 S

The boilers can be identified by the:

bIf the plates or other means for clearly identifying the product have been tampered with, removed or are missing,

the installation and servicing operations will be much more difficult.

- Rating plate

This shows the technical and performance specifications.

- Packaging label

This shows the code, the serial number and the barcode.

- Gas label

This is applied on the side of the frame, and describes the type of fuel used by the boiler, and the country of destination.

Country of destination:

Type of appliance Boiler category::

II2H3+

Gas supply pressure:

G20

G30+G31

20 mbar 28-30/37 mbar

Manufacturer settings:

G20 - 20 mbar - 2H NATURAL GAS

WARNING

Carefully read the instruction manual before installing and starting the appliance.

(Laterale DX)

B23, C63

068465EN_1_E0

IDENTIFICATION

CONDEXA PRO8

1 2 3 4

6 7

1 2 3 4 1 2 3 4

6 7

14 13 12 15

17 16

14 13 12 1514 13 12 16 17

1 - Fan 2 - Combustion air intake fitting 3 - Gas valve 4 - Flue gas outlet fitting 5 - Flue gas analysis test point 6 - Outlet probe 7 - Safety thermostat 8 - SECOND combustion chamber

(models 100 M and 100 S) 9 - Return probe 10 - Condensate collection drain trap 11 - Control panel (90° rotation) 12 - Gas supply

CONDEXA PRO 50 M CONDEXA PRO 100 M - 100 S

13 - Central heating return inlet 14 - Central heating flow outlet 15 - Main switch 16 - Safety valve connection pipe 17 - Safety valve 6 bar 18 - Water differential pressure switch 19 - Drain cock 20 - Flue gas probe 21 - FIRST combustion chamber 22 - Automatic vent valve 23 - Ignition / detection electrode 24 - Panelling

STRUCTURE

CONDEXA PRO 9

ACCESSORY CODE

Flue gas header kit 5037685135005 Water connection kit for installations < 100 kW 5037685135012 Water connection kit for installations > 100 kW 5037685135029 Remote control kit 5037685135036 Two-way valve kit 5037685135043 Injection pump kit 5037685135050 Conversion kit for room-sealed operation

CONDEXA PRO 50 5037685135067

Conversion kit for room-sealed operation

CONDEXA PRO 100 5037685135074

The following accessories are available to be ordered separately.

Fuel G20 - G30 - G31 Appliance category II2H3+ Type of appliance B23 - C63 Heat input ref. HHV (min - max) 16,3 - 50 16,3 - 100 16,3 - 100 kW Heat input ref. NHV (min - max) 15 - 45 15 - 90 15 - 90 kW Useful heat output (80°/60°C) 44,2 88,30 88,30 kW Useful heat output (50°/30°C) 48,5 96,8 96,8 kW Useful efficiency ref. NHV (80°C/60°C) 98,2 kW Useful efficiency ref. NHV (50°C/30°C) 107,7 % Useful efficiency at 30% ref. NHV (50°C/30°C) 108,7 % Losses through the chimney with the burner operating 1,3 % Losses through the chimney with the burner off 0,1 % Losses through the casing (Tm=70°C ) 0,5 % Flue gas temperature Return temp. + 5 °C CO2 at minimum - maximum 8,4 - 9,4 % CO without air at minimum - maximum less than 10 - 120 p.p.m. NOx without air at minimum - maximum less than 10 - 20 p.p.m. NOx class 5 Maximum operating pressure, central heating 6 bar Maximum admissible temperature 90 °C Range of boiler water temperature settings (± 3 °C) 20-80 °C Water content 5 10 10 l Power supply 230~50 V~Hz Maximum power input 169 333 333 W Index of protection X0D IP Quantity of condensate 7,2 14,4 14,4 l/h

DESCRIPTION

CONDEXA PRO

50 M 100 M 100 S

TECHNICAL SPECIFICATIONS

ACCESSORIES

CONDEXA PRO10

Water-side pressure drop in the boiler

The CONDEXA PRO Boiler does not come with a pump, which must be installed in the system. When sizing the pump, refer to the water-side pressure drop in the boiler, as shown in the figure below.

MI RI GASSC2

7 8

SC1

Pressure drop (mbar)

Flow-rate (l/h)

1200 1100 1000

900 800 700 600 500 400 300 200 100

250 500 750 1000 1250 1500 1750 2000 2250 30002500 2750

1 - Fan 2 - Gas valve 3 - Automatic vent valve 4 - Burner 5 - Heat exchanger 6 - Condensate drain trap 7 - Drain cock 8 - Water differential pressure switch 9 - Safety valve (6 bar)

AA - Air intake SF - Flue gas outlet SC1 - Safety valve drain SC2 - Condensate drain MI - Central heating flow outlet RI - Central heating return inlet GAS - Gas supply

WATER CIRCUIT

CONDEXA PRO 11

CENTRAL HEATING

OUTLET PROBE

SAFETY THERMOSTAT

FLUE GAS PROBE

CENTRAL HEATING

RETURN PROBE

The following probes/thermostats are installed for each heating unit:

POSITIONING THE PROBES

80°C

60°C

50°C

30°C

Configuration with distribution pumps

Boiler discharge head: 7 mWC Boiler flow-rate: 2 m

/h for each heating unit.

Also consider the pressure drops in the individual circuit.

PZ1

PZ2

V2V2

THE CONDEXA PRO Boiler

does not come with a pump, which must be installed in the system.

When choosing the pump, refer to the following system diagrams.

PB - DHW pump PZ1 - Pump in zone 1

(high temperature)

PZ2 - Pump in zone 2

(low temperature)

V2 - Two-way valve

(accessory)

PUMPS

CONDEXA PRO12

80°C

60°C

50°C

30°C

Configuration with injection pumps

Boiler discharge head: 6 mWC Boiler flow-rate: 2 m

/h for each pump.

Recommended pump TYPE A for each heating unit.

PZ1

PZ2

80°C

60°C

50°C

30°C

Configuration with loop pump and valves on the heating units (*)

Boiler discharge head: 7 mWC. Boiler flow-rate: 2 m

/h for each heating unit.

Recommended: p 50 M: TYPE A; 100M/S: TYPE B; 100M+100S: TYPE C.

PZ1

PZ2

V2V2

(*) With this configuration the pump in the low temperature circuit is managed externally by a

thermostat (see parameter 34 on page 59).

PB - DHW pump PZ1 - Pump in zone 1

(high temperature)

PZ2 - Pump in zone 2

(low temperature)

P - Injection pump

(accessory)

PB - DHW pump PZ1 - Pump in zone 1 (high temperature) PZ2 - System pump V2 - Two-way valve (accessory)

CONDEXA PRO 13

Pump TYPE A

Residual head (mbar)

III

100

200

300

400

500

600

700

0 1 2 3 4 5 6 7 8 9

800

Flow-rate (m /h)

Pump TYPE B

100

200

300

400

500

600

700

0 2 4 6 8 10 12 14 16 20

1100

800

900

1000

Residual head (mbar)

Flow-rate (m /h)

Pump TYPE C

100

200

300

400

500

600

700

0 4 8 12 16 20 24 32 36 44

800

28 40

900

1000

1100

1200

Residual head (mbar)

Flow-rate (m /h)

CONDEXA PRO14

The control panel on

CONDEXA PRO

models 50 M and 100 M contains one master board and one or two slave boards,

depending on the output of the boiler. Model

100 S contain just two slave boards. If connecting a series of boilers in casca-

ding, the master board on the

CONDEXA PRO

50 M or 100 M manages all the boards on the

CONDEXA PRO

100 S boi-

lers via BUS.

CONDEXA PRO 50 M - 100 M part 1

Bus

Com.

8 7

23 22 21

Max valve

OFF

Alarm

24V

1314

Input

Analogic

NTC

Circ. 2

10 9

Circ.2

J12

4 3 2 1

J10

28 27

Pump

25 24

Pump 3

Pump

1 2

J11

NTC

1 2

NTC

4 5

Off - Max. valve

Neutral 230 Vac.

Line 230 Vac.

Earth

Line Pump 1

Neutral pump 1

Line DHW pump

Neautral DHW pump

Neutral Max. valve

Line Pompa 3

Neutral pump 3

J9 J8

J10

Fuse

3.15 A

R3 R2

342

On - Max. valve

Alarm

Common

J12

BUS J14

Ebus remote cont.

24V remote cont.

Common

Analogic Input

Common

765

R.T. circ. 1

Common

R.T. circ. 2

243

Common

Bus line with female connector for connection to another model 100S boiler.

J11

BARCODE

Climate NTC

J11 8

Common

Outlet NTC circ. 2

Outlet NTC circ. 1

Common

DHW NTC

Common

13 2

Main earth

pole

Joint with sheath

Line

Earth Neutral

MASTER

230V~50Hz

PZ1

PZ2

SZ1

SZ2

TA1TA2

J11 7

J11 6

J11 5

J11 4

J11 3

J11 2

J11 1

J11 1 J11 2 J11 3 J11 4 J11 5 J11 6

J11 7

J11 8

IACR

J12 1

J12 2

J12 3

J12 4

J12 5

J12 6

J12 7

J12 8

J12 9

J12 8

J12 7

J12 6

J12 5

J12 4

J12 3

J12 2

J12 1

J10 6

J10 5

J10 4

J10 3

J10 2

J10 1

J9 3

J9 2

J9 1

J8 2

J8 1

J10 6 J10 5 J10 4 J10 3 J10 2 J10 1

J9 3 J9 2 J9 1 J8 2 J8 1

Bus line with male connector for connection to another model 100S boiler.

WIRING DIAGRAMS

CONDEXA PRO 15

SLAVE 1

Hall sensor power

BUS 1

Main

J16

J12

4 3 2

b m

v g

21 3

Flue gas NTC

J11

1 2

5 4

4 3

1 3

Blower (-)

Outlet NTC

Hall sensor imput

Blower (+)

Return NTC

Hall sensor common

Safety thermostat

Gas valve

1 2

BUS 2

Fuse 4A

to main earth pole

3 2 1

J15

J14

Line Neutral

Earth Earth

Earth

123

Line Neutral

Earth

SLAVE 2

IG1

EA/ER

IG2

J10

J17

to main earth pole

EA/ER

Diff. pressure switch

PB - DHW pump PZ1 - Pump in zone 1

(high temperature)

PZ2 - Pump in zone 2

(low temperature) VM - Mixing valve CR - Remote control (accessory) IA - Analogue input SB - DHW probe SZ1 - Probe in zone 1 SZ2 - Probe in zone 2 SE - Outside probe TA1 - Room thermostat in zone 1

(high temperature) TA2 - Room thermostat in zone 2

(low temperature)

or injection pump (accessories) IG - Main boiler switch IG1 - FIRST heating unit switch IG2 - SECOND heating unit switch J10/J17 - Microswitches for setting the address

(see page 54)

SYSTEM

The pumps should be connected by installing suitable contactors with manual emergency operation.

HEATING UNIT

part 2

CONDEXA PRO16

CONDEXA PRO 100 S part 1

Bus line with male connector for connection to another model 100S boiler.

L = 1500 mm

Main

BUS 1

J16

J12

a m gv

11109

4 3

1 2

J11

7 5

J6 J14

123

J15

230V~50Hz

SLAVE 1

EA/ER

IG1

SM SR

J10

J17

to main earth pole

Main earth pole

Joint with sheath

Earth

Line

Neutral

Fuse 4A

Earth

Neutral

Line

Earth

Gas valve

Safety thermostat

Diff. pressure switch

Hall sensor common

Blower (+) Hall sensor imput

Blower (-)

Hall sensor power

Flue gas NTC

Return NTC

Outlet NTC

CONDEXA PRO 17

Fuse 4A

Bus line with female connector for connection to another model 100S boiler.

to main earth pole

J12

BUS 1

L = 1200 mm

Main

J16

1 2

9 10 11

J15

J14

J11

v g

2 3

1 6 6

575

3 2 1

gv m

SLAVE 2

EA/ER

IG2

J10

J17

Line Neutral

Earth Earth Earth

Gas Valve

Safety thermostat

Diff. pressure switch

Hall sensor common

Blower (+) Hall sensor imput

Blower (-)

Hall sensor power

Flue gas NTC

Return NTC

Outlet NTC

VG - Gas valve TS - Safety thermostat PD - Water differential pressure switch SM - Outlet probe SR - Return probe SF - Flue gas probe EA/ER - Ignition/detection electrode C - Cable for connection to two-way valve or injection pump (accessories) IG - Main boiler switch IG1 - FIRST heating unit switch IG2 - SECOND heating unit switch J10/J17 - Microswitches for setting the address (see page 54)

part 2

CONDEXA PRO18

12131411 12 13

2 3 4 65 7 98 10

121314 1511 12 13

1 2 3 4 65 7 98

1411 12 13

1 - FIRST heating unit switch 2 - Button for selecting

the operating mode 3 - Reset button (Master) 4 - Boiler lockout signal 5 - Button for selecting

the parameters 6 - Display 7 - Save button 8 - Button to increase values 9 - Button to decrease values 10 - SECOND heating unit switch 11 - Slave power supply signal 12 - Slave lockout signal 13 - Reset button (Slave) 14 - Instrument panel 15 - Main boiler switch

CONDEXA PRO 50 M

CONDEXA PRO 100 M

CONDEXA PRO 100 S

CONTROL PANELS

CONDEXA PRO 19

- The domestic hot water priority function whereby when there is demand for domestic hot water, the master board can also serve the high or low temperature circuit.

- The fr

ost protection function, also active in standby, which starts the pump in the high temperature circuit and the loop pump if the temperature in the manifold falls below 5°C. If the outside probe is fitted, the pumps start if the outside temperature falls below 3°C. If after 10 minutes the temperature in the manifold is less than 5°C, one burner starts at maximum output, until the temperature in the manifold reaches 20°C. If after 10 minutes the temperature in the manifold exceeds 5°C but the outside temperature is less than 3°C, the pumps stay on until the outside temperature exceeds this value.

- The dispersion function

: the pumps in the high and low temperature circuits remain on for 5 minutes after the last burner has shut down. There is a 6 minute delay from when the burner shuts down before closing the two-way valve. When the last burner has shut down, the valve closes only when there is no demand from the room thermostat.

- The cascading function

: to manage the output delivered by the system, the minimum and maximum number of burners started can be selected.

- The bur

ner on/off control function: in both cascading modes there is a function that limits the ignition and shutdown of the burners in the event of low heating requirement.

Functional notes

The control panel on the CONDEXA PRO Boiler models 50 M and 100 M manages:

The buttons on the CONDEXA PRO 50 M and 100 M control panel have different functions in different modes. For example, the combination of two buttons corresponds to one specific function. Alternatively, a function can be activated by pressing the button briefly or by holding it for around 5 seconds.

RESET

This resets the electronic board after a permanent lockout.

MODE

This is used to enter parameter setting mode and monitor mode on the individual units.

SEL

This is used to display the operating status of the various circuits managed by the Master board.

+ and -

Permettono di aumentare o diminuire un determinato valore

MEMO

This is used to save the new values.

USER INTERFACE

CONDEXA PRO20

DISPLAY MODE

The red LED (see ref. 4 on page 18) comes on in the event of faults that cause the permanent lockout of a heating unit (normal operation is reset only by pressing the Master or Slave reset button).

The 3 digits with seven segments display the status of the system:

Status of the system Display

No central heating or DHW demand. The two digits on the right display the outlet temperature T1. E.g.: T1 = 30°C

Demand from circuit no.1 or from circuits 1 and 2 together. The two digits on the right display the outlet temp. T1. E.g.: T1 = 80°C

Demand from the DHW circuit or simultaneous operation. The two digits on the right display the outlet temp. T1 E.g.: T1 = 80°C. The decimal point after the 1st digit on the left flashes

Demand from the 2nd circuit The two digits on the right display the outlet temperature T1. E.g. T1 = 80°C.

READOUT MODE

(TEMPERATURE VALUES AND OPERATING STATUS OF THE VARIOUS CIRCUITS)

Press the "SEL" button to scroll forwards and display the values set for the individual circuits. The values listed below will be displayed in sequence when pressing the "SEL" button.

Value displayed Display

1 Outlet temperature T1 in the high temperature circuit. E.g. : T1 = 80°C

2 DHW temperature T3. E.g.: storage heater temperature = 50°C

3 Outside temperature T4. E.g. T4 = 7°C

4 Outlet temperature in 2nd circuit or low temperature circuit T6

5 Room thermostat in the 1st circuit, closed or open.

OFF = contact open ON = contact closed

6 Room thermostat in the 2nd circuit, closed or open

OFF = contact open ON = contact closed

7 0-10V analogue input

E.g. 5.5V, 10V

CONDEXA PRO 21

To exit the display of the values, press the "MEMO" button. If no operation is performed for 5 minutes, the board automatically returns to Display mode.

Value displayed Display

8 Operating status of the mixing valve

E.g.: closing, opening, standby

9 Operating status of the main pump

E.g.: pump not working, pump working

10 Operating status of the DHW pump

E.g.: pump not working, pump working

11 Operating status of the secondary pump

E.g.: pump not working, pump working

SETTING THE USER PARAMETERS

Pressing "SEL" displays the following values in sequence:

- Outlet temperature T1 in the high temperature circuit

- DHW temperature T3

- Outlet temperature in the second circuit or low temperature circuit T6.

To change the corresponding set points:

- Press "

MODE", the corresponding value will be displayed and the two digits on the right will flash.

- If the value does not need to be changed, press "

MODE" again to return to Display mode.

- If the value needs to be changed, press "

+" or "-" until reaching the desired value. Press "MEMO" to save the new value.

The value displayed will stop flashing and the display will return to Display mode.

Procedure Display

1 E.g.: Value read on the display in the high temperature circuit 80°C

2 Press "

SEL" to access Readout mode, press the button again

and scroll the first digit to 6 so as to display the set value, E.g.: 50°C

Example: changing the set point in the low temperature circuit from 50°C to 40°C

CONDEXA PRO22

If after having pressed “MODE” no change is made for 10 seconds (because the desired value is already set), the operation of the board returns to Display mode.

If after having pressed “+” or “-” no other button is pressed for at least one minute, Display mode resumes. If this hap-

pens, the new value is not saved.

Procedure Display

3 Press “MODE” 4 Press “-” to change the set point to the desired value. E.g.: 40°C.

5 Press “MEMO” to save the new value

6 After 3 seconds Display mode resumes, with the new value set.

MONITOR MODE

Press “MODE” for 5 seconds to access "Monitor" mode. This mode is used to check the operating values of each individual unit in the system (addresses from 1 to 60).

Operation Display

1 The boiler is operating with the high temperature circuit at 80°C

2 Press “

MODE” for 5 seconds. The display indicates that the values

and the operating status of unit 1 can be read.

3 Press “+” or “-” to scroll and read the values for the desired unit.

4 Pressing “

SEL” on the display shows the 1st value for the selected unit.

Pressing the "

SEL" button again displays the following values.

E.g. outlet temperature 70°C

5 To exit Monitor mode, press “

MODE”.

If within 5 minutes no button is pressed or no operation is performed, Display mode resumes.

Value Display

1 Outlet temperature E.g.: 70°C

2 Return temperature E.g.: 50°C

3 Flue gas temperature E.g.: 60°C

4 Ionisation current (index from 0 to 99)

E.g.: ionisation current index 44

Press “SEL” to display the subsequent values for the individual unit:

CONDEXA PRO 23

Value Display

5 Fan PWM signal (%).

If PWM = 100%, this corresponds to 99 on the display. E.g.: 66 %

6 Flow switch contact open/closed (not active)

E.g.: contact open

7 Pump or motorised valve on the individual unit on/off

E.g.: Pump ON E.g.: Pump OFF

8 Maximum ionisation current (range from 0 to 99) at first attempt

E.g.: maximum ionisation current 80

INSTALLER PROGRAMMING MODE

The installer parameters can be changed by entering the password (22). The password for the installer level allows access to display and change the user and installer parameters. Procedure to enter programming mode:

Procedure Display

1 E.g.: the outlet temperature T1 is 80°C

2 Press “MODE” and “MEMO”. After 5 seconds the second and third digit will flash.

3 Use “

+” and “-” to enter the first number in the password on the centre digit.

E.g.: password = X2

4 Press “MEMO” to save the second number in the password.

5 Use “

+” and “-” to enter the first number in the password on the centre digit.

E.g.: password = 22

5 Press “

MEMO” to confirm the password, if the password is wrong

the board returns to Display mode.

6 Press “

+” and “-” to scroll the parameters enabled by the password.

Press “

MODE” to start setting the parameters.

The code P-XX and the corresponding value will alternate on the display.

7 Use “

+” and “-” to change the value of the parameter.

Whenever a button is pressed, the alternating display of the parameter and the corresponding value is stopped for 5 seconds and only the value is shown.

8 Press “MEMO” to save the new value of the parameter.

To exit installer programming mode press “MEMO”.

For the complete list of parameters see page 58.

CONDEXA PRO24

TEST MODE

In Test mode, a high temperature heating demand can be generated corresponding to maximum output and minimum output. All the system fans must be on. If the installer switches off some of the Slaves, the others, connected to the Master, must continue operating. To enter Test mode from Display mode, proceed as follows:

Procedure Display

1 Press “MODE” and “+” at the same time per 5 seconds.

After 5 seconds the maximum or minimum speed

can be selected using the “+” and “-” buttons.

All the system fans will operate at the selected speed. The first digit will show the selected speed: H = maximum speed L = minimum speed. The other two digits will show the outlet temperature. E.g.: T1 = 80°C.

2 Press “MEMO” to exit Test mode and return to Display mode.

For the complete list of errors, see page 56.

ERROR MODE

The display starts flashing when there is a fault on any of the heating units. Proceed as follows to identify the faults.

PERMANENT LOCKOUT

In the event where the burners are in permanent lockout, press “RESET” to resume operation.

If “

RESET” is pressed in readout mode, all the Slave heating units will be reset.

If “

RESET” is pressed when displaying the error that caused the permanent lockout, only the heating unit in question

will be reset.

Procedure Display

1 The display starts flashing to signal one or more errors.

1.b Press “

+”: the display will show the address of the

first unit, alternating with the first error code. Press “

+” again to display the other errors on this unit.

The errors on the following unit with faults will be displayed in sequence, by pressing “

+” Pressing "-" displays the errors in reverse order

(E.g. unit 2 error code E02). If the errors come from the Master board, these are displayed as errors on unit 00 (U 00 + error code).

2 Press “MODE” to exit Error mode and return to Display mode.

CONDEXA PRO 25

The Vokera CONDEXA PRO Boiler is supplied in a single package protected by a cardboard box.

The following material is supplied with the boiler:

- Installation and operation manual

- Warranty certificate

- Water pressure test certificate

- Spare parts catalogue

- Outside probe

- Kit for conversion from natural gas to LPG

- Assembly template.

bThe Installation and operation manual is an integral

part of the appliance and must be read and kept with care.

W 600 mm D 380 mm H 1000 mm Net weight ~ 60 ~ 90 kg Weight with packaging

~ 65 ~ 95 kg

Description

50 M

100 M - 100 S

RECEIVING THE PRODUCT

DIMENSIONS AND WEIGHT

CONDEXA PRO26

Once having removed the packaging, the Vokera CONDEXA PRO

Boiler is handled manually by tilting and

lifting it, grabbing the points shown in the figure.

bAdopt suitable safety and protection measures.

aThe packaging material must not be dispersed in

the environment or left within the reach of children as it is a potential source of hazard. It must be disposed of according to the legislation in force.

The Vokera CONDEXA PRO boiler must be installed in rooms used exclusively for this purpose, provided with adequately sized ventilation openings, in compliance with any current standards and low applicable. If the combustion air is taken from outside (accessories code 5037685135067 and 5037685135074) the room where the boiler is installed, CONDEXA PRO operates as a room-sealed appliance (type C).

bProvide enough clearance to access the safety and

control devices and to carry out the servicing operations.

bCheck that the index of protection of the boiler is

suitable for the characteristics of the room where the appliance is installed.

bIf the boilers operate on gas fuel with a higher spe-

cific weight than air, the electrical parts must be located at least 500 mm from the floor.

aThe boilers cannot be installed outside as they are

not designed for outdoor operation.

HANDLING

ROOM WHERE THE BOILER IS INSTALLED

CONDEXA PRO 27

Where Vokera CONDEXA PRO Boilers are installed in old systems or systems to be upgraded, check that:

- The flue is suitable for the temperature of the products of combustion with condensing operation, calculated and manufactured according to the standards, as straight as possible, airtight, insulated and not blocked or choked. It must also be fitted with suitable condensate collection and drain systems

- The electrical system has been installed in compliance with the relevant standards by qualified personnel

- The fuel supply line and any cylinders or tanks (LPG) are made and installed according to the relevant standards

- The expansion vessel can completely absorb the expansion of the fluid contained in the system

- The flow-rate and the discharge head of the pump are suitable for the characteristics of the system

- The system is flushed, treated, vented and pressure tested. To clean the system, see the paragraph on "Water connections", page 28. The manufacturer is not liable for any damage caused by the incorrect flushing, treatment and venting etc of the system.

- The condensate drain system (drain trap) is connected and runs into the sewerage drain or a neutraliser, where required by the legislation in force.

- A treatment system is available for special supply/topup water requirements (for the reference values, see the table).

bThe manufacturer is not liable for any damage cau-

sed by the incorrect layout or installation of the flue system which must be in-accordance with any current standards and law applicable

bThe flues for condensing boilers are made from

special material and differ from those used for standard boilers.

INSTALLATION IN OLD SYSTEMS OR SYSTEMS TO BE UPGRADED

SUPPLY WATER VALUES

pH 6-8 Conductivity less than 200 mV/cm (25°C) Chloride ions less than 50 ppm Sulphuric acid ions less than 50 ppm Total iron less than 0,3 ppm Alkalinity M less than 50 ppm Total hardness less than 35°F Sulphur ions none Ammonia ions none Silica ions less than 30 ppm

CONDEXA PRO28

The Vokera CONDEXA PRO Boiler must be secured to a solid brick wall using the bracket (1).

For installation:

- Position the bracket (1) on the wall at a height of around 200 cm from the ground, using a spirit level to make sure that the holes are perfectly horizontal

- Mark the fastening holes on the wall

- Drill the holes and insert the expansion plugs (2)

- Fasten the bracket to the wall using the screws (3)

- Hook the boiler to the bracket.

bThe height of the boiler should chosen so as to sim-

plify the dismantling and servicing operations.

bThe Vokera CONDEXA PRO Boiler is not designed

for outdoor installation.

MI RI GASS MI RI GAS

The Vokera CONDEXA PRO Boilers are designed and built to be installed in central heating and domestic hot water systems. The characteristics of the water fittings are as follows:

MI - Central heating flow outlet 1" M RI - Central heating return inlet 1" M Gas - Gas supply 3/4" M

CONDENSATE COLLECTION

Identify the condensate drain (S) located at the bottom of the boiler and then:

- remove the ring nut/nuts (1)

- pass the hose (2) through the hole and replace the ring nut on the outside.

Pipe the condensate into the sewerage drain or a neutraliser, where required and in-accordance with any legislation in force.

bThe manufacturer is not liable for any damage cau-

sed by the failure to install the condensate drain pipe.

bThe condensate drain pipe must be watertight.

INSTALLING THE BOILER

WATER CONNECTIONS

CONDEXA PRO 29

250 250 300

1000

1500

GAS

400

150

CLEANING THE SYSTEM

This preliminary operation is required when installing the heat generator in pre-existing systems, and is also recommended in new systems, so as to remove any scale, impurities, processing residues etc. Power Flushing is recommended for system cleaning.

To clean the system, if the old heat generator is still installed in the system, proceed as follows:

- Add scale-remover into the system water circuit;

- Operate the system with the heat generator on for around 7 days;

- Empty the dirty water from the system and flush with clean water. Repeat the operation until the system is clean.

If the old heat generator is not installed or not available, use a pump to circulate the water with the additive in the system for around 10 days, and carry out flushing as described in the previous point. At the end of the cleaning operations, before installing the boiler, an additive should be introduced into the water circuit that provides protection against corrosion and fouling.

bFor additional information on the type and the use

of the additives, contact

Vokera Ltd or a suitable

additives manufacture.

Water connection kits

To assist the construction of the water circuit, two accessory kits are available, featuring water headers and support brackets:

water connection kit for installations up to 100 kW (code 5037685135012)

1 gas manifold, diameter 45 mm 1 central heating outlet manifold, diameter 45 mm 1 central heating return manifold, diameter 45 mm

2" female fittings.

water connection kit for installations above 100 kW (code 5037685135029).

1 gas manifold, diameter 3" 1 insulated central heating outlet manifold, Ø 3” 1 insulated central heating return manifold, Ø 3”

DN 80 - PN 6 flanged pipes.

bIdentify the unit that is closest to the central heating

flow outlet as the Master boiler, so as to minimise the length of the cables to the pumps, the outlet probe and any storage heater probe.

bThe outlet probe should be fitted in the socket nea-

rest to the central heating flow outlet, in the direction of water flow.

WATER CONNECTION KIT code 5037685135012

125

700

125 200

1000

MI RI GAS

400

WATER CONNECTION KIT code 5037685135029

CONDEXA PRO30

The Vokera CONDEXA PRO Boiler must be connected to the natural gas or LPG supply in compliance with the relevant standards in force.

Before making the connections, check that:

- the type of gas is the same that the appliance is set for

- the pipes are thoroughly clean

- the gas supply pipes are the same size or larger than the fitting on the boiler (3/4"), with a pressure drop that is less than the pressure drop between the gas supply and the appliance.

When installation is completed, check that the joints are all tight, as required by the installation standards.

A suitable filter should be installed on the gas line.

The flue and the fitting to the flue must be made in compliance with the standards and the legislation in force, as well as with local regulations. The pipes used must be rigid and resistant to temperature, condensate and mechanical stress, and airtight.

bNon-insulated flues are potential sources of danger.

275

275 212

C63 B23

B23 Fan upstream. Combustion air intake directly

from the room where the boiler is installed. Flue gas exhaust through horizontal or vertical pipes, fitted with ventilation openings.

C63 Fan upstream. Combustion air intake and flue

gas exhaust without terminals.

Please refer to any current standards and law applicable to flues and ventilation.

A - Air intake Ø 50 mm

(Conversion kit for room-sealed operation

CONDEXA PRO

50 code

5037685135067

Conversion kit for room-sealed operation

CONDEXA PRO

100 code

5037685135074

)

S - Flue Ø 50 mm

FUEL CONNECTIONS

FLUE GAS OUTLET AND COMBUSTION AIR INTAKE

CONDEXA PRO 31

50 20

230 mm

90 mm

160 mm

Square compartment

Rectangular compartment

Minimum dimensions of the compartment for the passage of three flues, diameter 50 mm

90 mm

160 mm

205050

Ø 160 mm

Circular compartment

Rectangular compartment

Minimum inside dimensions of the compartment for the passage of 2 flues, diameter 50 mm

50mm

63 mm

71 mm

Minimum inside dimensions of the compartment for the passage of 1 flue, diameter 50 mm

Circular compartment

Square compartment

MAXIMUM LENGTH OF THE PIPES

The maximum equivalent length of the sum of the 50 mm intake pipes and flues is 30 metres, with a pressure drop of 2 metres for each 90° bend.

Installation of a single boiler with flue passing inside a compartment (open flue operation).

For this type of operation, make sure that the size of the compartment complies with the standards in force. The figure on the side shows the minimum dimensions of the compartment when passing one flue (model 50 M) or two flues (models 100 M or 100 S).

bParameter 36 (see page 59) needs to be set based

on the type of gas and the length of the chimney.

model 50 M

models 50 M + 100 S

model 100 M

CONDEXA PRO32

Minimum

distance

10 mm

Minimum distance 300 mm

Condensate collector

(at atmospheric pressure)

i > 3% Mains sewers

i ≥ 3°

PREPARING THE CONDENSATE DRAIN

The condensate produced by the boiler during normal operation must be drained at atmospheric pressure and must conform to any current standards and law applicable.

- install a neutraliser where required by law.

bSpecific pipes for condensing boilers must be

used. For installation, follow the instructions provided with the kit.

Drain trap along the drain pipe

If the vertical or horizontal section of the drain pipe needs to be extended by more than 4 metres, a drain trap must be installed at the foot of the pipe. The useful height of the drain trap must be at least 300 mm. The discharge of the drain trap must then be connected to the sewerage system.

CONDEXA PRO 33

The

CONDEXA PRO

50 M and 100 M boilers leave the factory completely wired, with the power cable already connec-

ted, and only require the connection of the room thermostats, the outside probe and the pumps used, to the corresponding terminals. For the

CONDEXA PRO

100 S boiler, only the Bus cable needs to be connected (see the wiring diagram

on page 16).

To do this:

- Move the main system switch to "off"

- Unscrew the fastening screws (1) on the front panel (2)

- Pull the base of the panel (2) outwards and then upwards to release it from the frame and then remove it

- Turn the control panel (3) and remove the rear cover, taking out the locking screws (4)

OFF

ELECTRICAL CONNECTIONS

CONDEXA PRO34

- Identify the terminal block (5) and make the connections, as in the diagram shown below.

Pbas (*) Low temperature

system pump

PB (*)

28 27 26 25 24 23 22 21 20 19 18

1 2 3 4 5 6 7 8

DHW pump

PZ1 (*)

High Temperature system pump

PZ2 (*) Loop pump or

VM (*)

Mixing valve

Storage heater probe

SZ1

Probe in zone 1, high temperature

Outside probe

Contact for alarm signal

17 16 15 14 13 12 11 10 9

TA1

High temperature

room thermostat

TA2

Low temperature

room thermostat

TERMINAL BLOCK INSIDE THE MASTER CONTROL PANEL

SZ2

Probe in zone 2, low temperature

(*) 230V~50Hz

0-10V

analogue

input

Remote

control

24V

COM

BUS

b The following measures are compulsory:

1 -the use of an omnipolar thermal overload swit-

ch, mains disconnecting switch, compliant with the CEI-EN standards (minimum contact opening 3 mm);

2 - respect the connection L (Line) - N (Neutral).

Leave the earth wire around 2 cm longer than the power wires;

3 -use wires with a cross-section greater than or

equal to 1.5 mm

, complete with pointed end

terminals;

4 -refer to the wiring diagrams in this booklet for

any operations on the electrical system;

5 -connect the appliance to an effective earth

system.

The pumps should be connected by installing suitable contactors with manual emergency operation.

aThe gas and/or water pipes must not be

used to earth the appliance.

aThe power supply and room thermostat

cables must not run near hot surfaces (outlet pipes).

The manufacturer is not liable for any damage due to the failure to earth the appliance and to observe the information provided on the wiring diagrams.

CONDEXA PRO 35

Fastening the outside probe to the wall

- Unscrew the cover on the probe protection box, turning it anticlockwise to access the terminal block and the fastening holes

- Trace the fastening points using the protection box as the template

- Remove the box and drill the holes for the 5x25 expansion plugs

- Fasten the box to the wall using the two plugs supplied

- Unscrew the nut on the cable gland, pass a two-wire cable through (cross-section from 0.5 to 1mm

, not supplied) to connect the probe to terminals 7 and 8 (see the diagram on page 34)

- Connect the two wires on the cable to the terminal block, without needing to identify the polarity

- Tighten the nut on the cable gland and close the cover on the protection box.

bThe probe should be placed on a smooth section of

the wall; in the event of exposed brick walls or uneven walls, a smooth contact area should be used.

bThe maximum length of the connection between

the outside probe and the control panel is 50 m.

Conversion table valid for all probes

Temperature measured (°C) - Resistance of the probes (Ω).

T (°C) R (°Ω) T (°C) R (°Ω) T (°C) R (°Ω) T (°C) R (°Ω) T (°C) R (°Ω) T (°C) R (°Ω) T (°C) R (°Ω)

bThe connection cable between the probe and con-

trol panel must not have junctions; if required, these must be sealed and adequately protected.

bAny conduits used for the connection cable must

be separate from the power cables (230Vac).

The correct positioning of the outside probe is fundamental for the correct operation of the climate control function. The probe must be installed outside of the building being heated, at a height of around 2/3 of the wall facing NORTH or NORTH-WEST, and away from flues, doors, windows and areas exposed to direct sunlight.

-20

-19

-18

-17

-16

-15

-14

-13

-12

-11

-10

-9

-8

-7

-6

-5

-4

-3

-2

-1

67739 64571 61568 58719 56016 53452 51018 48707 46513 44429 42449 40568 38780 37079 35463 33925 32461 31069 29743 28481

0 1 2 3 4 5 6 7 8 9

11 12 13 14 15 16 17 18 19

27279 26135 25044 24004 23014 22069 21168 20309 19489 18706 17959 17245 16563 15912 15289 14694 14126 13582 13062 12565

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

12090 11634 11199 10781 10382

9999 9633 9281 8945 8622 8313 8016 7731 7458 7196 6944 6702 6470 6247 6033

40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

5828 5630 5440 5258 5082 4913 4751 4595 4444 4300 4161 4026 3897 3773 3653 3538 3426 3319 3216 3116

60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79

3021 2928 2839 2753 2669 2589 2512 2437 2365 2296 2229 2164 2101 2040 1982 1925 1870 1817 1766 1717

80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99

1669 1622 1577 1534 1491 1451 1411 1373 1336 1300 1266 1232 1199 1168 1137 1108 1079 1051 1024

998

100 101 102 103 104 105 106 107 108 109 110

973 948 925 901 879 857 836 815 796 776 757

INSTALLING THE OUTSIDE PROBE

CONDEXA PRO36

The Vokera CONDEXA PRO Boiler is not fitted with an automatic filling valve, which must be installed on the system return.

FILLING

- Open the valves (1) installed on the boiler water fittings;

- Open the caps on the automatic vent valve/valves (2) two or three turns;

- Open the filling valve on the system until the pressure shown on the pressure gauge is

1,5 bar;

- Close the filling valve again.

bThe air is vented from the CONDEXA PRO boiler

automatically through the automatic vent valve/valves installed on the top of the heating units. Check that the cap on the valve is open.

MI RI GAS

2 2

FILLING AND EMPTYING THE SYSTEMS

CONDEXA PRO 37

OFF

EMPTYING

Before starting to empty the system, disconnect the power supply by moving the main system switch to "off".

Emptying the BOILER

- Close the valves (1) installed on the boiler water fittings;

- Connect a plastic hose to the drain cock (4), on each heating unit, and open the cock;

bBefore opening the drain cock (4), protect the elec-

trical devices underneath against water spillage.

Emptying the SYSTEM

- Check that the valves (1), installed on the water circuit, are open;

- Connect a plastic hose to the drain cock (5), fitted on the system return line, and open the cock.

MI RI GAS

4 4

CONDEXA PRO38

Before starting the system and running the functional tests on the

Vokera CONDEXA PRO Boiler, check that:

- The fuel valve and valves in the central heating system are open;

- The type of gas and the supply pressure are correct for the boiler;

- The system is filled, pressure in the water circuit, when cold, is around 1,5 bar and the circuit has been vented;

- The system expansion vessel is suitably pre-charged;

- The electrical connections have been performed correctly.

bThe pumps should be connected by installing sui-

table contactors with manual emergency operation.

- Check that the cap on the vent valve/valves is unscrewed;

- The pumps turn freely: loosen the inspection screw and check with a flathead screwdriver that the motor shaft is rotating without impediments.

bBefore loosening or removing the seal cap on the

pump, protect the electrical devices underneath against water spillage.

- The flues have been properly made and installed.

PREPARING FOR FIRST START-UP

CONDEXA PRO 39

- Move the main system switch to "on";

- Move the main switch (1) on the boiler and the switches (2) on each heating unit to "on".

The green SLAVE power supply signal (3) flashes. The boiler performs a self-diagnosis cycle, after which it will enter DISPLAY mode.

The display (4) shows the status of the system and the temperature measured by the probe in the "high temperature" circuit (see Display mode on page 20).

If there are more than two boilers installed, configure the addresses from the third boiler on. To do this, see the paragraph "Setting the addresses for cascading configurations" on page 54).

- Set the room thermostats in the high and low temperature zone to the desired temperature (~20°C) or if the systems are fitted with a timer-thermostat or timer, check that this is on and set (~20°C).

- Press the “

SEL” button: the maximum temperature of

the boiler will be displayed, that is, the maximum temperature in the high temperature circuit, preceded by the symbol "1".

- Press “

MODE”: the corresponding set point will be

displayed and the two digits on the right will flash. To change the value, press “

+” or “-”.

To confirm press “

MEMO”.

OFF

2 2

STARTING FOR THE FIRST TIME

CONDEXA PRO40

- Press the “SEL”button four times: the maximum tem-

perature in the low temperature circuit will be displayed, preceded by the symbol "6".

- Press “

MODE”: the corresponding set point will be

displayed and the two digits on the right will flash. To change the value, press “

+” or “-”.

To confirm press “

MEMO”.

bFor low temperature systems, select a temperature

between 20°C and 45°C. When setting the system as "Low temperature", the maximum outlet temperature will be limited at 50°C (Par. 23=T_CH_Low_limit).

bChanging the outlet temperature modifies the cli-

mate control curve (see the paragraph "Setting the temperature controller"). These settings must only be performed by

Vokera Ltd or a suitably qualified

person.

- Press “

SEL”button twice: the DHW temperature will be

displayed, preceded by the symbol "3".

- Press “

MODE”: the corresponding set point will be

displayed and the two digits on the right will flash. To change the value, press “

+” or “-”.

To confirm press “

MEMO”.

The boiler will start in DHW mode, until the demand is satisfied.

If the boiler is connected to a storage heater, set parameter 6 (pre-set to 0=no DHW service). To do this, access "Installer programming" mode and set parameter 6 to:

2 = for storage heater with probe 6 = for storage heater with thermostat.

In addition, set parameter 9 (DHW_Priority) to 2 for absolute priority. If the storage heater is fitted with an NTC probe, the desired temperature can be set on the display, from 10°C to 50°C. If the storage heater is fitted with a thermostat, the desired temperature should be set directly on the storage heater, while parameter 3 must be left at 50°C.

CONDEXA PRO 41

When the boiler is in Standby, the display on the Master unit is in Readout mode and the three digits show the number "1", followed by the value of the outlet temperature. The green LED (ref. 11 on page 18) flashes.

See the paragraph on "DISPLAY MODE", page 20, for details on the various information displayed by the system.

If ignition or operating faults occur on any heating unit, the display on the Master boiler starts flashing and the red LED (4) comes on.

There are two possible types of errors:

- Type A errors, which can only be deactivated by pressing RESET;

- Type E errors, which are deactivated when the causes are no longer present (see ERROR MODE on page 24 and the "Fault codes" paragraph on page 56).

When ignition is complete, check that the CONDEXA

PRO

boiler correctly:

- Starts and stops, closing the contacts on the zone thermostats;

- Displays the DHW temperature (only if the storage heater is fitted) and central heating temperature, pressing the “

SEL”button twice;

Check, if the storage heater is fitted, that parameter "6" is set correctly:

2 = storage heater with probe 6 = storage heater with thermostat

and check that operation is correct, by opening a hot water tap.

Check the complete shutdown of the boiler by moving the main system switch to "off".

OFF

CHECKS DURING AND AFTER FIRST START-UP

CONDEXA PRO42

After a few minutes of continuous operation controlled by the room thermostat, the adhesives and the processing residues will have evaporated, and the following checks can be completed:

- check the gas supply pressure;

- check combustion,

CHECKING THE GAS SUPPL

Y PRESSURE

- Move the main system switch to "off";

- Unscrew the fastening screws (1) on the front panel (2);

- Pull the base of the panel (2) outwards and then upwards to release it from the frame and then remove it;

- Unscrew the screw on the pressure test point (3), located upstream of the gas valve, around two turns, and connect a pressure gauge;

- Power-up the boiler by moving the main system switch and the main switch/switches on the appliance to "on".

OFF

CONDEXA PRO 43

In TEST mode, a high temperature heating demand at maximum output can be generated.

To do this:

- Press the “

MODE” and “+” buttons together for 5

seconds;

- Start the boiler by adjusting the room thermostat. The boiler will operate at maximum output showing "H" on the display, followed by the outlet temperature (chimney sweep function);

- Check that with the burner on at maximum output the gas pressure is the rated supply pressure, as shown in the table to the side;

- Adjust the thermostat so as to stop the boiler;

- Press “

MEMO” to exit TEST mode;

- Disconnect the pressure gauge and tighten the screw on the pressure test point (3) upstream of the gas valve.

CHECKING COMBUSTION

- Power-up the boiler by moving the main system switch and the main switch/switches on the appliance to "on";

In TEST mode, a high temperature heating demand at maximum output can be generated.

To do this:

- Press the “MODE” and “+” buttons together for 5 seconds;

- Start the boiler by adjusting the room thermostat. The boiler will operate at maximum output showing "H" on the display, followed by the outlet temperature (chimney sweep function).

OFF

DESCRIPTION G20 G30 G31

Wobbe index 45,7 80,6 70,7 MJ/m

Rated supply pressure 20 28-30 37 mbar

CONDEXA PRO44

- Combustion can be checked by unscrewing the cap (4) and inserting the analyser probe in the available position;

- Once having completed the check, stop the chimney sweep function by pressing “

MEMO”;

- Adjust the thermostat so as to stop the boiler;

- Remove the analyser probe and carefully retighten the cap (4);

FAN SPEED

The fan speed is controlled automatically based on the type of gas and the length of the flue (L). This information is managed by parameter 36.

To change the settings:

- Enter "INSTALLER PROGRAMMING MODE" following the procedure described on page 23, and set parameter 36 to:

1 = natural gas and L<15 m 2 = natural gas and L>15 m 3 = LPG and L<15 m 4 = LPG and L>15 m.

The

CONDEXA PRO boilers are supplied for operation

on G20 (natural gas), with a flue L<15m (parameter 36=1).

Once the checks are complete, replace the front panel and secure it using the same screws.

bAll checks must be performed by a suitably quali-

fied person.

CONDEXA PRO 45

The functions of the central heating high temperature and low temperature circuits and the DHW circuits can be set based on the system requirements, by setting the functional parameters.

The first three parameters are accessible at a user level, while the remaining parameters require the password to be entered ("22", see page 23).

To access the user parameters, press the "SEL" button, after which the following values will be displayed:

- Outlet temperature in the high temperature circuit T1

- Temperature in the DHW circuit T3

- Outlet temperature in the low temperature circuit T6

To change the corresponding set points:

- Press "

MODE", the corresponding value will be displayed and the two digits on the right will flash.

- Press “

+/-” until reaching the desired value. Press "MEMO" to save the new value. The value displayed will stop fla-

shing and will be valid after 3 seconds.

For a detailed description of all the parameters and the default values see page 58.

The following functions can be set for central heating:

1 Setpoint_T_CH_High

Set point in the high temperature circuit (parameter 1)

If the operating mode is set to "fixed set point" (par. 14=CH_type_high=0), this is the objective temperature. If the operating mode is set to "climate control" (par. 14=1), this is the maximum objective temperature for the minimum outside temperature (T_out_min=par. 37, pre-set to 0°C). Parameter 18 (T_CH_high_foot, pre-set to 50°C) defines the minimum set point for the maximum outside temperature (T_out_max, pre-set to 18°C).

Pre-set to 70°C with upper limit set by par. 17 (T_CH_high_limit, pre-set to 80°C).

T_out_max

Outside temperature (°C)

Outlet temperature (°C)

100

25 20 15 10 5 0 -5 -10 -15 -20

CLIMATE CONTROL CURVE

HIGH TEMPERATURE CIRCUIT

T_CH_High

Max heating requirement

T_CH_High_foot

T_out_min

SETTING THE FUNCTIONAL PARAMETERS

SETTING THE CENTRAL HEATING PARAMETERS

CONDEXA PRO46

2 Setpoint_T_CH_Low

Set point in the low temperature circuit (parameter 3)

If the operating mode is set to "fixed set point" (par. 22=CH_type_low=0), this is the objective temperature. If the operating mode is set to "climate control" (par. 22=1), this is the maximum objective temperature for the minimum outside temperature (T_out_min=par. 37, pre-set to 0°C). Parameter 24 (T_CH_low_foot, pre-set to 25°C) defines the minimum set point for the maximum outside temperature (T_out_max, pre-set to 18°C).

Pre-set to 40°C with upper limit set by par. 23 (T_CH_Low_limit, pre-set to 50°C).

3 CH_Priority

Central heating priority (parameter 16)

If this is set to 0 the system works without central heating priority, that is, with the high temperature and low temperature circuit served in parallel. If set to 1, the demand from the low temperature circuit is ignored and the corresponding pump remains off. The demand from the low temperature circuit is only accepted when the high temperature circuit is off. Vice-versa, if set to 2 the low temperature circuit has priority.

Pre-set to 0.

Consequently, each circuit can operate with a fixed set point or using a set climate control curve.

T_out_max

Outside temperature (°C)

Outlet temperature (°C)

100

25 20 15 10 5 0 -5 -10 -15 -20

CLIMATE CONTROL CURVE

LOW TEMPERATURE CIRCUIT

T_CH_Low

Max heating requirement

T_CH_Low_foot

T_out_min

CONDEXA PRO 47

The following functions can be set for the domestic hot water circuit:

1 Setpoint_DHW

Domestic hot water set point (parameter 2)

This is the temperature value for the production of domestic hot water. The maximum limit is set by par. 8 (T_DHW_limit, pre-set to 60°C).

Pre-set to 50°C.

2 DHW_Type

Type of storage heater (parameter 6)

0 = No DHW service 1 = Rapid heat exchanger with probe 2 = Storage heater with probe 6 = Storage heater with thermostat

For the storage heater with thermostat, if the input is a closed contact, the domestic hot water demand is activated, if it is an open contact the demand is no longer present.

Pre-set to 0.

3 DHW_Priority

Domestic hot water priority (parameter 9)

0 = Sliding priority A

The purpose of the sliding priority A function is to allow the system to also serve the central heating function when the heating demand is low. The system responds to the heating demand if:

(Setpoint_Ch - 50°C) < Manifold temp. < (Setpoint_Ch + 1°C)

Setpoint_Ch = Set point in the high or low temperature circuit, according to the demand.

1 = Sliding priority B

The purpose of the sliding priority B function is to ensure that the system does not stop the central heating service for too long. The system responds to the heating demand if:

(Setpoint_Dhw+T_Tank_extra) - 50°C < Manifold temp. < (Setpoint_Dhw+T_Tank_extra) + 1°C

T_tank_extra = Par. 10 = pre-set to 30°C.

2 = Absolute priority (DHW service only)

Pre-set to 0.

SETTING THE DOMESTIC HOT WATER PARAMETERS

CONDEXA PRO48

1 Attenuation_High

Attenuation function for the HIGH TEMPERATURE circuit (parameter 21)

Two cases are possible:

- Operation with fixed set point, Par. 14=0

- Operation with climate control Par. 14=1.

OPERATION WITH FIXED SET POINT, PAR. 14=0

With attenuation in the high temperature circuit disabled, Par21=0, when the thermostat in the high temperature circuit closes, the heating demand is signalled. When opening, the system stops.

The Master controller starts the pump in the high temperature circuit PZ1 and the loop pump PZ3, if the parameter for the third pump is set to 0 (Par. 34=0 ), otherwise the third pump remains off.

The set point for the high temperature circuit can be set on the Master controller, Setpoint_T_CH_High = Par. 1, preset to 70°C, in the range from 10°C to T_CH_high_limit=Par 17, in turn pre-set to 80°C. The set point used will be the value set for parameter 1.

The burner is on when: Manifold Temperature <=Set point – Start hysteresis. The start hysteresis can be set, CH_High_mod_hyst_on = Par. 19, pre-set to 7°C, between 0 and 20°C. The Master controller converts the heating demand into an output requirement for each slave controller.

The burners are off when: Manifold Temperature >=Set point + Stop hysteresis. The stop hysteresis can be set (CH_High_mod_Hyst_off=Par. 20, pre-set to 3, between 0 and 20°C).

When the attenuation in the high temperature circuit parameter is enabled, Par. 21≠0, the contact on the high tem-

perature thermostat is ignored, and a demand for heat in the high temperature circuit is present when: Manifold Temperature <=Set point – Start hysteresis

The demand for heat stops when: Manifold Temperature >=Set point + Stop hysteresis. The set point in this case coincides with the value set for parameter 1 (Setpoint_T_CH_High), if the contact of the high temperature thermostat is closed, while it is calculated as the value set for parameter 1 minus the attenuation (Setpoint_T_CH_High-Attenuation_high) if the contact is open.

OPERATION WITH CLIMATE CONTROL, PAR. 14=1

If the attenuation in the high temperature circuit parameter is equal to 0, attenuation_high=Par. 21=0, the behaviour is the same as in the previous paragraph, except the set point is calculated according to the outside temperature.

If the outside temperature = T out_min=Par. 37, pre-set to 0°C, then set point =setpoint_T_Ch_high If the outside temperature = T out_max=Par. 38, pre-set to 18°C, then set point T_CH_high_ foot=Par. 18, preset to 50°C.

Between the two outside temperature values, the set point is calculated linearly.

Pre-set to 0.

SETTING THE TEMPERATURE CONTROLLER

CONDEXA PRO 49

2 Attenuation_Low

Attenuation function for the LOW TEMPERATURE circuit (parameter 25).

This paragraph is similar to the previous one, however in this case referred to the low temperature circuit.

Two cases are possible:

- Operation with fixed set point, Par. 22=0

- Operation with climate control Par. 22=1.

OPERATION WITH FIXED SET POINT, PAR. 22=0

With attenuation in the low temperature circuit disabled, Par. 25=0, when the thermostat in the low temperature circuit closes, the heating demand is signalled. When opening, the system stops. The Master controller starts the pump in the low temperature circuit PZ3. The set point for the low temperature circuit can be set on the Master controller, Setpoint_T_CH_low = Par. 3, pre-set to 40°C in the range from 10°C to T_CH_Low_limit=Par. 23, in turn pre-set to 50°C.

The set point used will be the value set for parameter 3.

The burner is on when: Manifold Temperature <=Set point – Start hysteresis. The start hysteresis can be set, CH_Low_mod_hyst_on = Par. 26, pre-set to 5°C, between 0 and 20°C.

The Master controller converts the heating demand into an output requirement for each slave controller.

The burners are off when: Manifold Temperature >=Set point + Stop hysteresis.. The stop hysteresis can be set (CH_Low_mod_Hyst_off=Par. 27, pre-set to 3, between 0 and 20°C).

When the attenuation in the low temperature circuit parameter is enabled, Par. 25≠0, the contact on the low tempe-

rature thermostat is ignored, and a demand for heat in the high temperature circuit is present when: Manifold Temperature <=Set point – Start hysteresis

The demand for heat stops when: Manifold Temperature >=Set point + Stop hysteresis. The set point in this case coincides with the value set for parameter 3 (Setpoint_t_ch_low) if the contact of the low temperature thermostat is closed, while it is calculated as the value set for parameter 3 minus the attenuation (Setpoint_t_ch_low-Attenuation_low) if the contact is open.

OPERATION WITH CLIMATE CONTROL, PAR. 22=1

If the attenuation in the low temperature circuit parameter is equal to 0, attenuation_low=Par. 25=0, behaviour is the same as in the previous paragraph, except the set point is calculated according to the outside temperature.

If the outside temperature = T out_min=Par. 37, pre-set to 0°C, then set point =setpoint_T_Ch_low. If the outside temperature = T out_max=Par. 38, pre-set to 18°C, then set point T_ch_low_foot=Par. 24, pre-set to

50°C.

Between the two outside temperature values, the set point is calculated linearly.

Pre-set to 0.

CONDEXA PRO50

3 T_out_correct

Outside temperature correction (parameter 39)

Normally the value displayed is the value read by the micro-controller, plus or minus a correction value (T displayed = T read by the probe +/- correction). The outside temperature value read can be corrected by changing the value of parameter 39, (the limit allowed for the correction is +/- 30 °C). In this phase, the use of a reference thermometer is suggested.

Pre-set to 0.

4 T4_frost_protection

Frost protection (parameter 35)

The electronic controller features a frost protection function that is also active in standby. The frost protection function has two levels, the first that starts the pump, and the second that starts the pump and the burner.

If the Manifold Temperature ≤5°C, the pump in the high temperature circuit and the loop pump are started, or, when CH_type=1 and the outside probe is connected, if the Outside Temperature ≤3°C (par. 35), the pump in the high tem-

perature circuit and the loop pump are started.

If after 10 minutes the Manifold Temperature ≤5°C, a burner is started at maximum output, until the Manifold Temperature ≥20°C.

If after 10 minutes the Manifold Temperature ≥5°C but, when CH_type=1 (Par. 14 or 22) and the outside probe is con-

nected, the Outside Temperature ≤3°C (par. 35), the pump continues operating until the Outside Temperature ≥3°C.

Pre-set to 3.

5 Power_control_mode

Cascading management (parameter 33)

To manage the output delivered by the system, two cascading strategies are available. In both cases, the Master controller can only start a new burner when another is already on. If the Master controller needs to increase the number of burners on, it first checks that the subsequent burner can be started: no error is present and temperature of the boiler is less than the maximum. Otherwise, it checks another burner. If no burner is available, the master decreases the number of burners to be started.

MODE: MINIMUM NUMBER OF BURNERS ON (PAR. 33=0)

The output of the system is modulated by a PID control algorithm, where the value controlled is the temperature in the manifold, and the set point refers to the active circuit (set point in the high or low temperature circuit, or DHW set point). The PID control directly manages the last 2 burners started, while the previous burners operate at maximum output.

If the Manifold Temperature < set point – 5°C, the next burner is started, and both are managed by the PID control algorithm. The Master controller waits 30 seconds, and then if the Manifold Temperature < set point - 5°C, another burner is started. The first burner works at maximum output, while the other two are managed by the PID control algorithm.

If the Manifold Temperature > set point + 2°C, the last burner is stopped, the other two most recently started burners are managed by the PID control algorithm, while the others work at maximum output. The Master controller waits 30 seconds before checking the situation again.

CONDEXA PRO 51

MODE: MAXIMUM NUMBER OF BURNERS ON (PAR.33=1)

All the burners are controlled by the same PID control algorithm, where the value controlled is the temperature in the manifold, and the set point refers to the active circuit (set point in the high or low temperature circuit, or DHW set point).

If the Manifold Temperature < set point – 5°C, the next burner is started. The Master controller waits 30 seconds, and then if the Manifold Temperature < set point - 5°C, another burner is started. If the Manifold Temperature > set point + 2°C the last burner is stopped. The Master controller waits 30 seconds before checking the situation again.

ADDITIONAL CASCADING MANAGEMENT FUNCTIONS Rotation of burner ignition sequence

When Master controller is switched on, the burner with address 1 is the first in the sequence. After 24 hours, the burner with address 2 becomes the first burner, while the burner with address 1 becomes the last in the sequence.

Limitation of starts/stops

In both cascading strategies, after each start or stop, a minimum time must expire before the Master can start or stop any of the burners.

Rapid start/stop

In both modes a function is available for rapidly reaching stable operating conditions and shutting down. If the Manifold Temperature < set point - 70°C the burners are started at 2 second intervals. If the Manifold Temperature > set point + 4°C the burners are stopped at 2 second intervals.

Low load

The low load function prevents the burners from stating and stopping when there is a low heating demand. The conditions for the activation of the Low Load function are checked on every Slave board, which sends the request to enable the function to the Master. During normal operation, the set point in the active circuit (set point in the high or low temperature circuit, or DHW

set point) is sent to the Slave boards, and the temperature of the heating unit is checked by each Slave board: if the Boiler temperature > Set point – 8°C or the Boiler temperature > 85°C - 8°C, the signal to start the burner is disabled. When the Slave board reads a boiler temperature greater than 85°C three times when the burner is on, the heating unit is stopped and the start-up procedure is enabled again.

Emergency function

In the event of faults on the Master board, there are two was of manually controlling the Slave boards:

- By eBUS and manifold pr

obe Disconnect the power supply from the system, unplug the BUS. Set the address 000000 on all the Slave boards (J10 and J17 OFF). Connect a power supply between 21 and 28 Vac to the BUS. If the Manifold Temperature < Emergency Temp. (Par.40; pre-set to 70°C; settable between 10 and 80°C) all the burners operate at maximum output. If the Manifold Temperature > Emergency Temp. + 5°C all the burners are stopped;

- By PC Disconnect the power supply from the system, unplug the BUS and connect the PC interface. The output of the burners can be sent directly to the Slave boards using the PC.

bIn the event of faults, contact Vokera Ltd or a suitably qualified person.

CONDEXA PRO52

Managing the heating demand in the high temperature circuit by analogue input (Par. 14=2 or 3)

The room thermostat in the high temperature circuit is ignored for the heating demand, and the input signal is used to calculate the output or the system set point. There is just one analogue input (see terminals 13-14 on the wiring diagram on page 34) on the Master board and this can also be used for the low temperature circuit (Par.22). The analogue input cannot be used for both the circuits.

ANALOGUE INPUT FOR HEAT OUTPUT, PAR. 14=2 (PAR. 22=2 FOR LOW TEMPERATURE CIRCUITS)

The demand for the high temperature (low temperature) circuit is made according to the following rules: 0-2Vdc:no demand from the high temperature (low tem-

perature) circuit

2-9Vdc:2-9Vdc: the demand for heat is converted into

an output demand for each Slave. An input of 2V corresponds to minimum output, 9V to maximum output (Par.15). Between 2V and 9V the output is calculated linearly. The hysteresis for the end of the demand is 0.2V and therefore the demand is active above 2V and ends below 1.8V. The burner starts when:

Outlet Temp. ≤ Setpoint_Ch_high (Par.1) –

Ch_high_mod_hist_on (Par.19)

(Outlet Temp. ≤ Setpoint_Ch_low (Par.3) –

Ch_low_mod_hist_on (Par.26)) The burner stops when: Outlet Temp. > Setpoint_Ch_high (Par.1) + Ch_high_hist_off (Par.20) (Outlet Temp. > Setpoint_Ch_low (Par.3) + Ch_low_hist_off (Par.27))

Voltage (Volt)

0 1 2 3 4 5 6 7 8 9 10

Heat output (kW)

100

150

200

250

ANALOGUE INPUT FOR TEMPERATURE, PAR. 14=3 (PAR. 22=3 FOR LOW TEMPERATURE CIRCUITS)

The demand for the high temperature (low temperature) circuit is made according to the following rules:

0-2Vdc:no demand from the high temperature (low tem-

perature) circuit

2-9Vdc:the demand for heat is converted into an output

requirement for each Slave, by the PID_CH_high (PID_CH_low) algorithm. 2V corresponds to a set point of T_Ch_high_foot, Par. 18 (T_Ch_low_foot, Par. 24), 9V to a set point of Setpoint_Ch_high, Par.1 (Setpoint_Ch_low, Par.3). Between 2V and 9V the set point is calculated linearly. The hysteresis for the end of the demand is 0.2V and therefore the demand is active above 2V and ends below 1.8V. The burner starts when:

Outlet Temp. ≤ Setpoint_ch_high (Par. 1) –

Ch_high_hist_on (Par 19)

(Outlet Temp. ≤ Setpoint_ch_low (Par. 3) –

Ch_low_mod_hist_on (Par.26)) The burner stops when: Outlet Temp. > Setpoint_ch_high (Par. 1) + Ch_high_hist_off (Par. 20) (Outlet Temp. > Setpoint_ch_low (Par. 3) + Ch_low_hist_off (Par. 27)).

Voltage (Volt)

0 1 2 3 4 5 6 7 8 9 10

Setpoint

CONDEXA PRO 53

Safety functions on the Slave boards

When the Outlet Temperature > 90°C for 5s, the Slave board shuts down (no. 46). When the Return Temperature > 80°C for 5s, the Slave board shuts down (no. 47). When the Flue Gas Temperature > 80°C for 5s, the Slave board shuts down (no. 48) and the fan operates for 10 minutes at maximum speed.

The Slave board can protect the main exchanger against the dangers of low water circulation, in three ways:

1 = by flow switch (water differential pressure switch) 2 = by controlling the difference between the outlet and return temperature DT 3 = by flow switch and DT

The control on the DT uses a parameter, DT_max (pre-set to 35°C) and limits the output of the burner as follows:

if DT_max -5°C > DT > DT max – 10°C burner modulation if DT_max > DT > DT_max –5°C burner at minimum if D_T > D_T_max burner off.

MANAGEMENT OF THE MIXING VALVE

The mixing valve is controlled by the following parameters:

Mix_valve_step_open_time: Par.28 pre-set to 5s Mix_valve_step_close_time: Par.29 pre-set to 7s Mix_valve_interval_time: Par.30 pre-set to 5s Mix_valve_p_hyst: Par.31 pre-set to 2°C Mix_valve_still_hyst: Par.32 pre-set to 2°C

Before opening or closing, the valve waits the time set for Par.30.

It opens if: T_low inlet temperature < Setpoint_low – Par32

It closes if: T_ low inlet temperature > Setpoint_low + Par32

Within the interval, the valve remains in the current position.

If: T_ low inlet temperature < Setpoint_low – Par31 it opens for a time equal to half of the value set for Par. 28

If: T_ low inlet temperature > Setpoint_low + Par31 it closes for a time equal to half of the value set for Par. 29.

Time (s)

0 5 10 15 20

Manifold Temperature

-5

Mixer Outlet Temperature (°C)

20 30 40 50 60

Valve Closing-Opening (s)

-4

-3

-2

-1

25 35 45 55

Open

default Par. 31 = 10

CONDEXA PRO54

The microswitches on the slave boards are factory-set so as to interface a master boiler (50 M or 100 M) to a slave boiler (100 S). If other slave boilers need to be connected, the microswitches must be set again.

Accessing the slave boards

- Move the main system switch to "off"

- Access the slave boards inside the boiler control panel (see the steps described on page 65)

- Follow the address setting procedure described below, and then connect the boilers using the special bus cable (see the wiring diagrams starting from page 14).

Setting the ADDRESSES

Each slave board (one for each heat generator) must be configured so as to be recognised in the right sequence by the master board. The slave generators should first of all be divided into blocks; the system can manage up to 15 blocks of four slave generators each. For example, if 5 slave generators are connected to a master, there are two blocks: the first made up of four slave generators and the second of one slave generator. Consequently, the addresses should be set as follows:

- Identify the block of four that the slave generator being configured belongs to (for example block 1, 2, ………, up to block15)

- Identify the position of the slave generator inside each block (e.g. position 1, 2, 3 or 4).

SLAVE address

Table of SLAVE addresses

Table of BLOCK addresses

SLAVE board

BLOCK address

OFF

1 2

1 2 3 4

OFF

OFF OFF OFF OFF Emergency OFF OFF OFF ON 1st block OFF OFF ON OFF 2nd block OFF OFF ON ON 3rd block OFF ON OFF OFF 4th block OFF ON OFF ON 5th block OFF ON ON OFF 6th block OFF ON ON ON 7th block

ON OFF OFF OFF 8th block ON OFF OFF ON 9th block ON OFF ON OFF 10th block

OFF OFF ON ON 11th block

ON ON OFF OFF 12th block ON ON OFF ON 13th block ON ON ON OFF 14th block ON ON ON ON 15th block

Microswitches BLOCK

1 2 3 4

OFF OFF 1 OFF ON 2

ON OFF 3 ON ON 4

Microswitches SLAVE

address

1 2

SETTING THE ADDRESSES FOR CASCADING CONFIGURATIONS

J10

J17

Main

CONDEXA PRO 55

OFF

1 2

1 2 3 4

OFF

1 2

1 2 3 4

OFF

1 2

1 2 3 4

OFF

1 2

1 2 3 4

OFF

1 2

1 2 3 4

OFF

1 2

1 2 3 4

OFF

1 2

1 2 3 4

OFF

Example configuration of a set of 7 burners in cascading

If installing a set of seven slave generators, there are two blocks: the first made up of four generators, and the second of three. Therefore, two blocks need to be configured, with address 1 and 2 respectively, and the generators belonging to the first block must have address 1, 2, 3 and 4, and those belonging to the second block address 1, 2 and 3.

SLAVE address

Generator no. 1

Generator no. 2

Generator no. 3

Generator no. 4

Generator no. 1

Generator no. 2

Generator no. 3

Block no. 1

Block no. 2

BLOCK address

CONDEXA PRO56

ERRORS ON THE MASTER BOARD

The following tables provide a description of the errors that may occur on the Master board.

The errors can be divided into two groups:

- Type A errors, which can only be deactivated by pressing RESET (see ref. 3 on page 18).

- Type E errors, which are deactivated when the causes are no longer present.

Permanent errors, TYPE A

N° Error Description

A 16 EEPROM ERROR The contents of the EEPROM are not correct

A 18 INCORRECT EEPROM SIGNATURE EEPROM not recognised by the processor

Errors deactivated automatically, TYPE E

The following errors may occur, and can be deactivated automatically. If any one of these errors occurs, the red LED comes on (see ref. 4 on page 18).

N° Error Description

E 02 NTC1 open (or not connected)

(NTC1 = outlet sensor) Probe manifold not connected

E 04 NTC3 OPEN Storage heater probe not connected

E 18 NTC1 short-circuited

(NTC1 = outlet sensor) Probe manifold short-circuited

E 20 NTC3 short-circuited

(NTC3 = sensor on the storage heater) Storage heater probe short-circuited

E 23 REFHI TOO LOW ERROR Temperature measured not correct

E 24 REFHI TOO HIGH ERROR Temperature measured not correct

E 25 EEPROM READING ERROR The EEPROM is not legible

E 25 REFLO TOO LOW ERROR Temperature measured not correct

E 26 REFLO TOO HIGH ERROR Temperatura misurata non corretta

E 32 SLAVES NON PRESENT There are no slave boards connected

E 34 50 Hz ERROR The mains frequency is not 50 Hz

FAULT CODES

CONDEXA PRO 57

ERRORS ON THE SLAVE BOARD

List of slave errors: manual reset (see ref. 3 on page 18)

If slave errors with manual reset occur, the Slave reset button can be used (see ref. 13 on page 18).

No. Error

A 01 5 failed attempts at ignition

A 02 Too many failed ignitions

A 04 Gas valve relay error

A 05 Gas valve relay error

A 06 Safety relay does not close

A 07 Safety relay does not open

A 08 Safety relay open when should be closed

A 09 RAM error

A 10 EEPROM error

A 11 Fan error

A 12 Incorrect EEPROM signature

A 16 Safety relay closed when should be open

A 17 Outlet sensor error for having exceeded the max. outlet temperature

A 18 Return sensor error for having exceeded the max. return temperature

A 19 Flue gas sensor error for having exceeded the max. flue gas temperature

(with this error the fan operates at maximum speed )

A 20 The flame is extinguished too late after the gas valve closes

A 24 Fan error

List of slave errors: automatic reset NO. Error

E 33 Phase error

E 34 Reset button error

E 35 Water pressure switch error – contact not closed

E 36 EEPROM reading error

E 37 Flame detection error – line and neutral reversed

E 38 Flue gas probe short-circuited

E 39 Flue gas probe open

E 40 50 Hz error

E 41 Communication error

E 42 Outlet probe short-circuited

E 43 Outlet probe with contact open

E 44 Return probe short-circuited

E 45 Return probe with contact open

E 46 Outlet probe error for having exceeded the temperature limit

E 47 Return probe error for having exceeded the temperature limit

E 48 Flue gas probe error for having exceeded the temperature limit (with this error, the fan operates at max.)

CONDEXA PRO58

No. Name lower upper default UOM Description

limit limit setting

User parameters

1 SetPoint_ch_high 10 Par. 17 70 °C

If Par14=0 this is the high temperature circuit set point

If Par14=1 this is the maximum temperature

in the high temperature circuit

2 SetPoint_DHW 10 Par. 8 50 °C

3 SetPoint_ch_low 10 Par. 23 40 °C

If Par22=0 this is the low temperature circuit set point

If Par22=1 this is the maximum temperature

in the low temperature circuit

INSTALLER parameters accessible by password: 22

6 DHW_type 0 6 0 0 = No DHW service

1 = Instant with NTC probe

2 = Storage heater with NTC probe

5 = Instant with flow switch

6 = Storage heater with thermostat

7 P_DHW_max 1 255 230 Maximum speed/output in DHW

8 T_DHW_limit 10 80 60 Limit for user DHW setting

9 DHW_priority 0 2 0 0 = Sliding A

1 = Sliding B

2 = Absolute priority

10 T_tank_extra 0 50 30 °C Modular temp system in DHW = Par. 2 + Par. 10

11 T_tank_hyst_up 0 20 1 °C Upper DHW differential

12 T_tank_hyst_down 0 20 5 °C Lower DHW differential

13 N°_bruc_DHW 1 60 60 Maximum no. of burners in DHW

14 CH_type_high 0 3 1 0 = Fixed temperature

1 = Climate with outside probe

2 = 0-10 Vdc for heat output

3 = 0-10 Vdc for temperature

15 P_ch_max 1 255 230 Maximum speed/output in CH

16 CH_priority 0 2 0 0 = No priority between circuits

1 = Priority to the high temperature circuit

2 = Priority to the low temperature circuit

17 T_CH_high_limit 10 80 80 °C Limit for user high temperature circuit setting

18 T_CH_high_foot 10 Par. 1 50 °C Min. high circuit set point at the maximum

outside temperature (Par. 38)

19 CH_high_hyst_on 0 20 7 °C Start hysteresis in high temperature circ.

20 CH_high_hyst_off 0 20 3 °C Stop hysteresis in high temperature circ.

21 Attenuation_high 0 70 0 °C Set point attenuation with room thermo. open

22 CH_type_low 0 3 1 0 = Fixed temperature

1 = Climate with outside probe

2 = 0-10 Vdc for heat output

3 = 0-10 Vdc for temperature

23 T_CH_low_limit 10 70 50 °C Limit for user low temperature circuit setting

24 T_CH_low_foot 10 Par. 13 25 °C Min. low circuit set point - at the maximum

outside temperature (Par. 38)

25 Attenuation_low 0 70 0 °C Set point attenuation with room thermo. open

LIST OF PARAMETERS

No. Name lower upper default UOM Description

limit limit settinglimit limit setting

26 CH_low_hyst_on 0 20 5 °C Start hysteresis in low circuit calculated

on the mixer outlet temp

27 CH_low_hyst_off 0 20 3 °C Stop hysteresis in low circuit calculated

on the mixer outlet temp

Mix_valve_step_ open_time

0 255 5 s For each step the valve opens

1/2 of the set value

Mix_valve_step_close_time

0 255 7 s For each step the valve closes

1/2 of the set value

30 Mix_valve_interval_time 0 255 5 s Mixing valve delay

31 Mixing_p_hyst 0 255 2 °C Hysteresis for maximum valve opening

32 Mixing_still_hyst 0 255 2 °C

33 Power control mode 0 1 1 0 = Minimum number of burners

1 = Maximum number of burners

34 3° pump 0 1 0 0 = System/loop

1 = Low temperature circuit

35 Frost protection -30 15 3 °C System

36 Gas_type 1 7 1 1 = NG with flue < 15m

2 = NG with flue > 15m

3 = LPG with flue < 15m

4 = LPG with flue > 15m

37 T_out_min -20 30 0 °C

38 T_out_max 0 30 18 °C

39 T_out_correct -30 30 0 °C

40 T_emergency 10 80 70 °C

41 Parameter_reset 0 1 0

42 Flow switch on slave 0 1 1 0 = The slave does not control the pressure switch

43 Protocol 0 1 1 0 = Eco protocol

1 = Argus link (new)

CONDEXA PRO 59

CONDEXA PRO60

OFF

The Vokera CONDEXA PRO Boiler is supplied for operation on G20 (natural gas). However, it can be converted for operation on G30-G31 (LPG), using the special kit supplied.

Before performing the conversion:

- Disconnect the power supply from the appliance by

moving the main switch to "off";

- Close the fuel valve.

To install the kit:

- Unscrew the fastening screws (1) on the front panel (2)

- Pull the base of the panel (2) outwards and then upwards to release it from the frame and then remove it

- Set parameter 36 to 3 or 4, according to the length (L) of the flue:

3 = L < 15 m 4 = L > 15 m.

The fan speed is controlled automatically.

- Disassemble the gas valve from the fan assembly by loosening the three screws (3)

bThe conversion must only be carried out by Vokera

Ltd

or personnel authorised by Vokera, even when

the boiler is already installed.

bOnce the conversion has been completed, set the

boiler again as described in the paragraph on "Adjustments".

CONVERSION FROM ONE TYPE OF GAS TO THE OTHER

CONDEXA PRO 61

- Replace the calibrated diaphragm fitted on the gas valve with the diaphragm (4) supplied inside the kit, marked “

6.5”.

Only if the boiler is supplied by a mixture of gases that causes ignition problems, use the other diaphragm (5) marked “

6.75”.

- Reassemble the gas valve

- Apply the sticker (6) for G30-G31, supplied inside the kit, on the inside of the panelling, and remove the sticker for G20

- Remove the G20 gas label from the inside of the frame.

6.5

6.75

Country of destination:

Type of appliance Boiler category::

II2H3+

Gas supply pressure:

G20

G30+G31

20 mbar 28-30/37 mbar

Manufacturer settings:

G20 - 20 mbar - 2H NATURAL GAS

WARNING

Carefully read the instruction manual before installing and starting the appliance.

(Laterale DX)

B23, C63

068465EN_1_E0

Boiler regulated for:

G30 - G31 28-30/37 mbar

Destination country:

GB - IE

After having installed the kit make sure that:

- All the joints made are tight

- All the calibration operations described in the "Adjustments" paragraph below have been completed.

CONDEXA PRO62

The Vokera CONDEXA PRO Boiler is supplied for operation on G20 (natural gas), as indicated on the rating plate, and has already been adjusted in the factory by the manufacturer. If, however, the adjustments need to be performed again, for example after special servicing operations, the replacement of the gas valve, or alternatively following the conversion from G20 to G30-G31 or viceversa, proceed as follows.

CO2 ADJUSTMENT AT MAXIMUM OUTPUT

- Press the “MODE” and “+” buttons together for 5s.

- Start the boiler by adjusting the room thermostat. The boiler will operate at maximum output showing "H" on

the display, followed by the outlet temperature (chimney sweep function).

- Unscrew the cap (1) and insert the combustion analyser probe

- Adjust the CO2 using a screwdriver on the adjustment screw (2) located on the fan assembly (

turning

clockwise decreases the CO2 value

), so as to achie-

ve a value of 9.4% for G20 and 10.7% for G30-G31.

CO2 ADJUSTMENT AT MINIMUM OUTPUT

- Press the “MODE” and “-” buttons together for 5s.

The boiler will operate at minimum output showing "L" on the display, followed by the outlet temperature.

- Adjust the CO2 using a screwdriver on the adjustment screw (3) located on the fan assembly (

turning anti-

clockwise decreases the CO2 value

), so as to achie-

ve a value of 8.4% for G20 and 8.7% for G30-G31.

CHECKING THE CALIBRATION

Press the "MODE" and "+" buttons together for 5s and check the max CO2 value (9.4% for G20 and 10.7% for G30-G31). Then press the "MODE" and "-" buttons for 5s and check the min CO2 value (8.4% for G20 and 8.7% for G30-G31).

After having completed the checks:

- Stop the chimney sweep function by pressing “

MEMO”

- Adjust the thermostat so as to stop the boiler

- Remove the analyser probe and carefully retighten the cap (1).

bThe adjustments at maximum and minimum out-

put must be carried out in the sequence described, and only by Vokera Ltd or personnel authorised by Vokera.

ADJUSTMENTS

CONDEXA PRO 63

In the event of temporary absence over the weekend, brief trips, etc. proceed as follows:

- Set the room thermostats to around 10°C

- Set parameter 2 to "10" or alternatively set the storage heater thermostat to 10°C

By leaving the power supply on, as signalled by the green LED flashing, and the fuel supply open the boiler is protected.

The electronic controller has a

frost protection function

that is also

active in standby

The frost protection function has two levels:

- the first starts the pump

if the manifold temperature ≥ 5°C, or alternatively, when

CH_type=1 and the outside probe is connected; if the

out. temp ≤ 3°C (Par. 35=Frost_protection) the system

pump and the pump in the high temperature circuit are started.

- the second star

ts the pump and the burner

if after 10 minutes the temperature in the manifold ≤

5°C, a burner is started at maximum output until the

temperature in the manifold ≥ 20°C; if after 10 minutes the temperature in the manifold ≥

5°C, while if CH_Type = 1 and the outside probe is con-

nected, and the outside temperature ≤ 3°C, the pump continues operating until the outside temperature ≥

3°C.

If the

CONDEXA PRO boiler is not used for an extended

period, the following operations must be performed:

- Move the main system switch and the main boiler switch (1) to "off" and check that the green indicator light is off (2).

- Close the fuel and water valves on the central heating system.

bIn this case, the frost protection system is deac-

tivated. Empty the central heating and DHW system if there is the risk of freezing.

OFF

TEMPORARY SHUTDOWN

SHUTTING DOWN FOR EXTENDED PERIODS

CONDEXA PRO64

OFF

Periodical servicing is a "requirement" and is also essential for the safety, the efficiency and the long life of the appliance. It ensures reduced consumption and polluting emissions and maintains the reliability of the product over time. The appliance can be serviced

Vokera Ltd or personnel

authorised by

Vokera.

Analysis of combustion, performed before starting servicing, provides useful information on the operations to be performed.

Before performing any operation:

- Disconnect the power supply by moving the main system switch to "off"

- Close the fuel valve.

Before performing any cleaning operation, disconnect the power supply by moving the main system switch to "off".

OUTSIDE

Clean the casing, the control panel, the painted parts and the plastic parts with cloths dipped in soap and water. In the case of hard-to-remove stains, wet the cloth with a 50% mixture of water and denatured alcohol or specific products.

aDo not use fuels and/or sponges with abrasive

solutions or detergent powder.

INSIDE

Before starting the inside cleaning operations:

- Close the gas valves

- Close the system valves.

OFF

SERVICING

CLEANING THE BOILER AND DISMANTLING THE INSIDE COMPONENTS

CONDEXA PRO 65

Removing the front panel, accessing the control panel and the inside of the boiler

- Unscrew the fastening screws (1) on the front panel (2)

- Pull the base of the panel (2) outwards and then upwards to release it from the frame and then remove it

- Turn the control panel (3) 90°C and take out the four screws (4) so as to remove the rear cover.

- The terminal block (5) and the boards can now be accessed:

- Master board (6) (models 50M and 100M)

- first Slave board (7)

- second Slave board (8) (models 100M and 100S)

Once the servicing operations have been completed, reassemble the components in the reverse order.

CONDEXA PRO66

Dismantling the Master and Slave boards

- Remove the panel front and access the inside of the control panel (see the steps described on the previous page).

- Remove the screws (V) and then the cover from the Master board.

- Repeat the same operation to remove the cover (7) from the first Slave board and (8) any second Slave board.

- Remove the wiring connectors from the boards and unscrew the fastening screws so as to remove the boards.

bIf replacing the Master board, refer to the wiring

diagram on page 14 to restore the connections.

Once the servicing operations have been completed, reassemble the components in the reverse order.

Dismantling the fan

- Remove the front and top panel of the boiler (see the operations described on page 65).

- Remove the wiring (5) from the fan (6)

- Unscrew the four screws (7) that fasten the fan (6) to the exchanger using an 8 mm socket wrench

- Unscrew the two screws (8) that fasten the fan (6) to the air conveyor (9)

- Remove the fan (6).

Once the cleaning operations have been completed, reassemble the components in the reverse order.

bCheck that the gas connection is tight.

CONDEXA PRO 67

Dismantling and cleaning the burner and the exchanger

- Remove the front and top panel of the boiler (see the operations described on page 65).

- Remove the wiring (5) from the fan (6)

- Unscrew the two screws (8) that fasten the fan (6) to the air conveyor (9)

- Unscrew the four screws (10) that fasten the fan assembly (6) to the exchanger, using a 10 mm socket wrench

- Remove the gasket (11) and remove the burner (12)

- Remove the electrode plate (13), check the condition of the electrode and replace if necessary.

Once the cleaning operations have been completed, reassemble the components in the reverse order.

bCheck that the gas connection is tight.

CONDEXA PRO68

Cleaning the drain trap and condensate drain

- Remove the front and top panel of the boiler (see the operations described on page 65) and identify the condensate drain trap (14)

- Remove the safety pin (15), remove the corrugated condensate drain pipe, remove the drain trap and dismantle it, using the two screw caps (16).

- Remove the float (17) and clean all the components.

Once the cleaning operations have been completed, reassemble the components in the reverse order.

CONDEXA PRO 69

CAUSE

SOLUTION

PROBLEM

Gas supply circuit

Smell of gas

Check the tightness of the joints and that the pressure test points are closed

Burner gas pressure

Irregular combustion

Check adjustment

Diaphragm installed

Check diameter

Condition of the burner

and exchanger

Check they are clean

Exchanger openings blocked

Check the openings are clean

Fan fault

Check operation

Flue gas circuit

Smell of unburned gas

Check:

- The tightness of the joints

- The absence of obstructions

- The quality of combustion

Gas valve

Check that 230 Vac is present at the terminals on the gas valve; check wiring and connections

Burner gas pressure

Delays in ignition with pulsa-

ting operation of the burner

Check adjustment

Ignition electrode

Check positioning and condition

Combustion

The boiler becomes dirty

in a short time

Check flame colour Check combustion adjustments

The burner does not start when receiving the signal

from the boiler controller

TROUBLESHOOTING

CONDEXA PRO70

CAUSE

SOLUTION

PROBLEM

No power supply

(the display is blank)

The boiler doesn’t start

Check:

- electrical connections

- fuse

Boiler body dirty

The boiler does not reach

the operating temperature

Clean combustion chamber

Insufficient burner flow-rate

Check burner adjustment

Boiler controller

Check correct operation Check set temperature

No water

Check vent valve Check pressure in central heating circuit

Air in the system

The heat generator

reaches the temperature

but the central heating

system is cold

Vent the system

Pump fault

Reset the pump Replace the pump Check the electrical connections to the pump

Boiler controller

Thermal overload

on the heat generator

Check correct operation Check set temperature Check electrical wiring Check position of the probe sensors

CONDEXA PRO 71

CAUSE

SOLUTION

PROBLEM

Pump fault

The pump doesn’t start

Reset the pump Replace the pump Check the electrical connections

to the pump

System expansion vessel

Check efficiency

Pressure in heating system circuit

Check charge pressure Check pressure reducer

System safety valve

Frequent activation of

the system safety valve

Check calibration or efficiency

CONDEXA PRO72

CONDEXA PRO 73

CONDEXA PRO74

CONDEXA PRO 75

Cod. 068464EN - Rev . 0 (09/05)

Registered address:

Vokèra Ltd

Borderlake House

Unit 7 Riverside Industrial Estate

London Colney Herts AL2 1HG

enquiries@vokera.co.uk

www.vokera.co.uk

www.vokera.ie

Sales, General Enquires

T 0844 391 099

F 0844 391 0998

Vokèra Ireland

West Court, Callan

Co Kilkenny

T 056 7755057 F 056 7755060

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

Vokera Condexa Pro 100 M LPG User guide

Specifications and Main Features

Frequently Asked Questions

User Manual