VOKERA Linea Installation & Servicing Instructions Manual

Supplied By www.heating spares.co Tel. 0161 620 6677

Linea

Installation & Servicing Instructions

THESE INSTRUCTIONS TO BE RETAINED BY USER

Supplied By www.heating spares.co Tel. 0161 620 6677

Contents

Design principles and operating sequence Page

1.1 Principle components 2

1.2 Mode of operation (at reset) 2

1.3 Mode of operation (Heating) 2

1.4 Mode of operation (DHW) 2

1.5 Safety devices 2

1.6 Optional accessories 2

Technical data Page

2.1 Central heating 3

2.2 Domestic hot water 3

2.3 Gas pressure 3

2.4 Expansion vessel 3

2.5 Dimensions 3

2.6 Clearances 3

2.7 Connections 3

2.8 Electrical 3

2.9 Flue details (concentric) 3

2.9A Flue details (twin pipes) 3

2.10 Efficiency 3

2.11 Pump duty 4

2.12 Emissions 4

General requirements (UK) Page

3.1 Related documents 5

3.2 Location of appliance 5

3.3 Gas supply 5

3.4 Flue system 5

3.5 Air supply 5

3.6 Water circulation 5

3.6.1 Pipework 6

3.6.2 Automatic by-pass 6

3.6.3 Drain cocks 6

3.6.4 Air release points 6

3.6.5 Expansion vessel 6

3.6.6 Filling point 6

3.6.7 Low pressure sealed system 6

3.6.8 Frequent filling 6

3.7 Electrical supply 6

3.8 Showers 6

3.9 Mounting on a combustible surface 6

3.10 Timber framed building 7

3.11 Inhibitors 7

General requirements (EIRE) Page

3.A1 Related documents 7

3.A2 Location of appliance 7

3.A3 Gas supply 7

3.A4 Flue system 8

3.A5 Air supply 8

3.A6 Water circulation 8

3.A6.1 Pipework 8

3.A6.2 Automatic by-pass 8

3.A6.3 Drain cocks 8

3.A6.4 Air release points 8

3.A6.5 Expansion vessel 8

3.A6.6 Filling point 8

3.A6.7 Low pressure sealed system 8

3.A6.8 Frequent filling 8

3.A7 Electrical supply 8

3.A8 Showers 8

3.A9 Mounting on a combustible surface 9

3.A10 Timber framed building 9

3.A11 Inhibitors 9

3.A12 Declaration of conformity 9

Installation Page

4.1 Delivery 9

4.2 Contents 9

4.3 Unpacking 9

4.4 Preparation for mounting the appliance 9

4.5 Fitting the flue 9

4.5.1 Concentric horizontal flue 9

4.5.2 Concentric vertical flue 11

4.5.3 Twin flue system 12

4.6 Connecting the gas and water 14

4.6.1 Gas 14

4.6.2 Flow and return 14

4.6.3 Cold water inlet 14

4.6.4 Hot water outlet 15

4.6.5 Safety valve 15

4.7 Electrical connections 15

4.7.1 Casing removal 15

4.7.2 Appliance terminal block 15

4.7.3 Connecting the mains (230V) input 15

4.7.4 Connecting the Vokera time clock 16

Commissioning Page

5.1 Gas supply installation 17

5.2 The heating system 17

5.3 Initial filling of the system 17

5.4 Initial flushing 1 7

5.5 Filling the hot water system 17

5.6 Pre-operation checks 17

5.7 Initial lighting 17

5.7.1 Checking burner pressures 17

5.8 Final flushing of the heating system 18

5.8.1 Inhibtors 18

5.9 Setting the boiler operating temperature 1 8

5.9.1 Setting the domestic hot water temperature 18

5.10 Setting the system design pressure 18

5.11 Regulating the hot water 18

5.11.1 Changing the flow restrictor 18

5.11.2 Regulating the central heating system 18

5.12 Final checks 19

5.13 Instructing the user 19

Servicing instructions Page

6.1 General 19

6.2 Routine annual servicing 1 9

6.4 Component removal procedure 20

6.5 Pump assembly 20

6.6 Safety valve 20

6.7 Automatic air release valve 20

6.8 Water pressure switch 20

6.9 Pressure gauge 21

6.10 Primary thermistors 21

6.11 High limit thermostat 21

6.12 Printed circuit board 21

6.13 Gas valve 22

6.14 Integral time switch 2 2

6.15 Electrode, burner thermostat, burner & injectors 22

6.16 Flue fan 22

6.17 Main heat exchanger 24

6.18 Air pressure switch 24

6.19 Flow restrictor 24

6.20 DHW flow switch 25

6.21 DHW heat exchanger 25

6.22 Valve actuator 25

6.23 Divertor valve assembly 25

6.24 Secondary thermistor 25

6.25 Automatic by-pass 2 6

6.26 DHW non-return valve 26

6.27 Expansion vessel 2 6

6.27.1 Expansion vessel removal 26

6.27.2 Expansion vessel removal 26

Checks, adjustments and fault finding page

7.1 Checking appliance operation 27

7.2 Appliance mode of operation 27

7.2.1 Selector switch in the off position 27

7.2.2 Selector switch in the hot water only position 27

7.2.3 Selector switch in the heating & hot water position 27

7.2.4 Appliance functions 27

7.2.5 Heating mode 27

7.2.6 DHW mode 28

7.3 Checking and adjusting burner pressure 28

7.3.1 Setting the maximum burner pressure 28

7.3.2 Setting the minimum burner pressure 28

7.4 Combustion analysis test 29

7.5 Checking the expansion vessel 29

7.6 External faults 29

7.6.1 Installation faults 29

7.7 Electrical checks 29

7.7.1 Earth continuity test 29

7.7.2 Short circuit test 29

7.7.3 Polarity check 29

7.7.4 Reversed polarity or supply fault 30

7.7.5 Resistance to earth check 30

7.8 Fault finding 30

7.8 Fault codes 31-38

Wiring diagrams Page

8.1 External wiring 39

8.2 T ypical control applications 39

8.3 Vokera time clock 39

8.4 Vok er a remote control 39

8.5 Vok era room thermostat 39

8.6 Other controls 39

Exploded diagrams Page

Table 1 43 Table 2 44 Table 3 45 Table 4 46 Table 5 47

L.P .G. instructions Page

10.1 Related documents 48

10.3 Converting the appliance gas type 48

10.4 Gas supply 48

10.5 Gas supply installation 48

10.6 Checking and adjusting burner pressure 48

10.6.1 Setting the maximum burner pressure 48

10.6.2 Setting the minimum burner pressure 48

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INTRODUCTION

The Linea 7 range is comprised of 3 models of combination boiler – 726, 730, 735 – with outputs to heating & DHW of 26, 30 & 35 kW respectively. Each appliance – by design – incorporates electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge, and automatic by-pass.

The Linea 7 range are produced as room sealed, category II2H3+ appliances, suitable for internal wall mounting applications only. They are provided with a f an po wered flue outlet with an annular co-axial combustion air

26 28

intake that can be rotated – horizontally – through 360 degrees for various horizontal or v ertical applications. The Linea 7 range can also be used with the Vok era twin flue system.

The Linea 7 range is approved for use with C12, C22, & C32 type flue applications.

These appliances are designed for use with a sealed system only; consequently they are not intended for use on open vented systems.

Fig.1 General Layout

1 Flue Outlet 2 Air Intake

3 Differential analog Pressure Switch 4 Silicone Pressure Tube 5 Silicone Negative Pressure Tube 6 Expansion Vessel

7 Main Heat Exchanger 8 Electrode 9 Burner Temperature control

10 Transformer 11 Gas Valve 12 Modulator Coil

13 Domestic Heat Exchanger 14 Domestic Hot Water Flow Switch

15 Safety Valve

16 Pressure Switch

17 Diverter V alv e Motor 18 Pump

19 Automatic Air Release Valve 20 Main Burner

21 Combustion Chamber 22 Fan Assembly 23 Air Chamber (with front removed) 24 Flue Gas Analysis Test Point 25 Hot W ater Temperature Control 26 Mode Selector Switch 27 Status LED 28 Temperature Indicator 29 Central Heating T emperature Control 30 Combustion Switch 31 Timeclock Aperture (optional) 32 Pressure Gauge

Fig. 1

312730

Linea

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SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS

●●

● A fully integrated electronic control board fea-

●●

turing electronic temperature control, anti-cycle control, pump over-run, self-diagnostic fault indicator, full air/gas modulation.

●●

● Low-water-content, copper heat e xchanger .

●●

● Electronic ignition with flame supervision

●●

● Integral high-head pump

●●

● Fan

●●

● Expansion vessel

●●

● Analogue pressure switch (PAD)

●●

● Water pressure switch

●●

● Two-stage gas valve

●●

● Pressure gauge

●●

● Safety valve

●●

● Burner T emperature control

●●

1.2 MODE OF OPERATION (at rest)

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

●●

● Pre-heat function – the pre-heat function ena-

●●

bles the appliance to periodically light and maintain the temperature of the DHW heat exchanger. This “keep-hot” facility enables the appliance to provide an instantaneous response to DHW requests.

●●

● 2-stage frost-protection system – the frost-pro-

●●

tection system protects the appliance against the risk of frost damage. The first stage enables activation of the pump should the temperature of the appliance fall to 7oC. The second stage becomes active when the temperature has dropped to 3oC. Should the second stage become active, the appliance will function on minimum power until it reaches 30oC.

●●

● Anti-block function – the anti-block function ena-

●●

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

1.3 MODE OF OPERA TION (Heating)

When there is a request for heat via the programmer/time clock and/or any external control, the pump and fan are started, the fan speed will modulate until the correct signal voltage is received at the control PCB. At this point an ignition sequence is enabled. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry increases the gas rate to 75% for a period of 15 minutes. Thereafter, the boiler’s output will either be increase to maximum or modulate to suit the set requirement. When the appliance reaches the desired temperature the burner will shut down and the boiler will perform a three-minute anti-cycle (timer delay). When the request for heat has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry increases the gas rate to maximum or will modulate output to stabilise the temperature. In the event of the appliance exceeding the desired temperature the burner will shut down until the temperature drops. When the request for DHW has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

1.5 SAFETY DEVICES

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

●●

● A water pressure switch that monitors system

●●

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

●●

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

●●

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

●●

● An analogue pressure switch (PAD) that checks

●●

the operation of the fan and flue thereby allowing safe operation of the b urner.

●●

● A safety valve which releases excess pressure

●●

from the primary circuit.

●●

● Burner T emperature control

●●

1.6 OPTIONAL ACCESSORIES

The Linea 7 is suitable for use with a range of optional accessories that enable enhanced operation and/or applications. These include:

●●

● RC05 remote control – the RC05 remote con-

●●

trol enables the appliance to be controlled, adjusted, and monitored from another location or room. The RC05 can also be used as a room thermostat or programmable room thermostat.

●●

● External sensor – used in conjunction with the

●●

RC05 the external sensor enables the appliance to automatically adjust its outlet flow temperature in response to the outside temperature.

Air Intake

Flue Outlet

1.4 MODE OF OPERATION (DHW)

When there is a request for DHW via a hot water outlet or tap, the pump and fan are started, the fan speed will modulate until the correct signal voltage is received at the control PCB . At this point an ignition sequence is enabled. Ignition is sensed by the electronic circuitry to

Fig. 2

NOTE

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SECTION 2 TECHNICAL DATA

2.1 Central heating 726 730 735

Heat input (kW) 28.2 32.6 37.8 Maximum heat output (kW) 26.0 30.1 35.2 Minimum heat output (kW) 8.28 8.93 9.22 Minimum working pressure 0.45 bar Maximum working pressure 3.0 bar Minimum flow rate 350 l/h

2.2 Domestic hot water

Maximum input (kW) 28.2 32.6 37.8 Maximum output (kW) 26.0 30.1 35.2 Minimum output (kW) 8.28 8.93 9.22 Flow rate (35oC rise) 10.6 l/min 12.3 l/min 14.4 l/min Maximum inlet pressure 6.0 bar Minimum inlet pressure 0.15 bar Minimum flow rate 2.5 l/min

2.3 Gas pressures

Inlet pressure (G20) 20.0 mbar Burner pressure maximum 9.8 mbar 9.6 mbar Burner pressure minimum 1.1 mbar 0.8 mbar 0.7 mbar Maximum gas rate 2.98 m3/h 3.45 m3/h 4 m3/h Minimum gas rate 0.95 m3/h 1.02 m3/h 1.05 m3/h Injector size (quantity) 12 x 1.4 mm 14 x 1.4 mm 16 x 1.4 mm

2.4 Expansion vessel

Capacity 8-litres 10-litres Maximum system volume 76-litres 95-litres Pre-charge pressure 1.0 bar

2.5 Dimensions

Height 820mm Width 400mm 450mm 500mm Depth 350mm Dry weight (kg) 37.0 40.0 46.0

2.6 Clearances

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

2.7 Connections

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

2.8 Electrical

Voltage (V/Hz) 230/50 Power consumption 140W 150W 160W Internal fuse 2A External fuse 3A

2.9 Flue details (concentric)

Maximum horizontal flue length (60/100mm) 4.0m 3.4m 2m Maximum vertical flue length (60/100mm) 4.8m 4.2m 2.8m Maximum horizontal flue length (80/125mm) 10.0m 8.5m 5m Maximum vertical flue length (80/125mm) 10.8m 9.3m 5.8m

2.9A Flue Details (twin pipes)

Maximum horizontal flue length (80mm + 80mm) 14m+14m 14m+14m 7m+7m Maximum vertical flue length (80mm + 80mm) 14m+14m 14m+14m 7.8m+7.8m

2.10 Efficiency

SEDBUK (%) 80.3 80.3 80.3

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SECTION 2 TECHNICAL DATA

2.11 PUMP DUTY

Fig. 3 shows the flow-rate available – af-

600

ter allowing for pressure loss through the appliance – for system requirements.

500

When using this graph, apply only the pressure loss of the system. The graph

400

is based on a 20oC temperature differential.

300

200

Water pressure (mbar)

100

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

Fig. 3

2.12 Emissions

Appliance

726 730

NOx max/min 160/140 180/120 150/130 CO max/min 120/120 140/100 130/130 CO2 max/min 6.95/3.45 6.70/3.20 7.0/3.40 CO/CO2 ratio max/min 0.0017 to 1/0.0035 to 1 0.0021 to 1/0.0031 to 1 0.0019 to 1/0.0038 to 1

Fig. 4

Litres Per Hour

735

Key Location Minimum distance

A Below an opening (windo w, air-brik, etc.) 300 mm B Abov e an opening (window , air-brik, etc.) 300 mm C To the side of an opening (window , air-brik, etc.) 300 mm D Below gutter , drain-pipe, etc. 75 mm E Below eaves 200 mm

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

I Above ground, roof, or balcony level 300 mm J F rom a surface or boundary facing the terminal 600 mm K F rom a terminal facing a terminal 1200 mm L From an opening in the car-port into the building 1200 mm

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

P F rom a structure to the side of the vertical terminal 300 mm

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

of the vertical terminal

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SECTION 3 GENERAL REQUIREMENTS (UK)

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

3.1 RELATED DOCUMENTS

The installation of this boiler must be in accordance with the relevant requirements of the Gas Safety (Installation & Use) Regulations, the local building regulations, the current I.E.E. wiring regulations, the bylaws of the local water undertaking, the Building Standards (Scotland) Regulation and Building Standards (Northern Ireland) Regulations. It should be in accordance also with any relevant requirements of the local authority and the relevant recommendations of the following British Standard Codes of Practice.

3.2 LOCA TION OF APPLIANCE

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

3.3 GAS SUPPLY

The gas meter – as supplied by the gas supplier – must be checked to ensure that it is of adequate size to deal with the maximum rated input of all the appliances that it serves. Installation pipes must be fitted in accordance with BS 6891. Pipe work from the meter to the appliance must be of adequate size. Pipes of a smaller size than the appliance gas inlet connection must not be used. The installation must be tested for soundness in accordance with BS6891. If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time.

3.4 FLUE SYSTEM

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

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

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

SELS AND ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS

When an appliance is installed in a room or internal space containing a bath or shower, the appliance or any control pertaining to it must not be within reach of a person using the bath or shower. The location chosen for the appliance must permit the provision of a safe and satisfactory flue and termination. The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the appliance. Where the installation of the appliance will be in an unusual location special procedures may be Necessary , BS 6798 giv es detailed guidance on this aspect. A compartment used to enclose the appliance must be designed and constructed specifically for this purpose. An e xisting compartment/cupboard may be utilised provided that it is modified to suit. Details of essential features of compartment/cupboard design including airing cupboard installations are given in BS 6798. This appliance is not suitable for external installation.

3.4 FLUE SYSTEM (Cont’d.)

In cold and/or humid weather, w ater vapour ma y condense on leaving the terminal; the effect of such pluming must be considered. If installed less than 2m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material. The guard must be fitted centrally over the terminal. Refer to BS 5440 Part 1, when the terminal is 0.5 metres (or less) below plastic guttering or 1 metre (or less) below painted eaves.

3.5 AIR SUPPLY

The following notes are intended for general guidance only. This appliance is a room-sealed, fan-flued boiler , consequently it does not require a Permanent air vent for combustion air supply. When installed in a cupboard or compartment, ventilation for cooling purposes is also not required.

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3.6 WATER CIRCULATION

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

must be fitted with an approved non-return valve and stopcock for isolation purposes. The feed pipe should be connected to the return pipe as close to the boiler as possible.

3.6.1 PIPEWORK

It is recommended that copper tubing to BS 2871 Part 1 is used in conjunction with soldered capillary joints. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and that water flows naturally to drain cocks. Except where providing useful heat, pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing. Particular attention should be paid to pipes passing through ventilated areas such as under floors, loft space, and void areas.

3.6.2 AUTOMATIC BY-PASS

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

3.6.3 DRAIN COCKS

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

2879.

3.6.8 FREQUENT FILLING

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

Automatic air-vent

Non-return

valve

Stopcock

Make-up vessel or tank

5.0 metres minimum

3.6.4 AIR RELEASE POINTS

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

3.6.5 EXPANSION VESSEL

The appliance has an integral expansion vessel to accommodate the increased volume of water when the system is heated. It can accept up to 8 litres (726/730) of expansion from within the system, generally this is sufficient, however if the system has an unusually high water content, it may be necessary to provide additional expansion capacity (see 6.19).

3.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. has been provided. This method of filling complies with the current W ater Supply (Water Fittings) Regulations 1999 and Water Bylaws 2000 (Scotland).

3.6.7 LOW PRESSURE SEALED SYSTEM

Fig. 5

Heating return

3.7 ELECTRICAL SUPPLY

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

3.8 SHOWERS

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

3.9 MOUNTING ON A COMBUSTIBLE SURFACE If the appliance is to be fitted on a wall of combustible material, a sheet of fireproof material must protect the wall.

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3.10 TIMBER FRAMED BUILDINGS

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

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

3.11 INHIBITORS

V ok era recommend that a inhibitor – suitab le f or use with low water-content, copper heat exchangers – is used to protect the boiler and system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers* instructions.

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

SECTION 3A GENERAL REQUIREMENTS (EIRE)

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

3A.1 RELATED DOCUMENTS

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

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

3A.2 LOCATION OF APPLIANCE

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

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

Fig. 6

within reach of a person using the bath or shower.

The location chosen for the appliance must permit the provision of a safe and satisfactory flue and termination. The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the appliance. Where the installation of the appliance will be in an unusual location special procedures may be necessary, refer to I.S. 813 for detailed guidance on this aspect.

A compartment used to enclose the appliance must be designed and constructed specifically for this purpose. An existing compartment/cupboard may be utilised provided that it is modified to suit.

This appliance is not suitable for external installation.

3A.3 GAS SUPPLY

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Pipe work from the meter to the appliance must be of adequate size. Pipes of a smaller size than the appliance gas inlet connection must not be used. The installation must be tested for soundness in accordance with I.S. 813.

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

3A.4 FLUE SYSTEM

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

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

3A.5 AIR SUPPLY

The following notes are intended for general guidance only. This appliance is a room-sealed, fan-flued boiler , consequently it does not require a permanent air vent for combustion air supply. When installed in a cupboard or compartment, ventilation for cooling purposes is also not required.

3A.6.3 DRAIN COCKS

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

3A.6.4 AIR RELEASE POINTS

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

3A.6.5 EXPANSION VESSEL

The appliance has an integral expansion vessel to accommodate the increased volume of water when the system is heated. It can accept up to 8 litres (726/730) or 10 litres (735) of expansion from within the system, generally this is sufficient, however if the system has an unusually high water content, it may be necessary to provide additional expansion capacity (see 6.19).

3A.6.6 FILLING POINT

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

3A.6.7 LOW PRESSURE SEALED SYSTEM

An alternative method of filling the system would be from an independent make-up vessel or tank mounted in a position at least 1 metre above the highest point in the system and at least 5 metres above the boiler (see fig. 5). The cold feed from the make-up vessel or tank must be fitted with an approved non-return valve and stopcock for isolation purposes. The feed pipe should be connected to the return pipe as close to the boiler as possible.

3A.6 WATER CIRCULATION

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

3A.6.1 PIPEWORK

It is recommended that copper tubing be used in conjunction with soldered capillary joints. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and that water flows naturally to drain cocks. Except where providing useful heat, pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing. Particular attention should be paid to pipes passing through ventilated areas such as under floors, loft space, and void areas.

3A.6.2 AUTOMATIC BY-PASS

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

3A.6.8 FREQUENT FILLING

3A.7 ELECTRICAL SUPPLY

3A.8 SHOWERS

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

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3A.9 MOUNTING ON A COMBUSTIBLE SURFACE

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

3A.10 TIMBER FRAMED BUILDINGS

If the appliance is to be fitted in a timber framed building, it should be fitted in accordance with I.S. 813 and local Building Regulations. The Institute of Gas Engineers publication (IGE/ UP/7) ‘Guide for Gas Installations in Timber Frame Buildings’ gives specific advice on this type of installation.

3A.11 INHIBITORS

Vokera recommend that a inhibitor – suitable for use with low water-content, copper heat exchang-

SECTION 4 INSTALLATION

ers – is used to protect the boiler and system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers* instructions. *Fernox and Sentinel manufacture products that have proved suitable for use with Vokera appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our appliances.

3A.12 DECLARATION OF CONFORMITY

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

813) must be provided on completion of the installation A copy of the declaration must be given to the responsible person and also to the gas supplier if required.

4.1 DELIVERY

Due to the weight of the appliance it may be necessary for two people to lift and attach the appliance to its mounting. The appliance is contained within a heavy-duty cardboard carton. Lay the carton on the floor with the writing the correct way up.

4.2 CONTENTS

Contained within the carton is:

●●

● The boiler

●●

● The fixing jig and wall bracket

●●

● Template

●●

● An accessories pack containing appliance serv-

●●

ice connections and washers

●●

● The instruction pack containing the installation

●●

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

gloves should be used to lift the appliance, the appliance back-frame should be used for lifting points.

4.4 PREP ARATION FOR MOUNTING THE APPLIANCE

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

When the position of the appliance has been decided – using the template supplied – carefully mark the position of the combined fixing jig and wall- mounting bracket (see fig. 6) and fluehole (if applicable).

4.5 FITTING THE FLUE

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

4.5.1 CONCENTRIC HORIZONTAL FLUE

(For concentric vertical flue, see 4.5.2)

(For twin flue applications, see 4.5.3)

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

Fig. 6A

4.3 UNPACKING (fig. 6A)

At the top of the carton pull both sides open – do not use a knife – unfold the rest of the carton from around the appliance, carefully remove all protective packaging from the appliance, and lay the accessories etc. to one side. Protective

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NOTE

These instructions relate only to the standard 60/100mm concentric flue system. For specific details on the installation of the 80/125mm concentric flue system please refer to the instructions supplied. The appliance flue outlet elbow can be rotated through 360° on its vertical axis. In addition the flue may be extended from the outlet elbow in the horizontal plane (see 2.9). A reduction m ust also be made to the maximum length (see table below) when additional bends are used.

Supplied By www.heating spares.co Tel. 0161 620 6677

Reduction for additional bends

Bend Reduction in maximum flue length for each bend

45° bend 0.5 metre 90° bend 1.0 metre

Horizontal flue terminals and accessories

Part No. Description Min-Max Length

2359029 Standard flue kit. For 833mm

use with add. Bends & (dimension ‘X’)

extensions 2359119 Telescopic flue kit. 2359069 750mm extension 750mm 2359079 1500mm extension 1500mm 2359089 Telescopic extension 350 – 490mm 2359049 45° bend (pair) N/A 2359059 90° bend N/A 0225760 Wall bracket (5) N/A

The telescopic flue kit (part no. 2359119) is suitable for a distance (dimension ’Y’) of up to 600mm.

Dimension ‘Y’ is measured from the end of the terminal to the end of the outer (100mm) pipe.

The internal trim should be fitted to the flue pipe before connection of the 90° bend.

Push-fit connection

Outer 100mm clip

Boiler

Fig. 8

7,5 mm

Inner 60mm clip

Terminal or

extension

Using the template provided, mark and drill a 107mm hole for the passage of the flue pipe. The hole should have a 1° drop from the boiler to outside, to eliminate the possibility of rainwater entering the appliance via the flue.

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

Dimension “Y”

110

7,5

Max 833 mm

Dimension “X”

Fig. 7

135 mm

4.5.1.1 FITTING THE HORIZONTAL FLUE KIT (see

4.5.1)

Carefully measure the distance from the centre of the appliance flue outlet to the face of the outside wall (dimension ‘X’ see fig. 7). Ensure the inner (60mm) pipe is fully inserted into the outer (100mm) pipe (when the inner pipe is fully inserted, it stands proud of the outer pipe by

7.5mm). Add 32mm to dimension ‘X’ to give the overall flue length (dimension ‘Y’).

NOTE

The standard horizontal flue kit (part no.

2359029) is suitable for a distance (dimension ‘Y’) of up to 865mm.

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

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

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

If the horizontal flue kit (2359029) requires to be cut to the correct size (dimension ‘Y’), you must ensure that the inner (60mm) pipe stands proud of the outer (100mm) pipe by 7.5mm (see fig. 8). Ensure any burrs are filed or removed and that any seals are located properly before assembly.

The telescopic flue terminal should be adjusted to the appropriate length and then fixed using the securing screw supplied.

4.5.1.2 STANDARD FLUE KIT (2359029)

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

4.5.1.3 TELESCOPIC FLUE KIT (2359119)

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

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Supplied By www.heating spares.co Tel. 0161 620 6677

Fig. 8A

You must ensure that the entire flue system is

properly supported and connected.

Seal the flue assembly to the wall using cement or a suitable alternative that provides satisfactory weatherproofing. The e xterior trim can now be fitted.

4.5.1.4 EXTENDING THE HORIZONTAL FLUE

The horizontal flue system can be extended using bends and/or extensions from the Uni-Flue range (see 4.5.1).

Connect the bend – supplied with the terminal kit – to the top of the boiler using the clips, screws, & gaskets supplied. The additional bends & extensions have an internal push-fit connection, care should be taken to ensure that the correct seal is made when assembling the flue system. Connect the required number of flue extensions or bends (up to the maximum equivalent flue length) to the flue terminal using the clips, screws, & gaskets supplied (see fig. 8 & 8A). The interior trim should be fitted at this point.

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension, and that the inner (60mm) pipe is 7.5mm longer than outer (100mm) pipe (see fig. 8 & 8A). Remove any burrs, and check that any seals are located properly.

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

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

an extension or bend can be connected to the appliance flue outlet if desired (see 4.4.2), however if additional bends are fitted, a reduction must be made to the maximum flue length (see table below).

Reduction for bends

Bend Reduction in maximum flue length for each bend

45° bend 0.5 metre 90° bend 1.0 metre

V ertical flue terminal and accessories

Part No. Description Length

2359039 Vertical flue terminal 1.0 metre 0225770 Pitched roof flashing plate N/A 0225765 Flat roof flashing plate N/A 2359069 750mm extension 750mm 2359079 1500mm extension 1500mm

2359049 45° bend (pair) N/A 2359059 90° bend N/A 0225760 Wall bracket (5) N/A

Using the dimensions given in fig. 9 as a reference, mark and cut a 105mm hole in the ceiling and/or roof. Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing. The fixing holes for the wall-mounting bracket should now be drilled and plugged, an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely. Once the bracket has been secured to the wall, mount the appliance onto the bracket.

4.5.2 CONCENTRIC VERTICAL FLUE

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

NOTE

The vertical flue terminal can be connected directly to the appliance flue outlet. Alternatively,

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Supplied By www.heating spares.co Tel. 0161 620 6677

Fig. 9

IMPORTANT

The vertical flue terminal is 1.0 metre in length and cannot be cut; therefore it may be necessary to adjust the height of the appliance to suit or use a suitable extension. Connect the vertical flue assembly to the boiler flue spigot using the 60mm & 100mm clips, gaskets, & screws (supplied), ensuring the correct seal is made. The flue support brack et (supplied with the vertical flue kit) can now be fitted.

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

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension and that the inner (60mm) pipe is 7.5mm longer than outer (100mm) pipe (see fig. 8). Remove any burrs, and check that any seals are located properly. You must ensure that the entire flue system is properly supported and connected.

●●

Ensure that the entire flue system is adequately

●

●●

supported, use at least one bracket for each extension.

●●

● The entire flue system must be adequately in-

●●

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

●●

● As the exhaust outlet pipe can reach very high

●●

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

●●

The condensate drain pipe must be connected

●

●●

in accordance with building regulations

Reduction for bends

Bend Reduction in maximum flue length for each bend

45° bend 1.0 metre 90° bend 1.0 metre

Twin flue accessories

Part No. Description Length

0225805 Horizontal flue terminal 1.0 metre 0225810 Vertical flue terminal 1.0 metre 362 Twin adapter kit N/A 0225770 Pitched roof flashing plate N/A 0225765 Flat roof flashing plate N/A 0225815 Condensate drain kit N/A 0225820 0.25m extension (pair) 250mm 0225825 0.5m extension (pair) 500mm 0225830 1.0m extension (pair) 1000mm 0225835 2.0m extension (pair) 2000mm 0225840 45° bend (pair) N/A 0225845 90° bend (pair) N/A 0225850 Twin bracket (5) N/A 0225855 Single bracket (5) N/A

MOUNTING THE BOILER

4.5.3 TWIN FLUE SYSTEM

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

GUIDANCE NOTES ON TWIN FLUE INSTALLATION

●●

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

●●

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

Fig. 10

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4.5.3.1 INSTALLATION OF TWIN ADAPTOR KIT (fig.

10)

●●

● Insert the exhaust connection manifold onto the

●●

appliance flue outlet.

●●

● Place the silicone seal (supplied with twin

●●

adapter kit) over the rim of the exhaust connection manifold.

●●

● Remove the required blanking plate (located to

●●

the left and right of the appliance flue outlet) and – using the same screws – install the air baffle.

●●

● Using the hole in the exhaust connection mani-

●●

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

●●

● Connect the air inlet pipe to the air baffle as

●●

above.

●●

● Prime the condensate trap with clean water prior

●●

to commissioning the appliance.

●●

● The twin flue pipes extensions and accesso-

●●

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

4.5.3.3 HORIZONTAL TERMINATION (See fig. 12)

The twin flue system must be converted to the

dedicated concentric flue kit for termination.

●●

● The horizontal terminal is supplied with a built-

●●

in converter box and cannot be shortened.

●●

● A 130mm hole is required for the passage of

●●

the concentric terminal through the wall.

●●

● The air inlet pipe must always be level with or

●●

below, that of the exhaust pipe.

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

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

Push-fit the twin flue pipes onto the concentric to twin converter box ensuring that the exhaust pipe connects to the exhaust connection on the concentric to twin converter.

If necessary cut the plain ends (male) of the twin flue pipes to allow connection to the concentric to twin converter.

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

NOTE;

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

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

Fig. 11

4.5.3.2 INSTALLATION OF CONDENSATE DRAIN KIT (fig. 11)

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

●●

● Fit the first bend to the condensate drain kit or

●●

exhaust connection manifold by firmly pushing in to position.

●●

● Using the two holes in the exhaust connection

●●

manifold as a guide, drill a 3mm hole in each and secure using the screws provided.

Fig. 12

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4.5.3.4 VERTICAL TERMINATION (See fig. 13)

The twin flue system must be converted to the

dedicated concentric flue kit for termination.

●●

● The vertical terminal is supplied with a built-in

●●

converter box and cannot be shortened.

●●

A 130mm hole is required for the passage of

●

●●

the concentric terminal through the ceiling and/ or roof.

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

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

Push-fit the twin flue pipes onto the concentric to twin converter ensuring that the exhaust pipe connects to the exhaust connection on the concentric to twin converter.

If necessary cut the plain ends (male) of the twin flue pipes to allow connection to the concentric to twin converter.

NOTE

●●

● Before cutting twin flue pipes ensure allowances

●●

have been made for connection onto the previous piece and onto the concentric to twin converter. The last twin flue pipes m ust be pushed 50mm onto the male spigots of the concentric to twin converter.

●●

● You must ensure that the entire flue system is

●●

properly supported and connected.

●●

● Ensure that any horizontal sections of pipe have

●●

a 1° fall towards the appliance (17mm per 1000mm).

4.6 CONNECTING THE GAS AND WATER

The appliance is supplied with a fixing jig that includes service valves (fig. 14). The service valves are of the compression type . The accessories pack contains sealing washers etc, for use with the service valves.

When connecting pipe work to the valves, tighten the compression end first then insert the sealing washers before tightening the valve to the appliance.

NOTE

It will be necessary to hold the valve with one spanner whilst tightening with another.

Hot water

Outlet

Cold water Inlet

Stopcock/filling

valve

C/H flow

valve

Gas

Cock

Fig. 14

C/H return

valve

Safety valve

outlet

4.6.1 GAS (fig. 6 & 14)

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

NOTE

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

4.6.2 FLOW & RETURN (fig. 6 & 14)

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

NOTE

Depending on system requirements, it may necessary to increase the size of the flow & return pipe work after the service valve connections.

Filling Loop

Fig. 13

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VOKERA Linea Installation & Servicing Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual