Vokera Linea 25 HE User guide

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Linea HE

High efficiency combi boiler

Installation

& Servicing

Instructions

THESE INSTRUCTIONS TO BE RETAINED BY USER

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

Contents

Design principles & operating sequence Page

1.1 Principle components 3

1.2 Mode of operation 3

1.3 Mode of operation (Heating) 3

1.4 Mode of operation (DHW) 3

1.5 Safety devices 3

1.6 Optional accessories 3

Technical data Page

2.1 Central heating 4

2.2 Domestic hot water 4

2.3 Gas pressure 4

2.4 Expansion vessel 4

2.5 Dimensions 4

2.6 Clearances 4

2.7 Connections 4

2.8 Electrical 4

2.9 Flow rates 4

2.9 Flue details (concentric) 4

2.9A Flue details (twin pipes) 4

2.9B Flue details (80/125) 4

2.10 Efficiency 4

2.11 Emissions 5

2.12 Pump duty 5

General requirements (UK) Page

3.1 Related documents 6

3.2 Location of appliance 6

3.3 Gas supply 6

3.4 Flue system 6

3.5 Air supply 7

3.6 Water circulation 7

3.7 Electrical supply 7

3.8 Showers 7

3.9 Mounting on a combustible surface 7

3.10 Timber framed buildings 7

3.11 Inhibitors 8

General requirements (EIRE) Page

3A.1 Related documents 9 3A.2 Location of appliance 9 3A.3 Gas supply 9 3A.4 Flue system 9 3A.5 Air supply 9 3A.6 Water circulation 9 3A.7 Electrical supply 10 3A.8 Showers 10 3A.9 Mounting on a combustible surface 10 3A.10 Timber framed buildings 10 3A.11 Inhibitors 10 3A.12 Declaration of conformity 10

6.3 Replacement of components 21

6.4 Component removal procedure 21

6.5 Pump assembly 21

6.6 Safety valve 22

6.7 Bottom automatic air release valves 22

6.8 Water pressure sensor/gauge 22

6.9 Primary thermistors 22

6.10 Return thermistors 22

6.11 Printed circuit board 22

6.12 Gas valve 22

6.13 Electrode and condense sensor 23

6.14 Flue fan & mixer 23

6.15 Burner 23

6.16 Main heat exchanger 23

6.17 Flow restrictor 24

6.18 DHW flow switch 24

6.19 DHW heat exchanger 24

6.20 Valve actuator 24

6.21 Divertor valve assembly 24

6.22 DHW thermistor 24

6.23 Automatic by-pass & DHW non-return valve 24

6.24 Expansion vessel 25

6.25 Condense trap removal 25

6.26 Fan transformer removal 25

6.27 Flue collector removal 25

Checks, adjustments and fault finding Page

7.1 Checking appliance operation 26

7.2 Appliance mode of operation 26

7.3 Service mode & parameters 27

7.4 Adjusting mode & the gas valve 29

7.5 Combustion analysis test 30

7.6 Checking the expansion vessel 30

7.7 External faults 30

7.8 Electrical checks 30

7.9 Fault finding 30

7.10 Temporary fault codes 31

7.11 Final fault codes 31

Wiring diagrams Page

8.1 External wiring 32

8.2 Typical control applications 32

8.3 Vokera room thermostat 32

8.4 Other devices 32

Exploded diagrams Page

9.1 Table 1 35

9.2 Table 2 36

9.3 Table 3 37

9.4 Table 4 38

9.5 Table 5 39

Installation Page

4.1 Delivery 11

4.2 Contents 11

4.3 Unpacking 11

4.4 Preparation for mounting the appliance 11

4.5 Fitting the flue 11

4.6 Connecting the gas & water 16

4.7 Electrical connections 16

Commissioning Page

5.1 Gas supply installation 18

5.2 The heating system 18

5.3 Initial filling of the system 18

5.4 Initial flushing of the system 18

5.5 Filling the hot water system 18

5.6 Pre-operation checks 18

5.7 Initial lighting 18

5.8 Final flushing of the heating system 18

5.9 Setting the boiler operating temperature 19

5.10 Setting the system design pressure 19

5.11 Regulating the hot water 19

5.12 Final checks 20

5.13 Instructing the user 20

Servicing Page

6.1 General 21

6.2 Routine annual servicing 21

L.P.G. instructions Page

10.1 Related documents 40

10.2 Technical data 40

10.3 Converting the appliance gas type 40

10.4 Gas supply 40

10.5 Gas supply installation 40

10.6 Adjusting the gas valve 40

Benchmark 41-42

INTRODUCTION

The Linea HE range of appliances is comprised of 3 models of high-efficiency combination boiler with inputs to heating & DHW of 25 & 30, 30 &35 and 35&35 kW respectively. Each appliance – by design – incorporates electronic ignition, circulating pump, expansion vessel, safety valve, water pressure sensor and automatic bypass. The Linea HE range is produced as room sealed, category II2H3P appliances, suitable for internal wall mounting applications only. They are provided with a fan

Fig. 1

IOG

powered flue outlet with an annular co-axial combustion air intake that can be rotated – horizontally – through 360 degrees for various horizontal or vertical applications. The Linea HE range can also be used with the Vokera twin flue system. The Linea HE range is approved for use with B23P-B53PC13-C23-C33-C43-C53-C63-C83 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 nor are they intended for external applications.

General layout (fig. 1)

1 Water pressure sensor/Transducer 2 Drain valve 3 Safety valve 4 Three port valve actuator 5 Domestic hot water heat exchanger 6 Pump 7 Bottom auto air vent (AAV) 8 Injector 9 Transformer 10 Condense trap 11 Return sensor 12 Flue gas analysis test point 13 Flue outlet & air intake 14 Ignition transformer 15 Top AAV 16 Flow sensor 17 Spark/Sensing Electrode 18 Cylindric Burner 19 Condensate level sensor 20 Main heat exchanger 21 Fan assembly 22 Mixer 23 Expansion vessel 24 Hydrometer 25 Domestic hot water sensor 26 Flow governor 27 DHW flow switch 28 Gas valve 29 Condensing drain R Heating return connection F Heating flow connection G Gas connection O Hot water outlet I Cold water inlet

Fig. 1A

1= central heating temperature control

2= ON/OFF/RESET button

3= MODE button

4= INFO button

5= hot water temperature control

Symbols description

Summer

Spring

Autumn

current water pressure

outside sensor

Winter

central heating temperature bar

hot water temperature bar

temporary fault indicator

reset

current appliance temperature

error code

current mode of operation

burner on

frost protection on

SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS

● A fully integrated electronic control board featur-

ing electronic temperature control, anti-cycle control, pump over-run, self-diagnostic fault indicator and premix burner control

● Low-water-content, aluminium heat exchanger

● Electronic ignition with flame supervision

● Integral high-head pump

● Fan

● Expansion vessel

● Water pressure sensor/gauge

● Two-stage gas valve

● Condensate level sensor

● Safety valve

1.2 MODE OF OPERATION (see section 7 for detailed information)

When the appliance is connected to the electrical supply, there are 5-possible modes of operation:

● STANDBY- Heating and DHW functions are

disabled, however anti-freeze and anti-seize functions are active*

● WINTER - Heating and DHW functions enabled

with DHW pre-heat and SARA BOOSTER function active

● SPRING - DHW only enabled, DHW pre-heat

disabled

● SUMMER - DHW only enabled, DHW pre-heat

disabled, TSC function enabled

● AUTUMN - Heating and DHW functions enabled,

DHW pre-heat disabled, SARA function active.

*Anti-freeze & anti-seize functions are active in all operating modes.

1.3 MODE OF OPERATION (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 (adjustable, see parameter 28, cap.

7.3.1). Thereafter, the boiler’s output will either 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 five-minute anti-cycle (timer delay). When the request for heat has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

1.4 MODE OF OPERATION (DHW)

When there is a request for DHW via a hot water outlet or tap, the pump and fan are started, the fan 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 maximum or will modulate output to stabilise the temperature. In the event of the appliance exceeding the desired temperature (set point) 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.

*When the appliance is in the SUMMER mode, the burner will remain on minimum power even if the set point has been achieved.

1.5 SAFETY DEVICES

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

● a water pressure sensor that monitors system

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

● 2 temperature sensors that control and prevent

the over-heating of the circuit, interrupting the operation of the burner;

● a differential temperature protection circuit which

interrupts the burner if the temperature differential is too high or inverted;

● a fan speed sensor that checks the correct

operation of the fan, thereby allowing safe operation of the burner;

● a sensor that interrupts the operation of the

appliance if the condense pipe becomes blocked;

● a safety valve which releases excess pressure

from the primary circuit.

1.6 OPTIONAL ACCESSORIES

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

● external sensor that enables the appliance to

automatically adjust its outlet flow temperature in response to the outside temperature

● RF wireless room thermostat.

return

temperature

sensor

water pressure sensor

flow

& gauge

heat exchanger

DHW

non-return

valve

DHW

expansion

vessel

Fig. 2

pump

diverter

valve

safety

valve

bottom

AAV

return

transducer

automatic

by-pass

top AAV

flow

temperature

sensor

main heat

exchanger

DHW

outlet

DHW

temperature

sensor

flow regu-

lator

DHW

switch

Domestic cold water inlet

flow

SECTION 2 TECHNICAL DATA

2.1 Central Heating Linea 28HE Linea 32HE Linea 36HE

Heat input (kW) 25.0 30.0 34.6 Maximum heat output @ 60/80 °C (kW) 24.4 29.4 33.7 Maximum heat output @ 30/50 °C (kW) 26.1 31.9 36.7 Minimum heat output @ 60/80 °C (kW) 5.9 6.9 6.9 Minimum heat output @ 30/50 °C (kW) 6.4 7.6 7.6 Minimum working pressure 0.5 bar Maximum working pressure 3 bar Minimum flow rate 350 litres per hour

2.2 Domestic Hot Water

Maximum input (kW) 30.0 34.6 34.6 Maximum output (kW) 30.0 34.6 34.6 Minimum input (kW) 6.0 7.0 7.0 Flow rate (35 °C rise) 12.3 14.2 14.2 Maximum inlet pressure 6.0 bar Minimum inlet pressure 0.15 bar Minimum flow rate 2.0 l/min

2.3 Gas Pressures

Inlet pressure (G20) 20.0 mbar Maximum gas rate (m3/hr) 3.17 3.66 3.66 Minimum gas rate (m3/hr) 0.63 0.74 0.74 Injector size 6.7mm 7.0mm 7.0mm Fan speed @ max output (rpm) DHW 5.900 6.000 Fan speed @ max output (rpm) HTG 4.900 5.500 Fan speed @ min output (rpm) 1.400 1.400 1.400

2.4 Expansion Vessel

Capacity 10 litres 10 litres 10 litres Maximum system volume 91 litres 91 litres 91 litres Pre-charge pressure 1.0 bar

2.5 Dimensions

Height 845 mm Width 453 mm Depth 358 mm Dry weight (Kg) 42.0 44.0 45.0

2.6 Clearances

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

2.7 Connections

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

2.8 Electrical

Voltage (V/Hz) 230/50hz Power consumption (W) 130 130 175 Internal fuse 2A External fuse 3A

2.9 Flue details (concentric)

Maximum horizontal flue length (60/100mm) 7.80m 7.80m 7.80m Maximum vertical flue length (60/100mm) 8.80m 8.80m 8.80m

2.9A Flue details (twin pipes)

Maximum horizontal flue length (80mm+80mm) 40m+40m 35m+35m 50m+50m Maximum vertical flue length (80mm+80mm) 40m+40m 35m+35m 50m+50m

2.9B Flue details (80/125mm)

Maximum horizontal flue length (80/125mm) 17m 2 5m 28m Maximum vertical flue length (80/125mm) 18 m 26m 29 m

2.10 Efficiency

SEDBUK (%) 90.1 (A) 90.3 (A) 90.0 (A) NOx class 5 5 5

6.000

2.11 Emissions Linea 28HE Linea 32HE Linea 36HE

NOx (max-min) 88,3 - 70,6 mg/kWh 88,3 -61,8 mg/kWh 123,5 - 105,9 mg/kWh CO (max-min) 193,5 - 43 mg/kWh 215 - 21,5 mg/kWh 268,8 - 43 mg/kWh CO2 (max-min) 9.0 - 9.30 % 9.0 - 9.0 % 9.0 - 9.0 % CO/CO2 ratio (max) 0.002 to 1 0.002 to 1 0.002 to 1 CO/CO2 ratio (min) 0.0004 to 1 0.0004 to 1 0.0004 to 1

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

2.12 PUMP DUTY

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

5,0

5 metre pump 6 metre pump

4,8

4,6 4,4

4,2

4,0 3,8

3,6

3,4 3,2

3,0 2,8

2,6 2,4

2,2

2,0 1,8

1,6 1,4

1,2

1,0 0,8

Residual head (x 100 mbar)

0,6

0,4 0,2

0,0

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 130 0 1400 1500

1st speed

Fig. 3

2nd speed

Flow rate (l/h)

Fig. 4

3rd speed

6,0 5,8 5,6 5,4 5,2 5,0 4,8 4,6 4,4 4,2 4,0 3,8 3,6 3,4 3,2 3,0 2,8 2,6 2,4 2,2 2,0 1,8 1,6 1,4 1,2 1,0 0,8

Residual head (x 100 mbar)

0,6 0,4 0,2 0,0

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

1st speed

2nd speed

3rd speed

Flow rate (l/h)

Key Location Minimum distance

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

B Above an opening (window, air-brick, etc.) 300 mm C To the side of an opening (window, air-brick, etc.) 300 mm D Below gutter, drain-pipe, etc. 25 mm E Below eaves 25 mm F Below balcony, car-port roof, etc. 25 mm

G To the side of a soil/drain-pipe, etc. 25 mm

H From internal/external corner or boundary 300 mm

I Above ground, roof, or balcony level 300 mm

J From a surface or boundary facing the terminal 1200 mm K From a terminal facing a terminal 1200 mm

L From an opening in the car-port into the building 1200 mm

M Vertically from a terminal on the same wall 1500 mm

N Horizontally from a terminal on the same wall 300 mm P From a structure to the side of the vertical terminal 500 mm

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

of the vertical terminal

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 Safet (Installation & Use) Regulations, the local building regulations, the current I.E.E. wiring regulations, the bylaws of the local water undertaking, the Building Standards (Scotland) Regulation and Building Standards (Northern Ireland) Regulations.

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

3.2 LOCATION OF APPLIANCE

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

lations are given in BS 6798. This appliance is not suitable for external installation.

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 disper-

BS 5440 PART 1 FLUES

BS 5440 PART 2 FLUES & VENTILATION

BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS

BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

(2nd FAMILY GASES)

BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW

BS 6891 LOW PRESSURE INSTALLATION PIPES

BS 7074 PART 1 APPLICATION, SELECTION AND INSTALLATION OF EXPANSION VESSELS AND

ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS

space containing a bath or shower, the appliance or any control pertaining to it must not be within reach of a person using the bath or shower. The location chosen for the appliance must permit the provision of a safe and satisfactory flue and termination. The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the appliance. Where the installation of the appliance will be in an unusual location special procedures may be necessary, BS 6798 gives detailed guidance on this aspect.

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

Details of essential features of compartment/ cupboard design including airing cupboard instal-

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

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

If installed less than 2m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material. The guard must be fitted centrally over the terminal. Refer to BS 5440 Part 1, when a terminal is sited less than 1m below a plastic gutter, or less than 500mm below a painted surface, a suitable one metre long heat shield should be fitted.

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.

3.6 WATER CIRCULATION

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

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.

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.

3.6.8 FREQUENT FILLING

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

3.7 ELECTRICAL SUPPLY

Make-up vessel or tank

Automatic air-vent

Non-return

valve

Stopcock

5.0 metres minimum

3.6.2 AUTOMATIC BY-PASS

The appliance has a built-in automatic by-pass. However it may be necessary to fit an external bypass should the design of the heating system require such. In any case, the design of the system should be such that it prevents boiler ‘cycling’.

3.6.3 DRAIN COCKS

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

3.6.4 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 10 litres 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 6.24).

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 Water Supply (Water Fittings) Regulations 1999 and Water Bylaws 2000 (Scotland).

3.6.7 LOW PRESSURE SEALED SYSTEM

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

Heating return

Fig. 5

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 thermosta, 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.

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

Vokera recommend that an inhibitor - suitable for use with copper and aluminium heat exchangers is used to protect the boiler and system from the effects of corrosion and/or electrolytic action.

The inhibitor must be administered in strict accordance with the manufacturers instructions*. *Water treatment of the complete heating system

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

Fig. 6

Fig. 6A

115

114

Fig. 6B

C/H flow

valve

Hot water outlet

Gas

cock

Cold water inlet

stopcock/filling

valve

Filling loop

C/H return

valve

Default screws position of fixing jig: No. 3

Safety

valve outlet

SECTION 3A GENERAL REQUIREMENTS (EIRE)

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

3A.1 RELATED DOCUMENTS

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

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

3A.2 LOCATION OF APPLIANCE

The appliance may be installed in any room or internal space, although particular attention is drawn to the requirements of the current ETCI National Rules for Electrical Installations, and I.S. 813, Annex K. When an appliance is installed in a room or internal space containing a bath or shower, the appliance or any control pertaining to it must not be within reach of a person using the bath or shower. The location chosen for the appliance must permit the provision of a safe and satisfactory flue and termination. The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the appliance. Where the installation of the appliance will be in an unusual location special procedures may be necessary, refer to I.S. 813 for detailed guidance on this aspect. A compartment used to enclose the appliance must be designed and constructed specifically for this purpose. An existing compartment/cupboard may be utilised provided that it is modified to suit.

This appliance is not suitable for external installation.

it is likely to cause a nuisance (see I.S. 813). In cold and/or humid weather, water vapour will

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

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

3A.5 AIR SUPPLY

The following notes are intended for general guidance only.

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

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

3A.6 WATER CIRCULATION

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

3A.6.1 PIPEWORK

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

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

3A.3 GAS SUPPLY

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

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

3A.6.2 AUTOMATIC BY-PASS

3A.6.3 DRAIN COCKS

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

3A.6.4 AIR RELEASE POINTS

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

3A.6.5 EXPANSION VESSEL

The appliance has an integral expansion vessel to accommodate the increased volume of water when the system is heated. It can accept up to 10 litres 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 6.24).

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

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.6.8 FREQUENT FILLING

accordance with the manufacturers’ instructions*.

*Water treatment of the complete heating system

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

3A.12 DECLARATION OF CONFORMITY

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

813) must be provided on completion of the installation.

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

3A.7 ELECTRICAL SUPPLY

3A.8 SHOWERS

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

3A.9 MOUNTING ON A COMBUSTIBLE SURFACE

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

3A.10 TIMBER FRAMED BUILDINGS

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

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

3A.11 INHIBITORS

Vokera recommend that an inhibitor - suitable for use with copper and aluminium heat exchangers is used to protect the boiler and system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict

SECTION 4 INSTALLATION

4.1 DELIVERY

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

4.2 CONTENTS

Contained within the carton is:

• the boiler

• the wall bracket & fixing jig

• template

• an accessories pack containing appliance serv-

ice connections and washers

• the instruction pack containing the installation & servicing instructions, user instructions, guarantee registration card and a 3-amp fuse.

4.3 UNPACKING

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

4.4 PREPARATION FOR MOUNTING THE APPLIANCE

The appliance should be mounted on a smooth, vertical, non-combustible surface, which must be capable of supporting the full weight of the appliance. Care should be exercised when determining the position of the appliance with respect to hidden obstructions such as pipes, cables, etc. When the position of the appliance has been decided – using the template supplied – carefully mark the position of the wall-mounting bracket (see fig. 6-6A) and flue-hole (if applicable). If you intend to run the pipe-work vertically behind the boiler, move the screws on the fixing jig from the default position (No. 3) to position No. 5. You will also require a spacer kit, part No. 435 (see 4.6).

horizontal plane (see 2.9). A reduction must also be made to the maximum length (see table below) when additional bends are used.

Reduction for additional bends Bend Reduction in maximum flue length for

each bend 45º bend 0.5 metre 90º bend 1.0 metre

Horizontal flue terminals and accessories

Part No. Description Length

520 Horizontal flue kit 900mm 521 Telescopic flue kit 350/530mm 522 Plume management kit 1370mm 523 90-degree bend N/A 524 45-degree bends (pair) N/A 525 500mm extension 500mm 526 1000mm extension 1000mm 527 2000m extension 2000mm 528 Telescopic extension 350/730mm 529 Wall bracket pack (5) 208mm

Using the template provided, mark and drill a 115mm hole for the passage of the flue pipe. The hole should be drilled to ensure any condense fluid that forms, is allowed to drain back to the appliance (see fig. 7A).

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 is mounted securely. Once the bracket has been secured to the wall, mount the appliance onto the bracket.

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 Vokera condensing 60/100mm concentric flue system or the optional 80/125mm concentric flue system.

NOTE

The appliance flue outlet elbow can be rotated through 360º on its vertical axis. In addition the flue may be extended from the outlet elbow in the

Fig. 7

FITTING THE HORIZONTAL FLUE KIT

Carefully measure the distance from the centre of the appliance flue outlet to the edge of the finished outside wall (dimension X). Add 65mm to dimension X to give you Dimension Y (see fig 9A). Measure dimension Y from the terminal end of the concentric flue pipe and cut off the excess ensuring any burrs are removed. Pass the concentric flue pipe through the previously drilled hole. Fit the flue bend to the boiler flue outlet and insert the concentric flue pipe into the flue bend ensuring the correct seal is made. Using the clamp, gasket, and screws supplied, secure the flue bend to the appliance flue spigot.

NOTE

Fit the internal (white) trim to the flue assembly prior to connecting the flue pipe to the bend. You must ensure that the entire flue system is properly supported and connected. Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The exterior trim can now be fitted.

“X”

Fig. 8

Fig. 7A

30mm

“X” + 65mm = “Y”

“Y”

4.5.1.1 EXTENDING THE FLUE

Connect the bend – supplied with the terminal kit – to the top of the boiler using clamp (supplied) see fig. 7. The additional bends & extensions have push-fit connections, care should be taken to ensure that the correct seal is made when assembling the flue system. Connect the required number of flue extensions or bends (up to the maximum equivalent flue length) to the flue terminal (see fig. 7 & 8). The flue system should have a minimum of 1º; maximum of 3º rise from the boiler to outside, to ensure any condense fluid that forms, is allowed to drain back to the appliance.

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (see fig. 7 & 8). Remove any burrs, and check that all seals are located properly. You must ensure that the entire flue system is properly supported and connected. Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The interior and exterior trim can now be fitted.

1-3 degree

4.5.2 CONCENTRIC VERTICAL FLUE

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

NOTE

These instructions relate only to the Vokera condensing 60/100mm concentric flue system. For specific details on the installation of the 80/ 125mm concentric flue system please refer to the instructions supplied. The vertical flue terminal can be connected directly to the appliance flue outlet. Alternatively, an extension or bend can be connected to the appliance flue outlet if desired (see 4.4.2), however if additional bends are fitted, a reduction must be made to the maximum flue length (see table below).

Reduction for bends Bend Reduction in maximum flue length for each

bend 45º bend 0.5 metre 90º bend 1.0 metre

Vertical flue terminal and accessories Part No. Description Length 530 Vertical flue terminal 1000mm 531 Pitched roof flashing plate N/A 532 Flat roof flashing plate N/A 523 90-degree bend N/A 524 45-degree bends (pair) N/A 525 500mm extension 500mm 526 1000mm extension 1000mm 527 2000mm extension 2000mm 528 Telescopic extension 350/730mm 529 Wall bracket pack (5) 208mm

Using the dimensions given in fig. 7 as a reference, mark and cut a 115mm hole in the ceiling and/or roof.

“X”

28/32/36 HE = 218 mm

“X”

12/15/20HE = 202mm 25/30/35HE = 218mm

“X”

Fig. 9

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

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 100mm clip, gasket & screws (supplied), ensuring the correct seal is made. The flue support bracket (supplied with the vertical flue kit) can now be fitted. If the vertical flue requires extension/s or additional bend/s, connect the required number of flue extensions or bends (up to the maximum equivalent flue length) between the boiler and vertical flue assembly (see fig. 8). Ensure that any horizontal sections of the flue system have a minimum 1º; maximum 3º fall back to the boiler (1º = 17mm per 1000mm).

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (see fig. 6). Remove any burrs, and check that any seals are located properly.

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

4.5.3 TWIN FLUE SYSTEM

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

GUIDANCE NOTES ON TWIN FLUE INSTALLATION

• The flue must have a have a minimum 1º; maximum 3º (1º = 17mm per 1000mm) fall back to the appliance to allow any condensate that may form in the flue system to drain via the condensate drain. Consideration must also be given to the fact that there is the possibility of a small amount of condensate dripping from the terminal.

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

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

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

• The condensate drain pipe must be connected in accordance with building regulations.

Reduction for bends Bend Reduction in maximum flue length for

each bend 45º bend 1.0 metre 90º bend 1.0 metre

Twin flue accessories Part No. Description Length

0225805 Horizontal flue terminal 1.0 metre 0225810 Vertical flue terminal 1.0 metre 359 Twin adapter kit N/A 531 Pitched roof flashing plate N/A 532 Flat roof flashing plate N/A 0225815 Condensate drain kit N/A 0225820 0.25m extension (pair) 250mm 0225825 0.5m extension (pair) 500mm 0225830 1.0m extension (pair) 1000mm 0225835 2.0m extension (pair) 2000mm 0225840 45º bend (pair) N/A 0225845 90º bend (pair) N/A 0225850 Twin bracket (5) N/A 0225855 Single bracket (5) N/A

MOUNTING THE BOILER

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

+ 33 hidden pages

Vokera Linea 25 HE User guide

Specifications and Main Features

Frequently Asked Questions

User Manual