VOKERA Linea Max Installation & Servicing Instructions Manual

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Room Sealed, Fanned Flue, Combination Boiler

Installation
& Servicing
Instructions

BRITISH GAS SERVICE LISTED
G.C. No 47 094 30

THESE INSTRUCTIONS
TO BE RETAINED
BY USER

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CONTENTS
Section Subject Page no

Section 1 Introduction 1

General Layout 1

Section 2 Design Principles & Operating

Principles 2

Schematic Diagram 2
Central Heating Mode 2
Domestic Hot Water Mode 2
Safety Devices 2
Frost Thermostat 2

Section 3 Technical Data 3

Dimensions & Contents 3
Connection Sizes 3
Installation Requirements 3
Electrical Details 3
Performance & Limitations 3
Working Pressure (H/W & C/H) 4
Flow Rates 4
Central Heating Pump Duty 4

Section 4 General Requirements 5

Related Documents 5
Location of Appliance 5
Gas Supply 5
Flue System 5
Air Supply 6
Water Circulation (C/H) 6
Pipework 6
By-Pass 6
System Design 6
Draining Taps 6
Air Release Points 7
Filling Point 7
Electrical Supply 7
Showers 7

Section 5 Installation 8

Delivery 8
Unpacking 8
Siting the Appliance 9
Connecting the Gas & Water 9-10
Fitting The Flue (Horizontal) 13
Fitting The Flue (Vertical) 14
Electrical connections 22

Section 6 Commissioning 17

Gas Installation 17
Initial Flushing of Pipework 17
Initial Filling of System 17
System Design Pressure 17
Filling the Hot Water System 17
Checking Electrical supply 17
Lighting The Boiler 17
Checking Burner Pressures 18
Range Rating C/H 19
Checking The Flue System 19
Checking The Heating Thermistor 19
Regulating The C/H System 19
Final Flushing The C/H System 19
Filling & Testing H/W System 19
Final Checks For Operation 20
Concluding Operations 20

Section Subject Page no

Section 7 Instructing The User 20
Section 8 Servicing Instructions 20

General 20
Recommended Routine Servicing 20
Annual Servicing 20
Replacement Of Parts 21
To Gain General Access 21

To Remove:

Room Sealed Chamber Front Cover 21
Main Burner & Electrode 22
Main Burner Injectors 22
Main Heat Exchanger 22
Flue Fan 23
Pressure Differential Switch 23
Combustion Chamber Insulation Panel 23
Ignition Control Box 24
Gas Control Valve 24
Pump 25
Domestic Flow Switch 25
Diverter Valve & Flow Switch Manifold 25
Domestic H/W Heat Exchanger 26
Diverter Valve 26
Main Expansion Vessel 26
Safety Valve 26
Flow Microswitch 26
Motorised Valve 26
Printed Circuit Board 26
Display Printed Circuit Board 26
Safety Thermostat 26
Thermistor Sensors 26
Pressure Gauge 26
Setting Gas Pressures 27
Combustion Analysis 27

Section 9 Operational Checks & Wiring 28

Sequence of Functions 28
Diagnostic Error Codes 29
Fault Finding Guides 30-40

Section 10 Appendix 41

Internal Time Clock Installation 41-42
External Time Clock Installation 42
S & Y Plan Installations 43
Exploded Diagrams 45-51
Short Spare Parts List 52
Abling & Disabling Controls 52
Functional Flow Diagram 53
Illustrated Wiring Diagram 54
Preliminary Electrical System Checks 55
LPG Instructions 56-57

Linea Max

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SECTION 1 INTRODUCTION

26

25

24

23

22

21

The Vokèra Linea Max is a com­bined central heating and domestic hot
water appliance. By design it incorporates
full sequence electronic ignition, circulating
pump, expansion vessel, safety valve,
temperature gauge, pressure gauge, 3 port
diverter valve and filling loop.

It is produced as a room sealed appliance
suitable for floor mounting only. It is pro­vided with a fan powered flue outlet with an
annular co-axial combustion air intake, twin
flue option is also available.

Fig. 1

14 13

35

This appliance is designed for use with a
sealed heating system only and is not
intended for use on an open vented system.

An automatic range-rating facility is incorpo­rated in the boiler for the central heating
system in conjunction with the electronic
burner modulation. The domestic hot water
(dhw) service utilises a motorised valve
combined with a 3 port diverter valve to give
hot water priority which also benefits from a
heatbank having a nominal capacity of 58
litres of circulating primary hot water posi­tioned at the rear of the appliance.

Fig.1 General Layout

1 Flue Elbow
2 Pressure Differential Switch
3 Silicone Pressure Tubes

1

4 Main Heat Exchanger
5 Combustion Chamber
6 Spark Electrode
7 Main Burner

2

8 Primary Store Isolation Valve (1 of 3)
9 Primary Store

3

10 Electronic Ignition Unit
11 Gas Valve
12 Gas Inlet
13 Domestic Flow Switch
14 Filling/Inlet Valve

4

15 Domestic NTC
16 Domestic Heat Exchanger

5

17 Hot Water Outlet
18 Safety Valve Outlet
19 Central Heating Flow

6

20 Central Heating Return

7

21 Motorised Valve
22 Pump

8

23 Sensing Electrode
24 Expansion Vessel

9

25 Fan

10

26 Automatic Air Vent
27 Timeclock Aperture (Optional)

11

28 Front Door Panel
29 Pressure Gauge
30 Status LED
31 Central Heating Temperature Control

1216171820 19 15

32 Mode Selector Switch
33 Hot Water Temperature Control
34 Temperature Indicator
35 Combustion Switch

34

Linea Max

31

29 28303233

27

1

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SECTION 2 DESIGN PRINCIPLES AND OPERATING SEQUENCE

2.1 Fig.1 illustrates the general layout of compo­nents. Fig.2 illustrates the operating princi­ples described below.

2.2 Central Heating Mode

2.2.1 When the various switches and controls

impose a demand for heat, the pump is
started. The flow of water from the pump
operates a flow switch. This in turn ener­gises the electronic circuitry. The fan is
started, the gas valve is energised at an
intermediate rate and the electronic ignition
goes through an ignition attempt.

2.2.2 The burner ignition is checked by the elec­tronic circuitry to ensure correct ignition of
the burner.

2.2.3 As water temperature increases this is
sensed by the temperature sensor on the
flow pipe which modulates the burner to
match the heat output to the heat require­ment of the system.

2.2.4 Depending on the load, either a) the water
temperature will continue to rise and the
burner will continue to modulate down until
the maximum setting is reached at which
point the burner is switched off, or b) the
water temperature will fall and the burner
will return to a higher output to match the
demand.

flue outlet air intake

26

24

22

21

2.3 Domestic Hot Water Mode

2.3.1 The appliances incorporate a hot water

preheat facility. The appliance will therefore
ignite periodically to maintain heat within the
appliance.

2.3.2 The appliance will operate in domestic hot
water mode whenever the mode selector
switch is on regardless of mode selector
switch position and any demand for central
heating.

2.3.3 The diverter valve will automatically ener­gise into the hot water position after central
heating demand, or will stay in the hot water
position after hot water demand. Opening a
draw off tap will energise the pump and fan
sending primary water to the domestic hot
water heat exchanger.

2.3.4 Temperature control is transferred to the
domestic hot water thermostat
(potentiometer) which modulates the burner
output between high and low flame to
maintain an average heat input to suit the
dhw output required.

2.3.5 An overrun is incorporated in the boiler in
both c/h & dhw modes. The fan overruns
until the boiler water cools to approximately
80°C (176°F).

2.4 Safety Devices

2.4.1 In both central heating and hot water modes

safe operating is ensured by:

A. Differential pressure unit in the primary
circuit which prevents burner operation if
water flow rates are too low.

B. An electronic device that checks the
primary pressure unit for activation. Failure

2

4
7

11

results in deactivation of the pump, after
approximately 10 minutes of operation.

C. A safety thermostat, which interrupts the
control circuit shutting off the gas valve. At
the same time the fan will still operate.

D. A Pressure differential switch in the flue
system to check the fan's operation before

9

allowing ignition.

2.4.2 A safety valve is provided to relieve excess

16

pressure from the primary circuit.

2.4.3 Frost Thermostat

The appliance has a built in frost protection
circuit. Should the boiler temperature sensed
at the primary thermistor fall below 5°C, the
boiler will operate in central heating mode and
continue to operate until the primary thermis­tor reaches approximately 40°C.

A

B

KEY:
A Gas
B Hot Water Outlet

DE

C

Fig. 2

This drawing is indicative only and does

not accurately represent pipe positioning.

C Cold Water Inlet
D Central Heating Flow
E Central Heating Return

2

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SECTION 3 TECHNICAL DATA

3.1 Units Dimensions and values are given in
the preferred Sl Units with Imperial units in
brackets where applicable.

3.2 Dimensions and Contents

Height 850mm (33.5in.)
Width 600mm (23.6in.)
Depth 585mm (23in.)
Weight Dry 88Kg (194lb)
Weight Full 151Kg (333lb)

Water content: 65 litres (14.3 gals)
For further dimensions see fig.13

3.3 Connection sizes

Heating flow and return: Nut and olive for
22mm o.d.Cold water inlet: Nut and olive for
15mm o.d.Hot water outlet: Nut and olive for
15mm o.d. Gas Service: Nut and olive for
15mm o.d. Safety valve outlet: Nut and olive
for 15mm o.d.

Flue outlet/Air inlet: nom dia 60/100mm
specially supplied with boiler (concentric).
Flue outlet/Air inlet: nom dia 80/80mm
specially supplied with boiler (twin).

3.4 Installation Requirements

3.4.1 Clearances (Horizontal or Vertical Flue)

Minimum - above casing 20mm (3/4in)
Minimum - In front 600mm (24in)
Minimum - At sides 12mm (½in) from casing

3.4.2 Maximum heating system contents approx.
100 litres (21.9 gals). Acceptance capacity
of expansion vessel 10 litres (2.2 gals).

3.4.3 Means of filling sealed system: To accord
with BS and/or local Water Authority require­ments.

3.4.4 Maximum flue lengths

Using extension tubes the flue may be
extended to the following lengths.

Concentric

Horizontal: 1.8 metres max.

Vertical: 4.4 metres max.

Twin: 6m/6m + concentric terminal.

(Horizontal termination only)

The reduction in flue length for each bend
used is:

Concentric Flue

Reduction in flue lenght

Bend

90° 850 mm
45° 425 mm

Offset 850 mm

for each bend

3.5 Electrical Details

Mains supply 230v ~ 50Hz Fused 3A
Internal fuse rating F2A and T100mA
Power consumption: 150W

3.6 Performance and Limitations

Max. input 31.0 kW (105,802 Btu/h)(net)
Min. input 11.9 kW (40,614 Btu/h)(net)(c/h)
Min. input 10.5 kW (35,836 Btu/h)(net)(h/w)
Max. input 34.4 kW (117,406 Btu/h)(gross)
Min. input 13.2 kW (45,051 Btu/h)(gross)(c/h)
Min. input 11.6 kW (39,590 Btu/h)(gross)(h/w)

Max. output 28.0 kW (95,563 Btu/h)
Min. output 9.9 kW (33,788 Btu/h)(c/h)
Min. output 8.7 kW (29,692 Btu/h)(h/w)

Central Heating output range

Max. 28.0 kW (95,563 Btu/h)
Min. 9.9 kW (33,788 Btu/h)

Designed temp rise 20°C
Max. flow temperature 85°C

Nominal hot water production

Max.water flow at temp rise of 25°C

16.1l/min Max.water flow at temp rise of
35°C 11.5l/min

Nominal hot water production (For first 10
minutes) (Inlet temp 12°C)
Water flow at 18 l/min - average water
temperature 43°C.

Gas Pressures

Max. gas pressure 10.1mbar
Min. gas pressure C/H 1.6mbar
Min. gas pressure H/W 1.3mbar

Gas Rate

Max. 3.27 m3/h 115.8 ft3/h
Min. 1.10 m3/h 39.0 ft3/h
Note: Use gross input values when gas
rating the appliance

Burner Details Main burner:

Polidoro type NP14
Main burner injectors 14 x 1.35

3.7 Working Pressure Heating System

Maximum 1.5bar/15m w.g./50ft w.g.
Minimum 0.15bar/1.5m w.g./5ft w.g.
Safety valve setting 3bar/30m/102ft w.g.

3.8 Flow Rates

Min. water flow (dhw) 2.0l/min. (0.45 gal/
min) Min central heating flow rate through
appliance 350litres/hr (1.28 gal/min)

3.9 Working Pressure Hot Water System

Maximum 6.0 bar/90psig
Minimum 0.6 bar/7psig

For LPG instructions see page 62

Twin Flue

Reduction in flue lenght

Bend

90° 850 mm

45° 850 mm

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for each bend

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3.10 Central Heating Pump Duty

Water

pressure

mbar

700

600

500

400

300

200

100

0

123456789101112131415

X 100

Water flow

l/h

Fig. 3

4

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SECTION 4 GENERAL REQUIREMENTS

4.0 General Requirements

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

1998.

4.1 Related Documents

The installation of this boiler must be in
accordance with the relevant requirements
of the Gas Safety (Installation & Use)
Regulations 1998 the Local Building Regula­tions, the current l.E.E. Wiring Regulations,
the by-laws of the local water undertaking,
and in Scotland, in accordance with the
Building Standards (Scotland) Regulation. In
Ireland the local building regulations (IE).

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:

BS 6891 1988 Low pressure installation pipes
BS 6798 1987 Boilers of rated input not exceeding 60kW.
BS 5449 Part 1 1990 Forced circulation hot water systems
BS 5546 1990 Installation of gas hot water supplies

BS 5440 Part 1 1990 Flues.
BS 5440 Part 2 1989 Flues & Ventilation.
BS 7074 Part 1 1989 Application, selection & installation of expansion

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

Details of essential features of cupboard/
compartment design including airing cup­board installations are given in BS
6798:1987. This appliance is not suitable for
external installation.

4.3 Gas Supply

A gas meter is connected to the service pipe
by the gas supplier.

An existing meter should be checked,
preferably by the gas supplier, to ensure that
the meter is adequate to deal with the rate of
gas supply required for all appliances it
serves.

Installation pipes should be fitted in accord­ance with BS 6891:1988.

for domestic purposes (2nd family gases).

vessels & ancillary equipment for sealed water
systems.

4.2 Location of Appliance

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

Where a room-sealed appliance is installed
in a room containing a bath or shower, any
electrical switch or appliance control, utilis­ing mains electricity, should be located in
such a position that it cannot be touched by
a person using the bath or shower.

The location chosen for the boiler must
permit the provision of a 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
boiler.

Where the installation of the boiler will be in
an unusual location special procedures may
be necessary and BS 6798:1987 gives
detailed guidance on this aspect.

Pipework from the meter to the boiler must
be of adequate size. Pipes of a smaller size
than the boiler inlet connection must not be
used.

The complete installation must be tested for
soundness as described in the above code.

N.B. If the gas supply for the boiler serves
other appliances ensure that an adequate
supply is available both to the boiler and the
other appliance when they are in use at the
same time.

4.4 Flue System

The terminal should be located where
dispersal of combustion products is not
impeded and with due regard for the dam­age or discoloration that might occur to
building products in the vicinity (see fig 4).

The terminal must not be located in a place
where it is likely to cause a nuisance.

In cold and/or humid weather water vapour
may condense on leaving the flue terminal.
The effect of such steaming must be
considered.

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For protection of combustibles, refer to BS
5440:1 where the terminal is less than 2m
(6.6ft) above a pavement or platform to
which people have access (including any
balcony or flat roof the terminal must be
protected by a guard of durable material).

A suitable guard is available from Vokéra
Ltd. Part No 018, G.C. No. 301 106

This guard must be fitted centrally over the
terminal. Mark the positions of the fixings,
drill the wall and secure using wall plugs and
3 of 1½" No.8 plated screws.

Fig. 4

Terminal position for fan assisted boiler

(minimum distance) mm
A - Directly below an open window or other 300

opening (e.g. air brick)
B - Below gutters, soil pipes or drain pipes 25
C - Below eaves 25
D - Below balconies or car port roof 25
E - From vertical drain pipes and soil pipes 75
F - From internal or external corners 25
G - Above ground or below balcony level 300
H - From a surface facing a terminal 600
I - From a terminal facing a terminal 1200
J - From an opening in the car port (e.g. door

window) into dwelling. 1200
K - Vertically from a terminal on the same wall 1500
L - Horizontally from a terminal on the same wall 300
M - Horizontally from a vertical terminal to a wall 300

NOTE: The flue must be terminated in a place not likely

to cause a nuisance.

4.5 Air Supply

The following notes are intended for general
guidance.

The room sealed fan flued boiler does not
require a permanent air vent for combustion
air supply.

Where installed in a cupboard or compart­ment ventilation is required for cooling.

The table following gives the recommended
minimum effective areas of such air vents.

Air Vent areas

Positions

of

Air Vents

High

Level

Low

Level

Air From
Room or

Internal

Spaces

310 cm

2

48 in

310 cm

2

48 in

2

2

Air Direct

From

Outside

155 cm

2

24 in

155 cm

2

24 in

2

2

4.6 Water Circulation (Central Heating)

Detailed recommendations are given in
BS 6798:1987 and BS 5449:1:1990 (for
smallbore and microbore central heating
systems).

4.6.1 The following notes are given for general
guidance.

4.6.2 Pipework

Copper tubing to BS 2871:1:1971 is recom­mended for water pipe. Jointing should be
either by capillary soldered or with compres­sion fittings.

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

It should be ensured as far as possible that
the appliance heat exchanger is not a
natural collecting point for air.

Except where providing useful heat, pipes
should be insulated to prevent heat loss and
to avoid freezing. Particular attention should
be paid to pipes passing through ventilated
spaces in roofs and under floors.

4.6.3 By-Pass

An automatic by-pass is incorporated in the
boiler, but systems should be designed to
ensure that with all radiators turned off a
flow rate of at least 350 litres/hour (1.28
gals/min) is achieved through the system.
See 6.9.4

4.6.4 System Design

Vokèra Ltd recommend a 2-pipe system. Sin­gle pipe systems are more liable to be trouble­some unless carefullly designed and installed.

4.6.5 Draining Taps

These must be located in accessible posi­tions to permit the draining of the whole
system. The taps must be at least 15mm
nominal size and manufactured in accord­ance with BS 2879:1980.

6

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4.6.6 Air Release Points

These must be fitted at all high points where air
will naturally collect, and must be sited to
facilitate complete filling of the system.

4.6.7 The appliance has an integral sealed expan­sion vessel to accommodate the increase of
water volume when the system is heated. It
can accept up to 10 litres (2.2gals) of expan­sion water. If the appliance is connected to a
system with an unusually high water content.
Calculate the total expansion and add addi­tional sealed expansion capacity as appropri­ate.

In general, modern systems will present no
problem.

4.6.8 Filling Point

A method for initially filling the system and
replacing water lost during servicing is pro­vided on the appliance.

In the event that this method is not suitable in
a particular area, contact the local authority for
preferred methods.

4.7 Electrical Supply

The appliance is supplied for operation on
230V ~ 50Hz electricity supply. It should be
protected with a 3-amp fuse.

THIS APPLIANCE MUST BE EARTHED.

The method of connection to the mains elec­tricity must allow complete isolation from the
supply.

The preferred method is by using a fused
double pole switch with a contact separation of
at least 3mm.

The switch must supply ONLY the appliance
and immediate electrical control circuits (e.g.
programmer / room thermostat)

Alternatively, use an unswitched shuttered
socket outlet with a fused 3-pin plug both
complying with BS 1363.

4.8 Showers

If a shower control is to be supplied from the
combination unit it should be of the type which
incorporates a thermostatic control and by
design is suitable for use with a combination
boiler. Check application with shower manu­facturer.

4.9 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.

C/H Return

Valve

C/H Flow

Valve

Hot Water

Outlet

Safety Valve

Outlet

Cold Water

Inlet Stopcock/

filling valve

Gas

Cock

Linea Max

Base Tray

Fig. 5

7

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SECTION 5 INSTALLATION

Fig. 6

Fig. 7









5.1 Delivery (fig. 6)

The appliance is delivered in a crated heavy
duty cardboard carton.

5.2 Unpacking (fig. 6 & 7)

Stand the boiler the correct way up and re­move the surrounding timber frame.Slide the
protecting packaging from around the appli­ance. Remove appliance from base pallet.

The appliance comes complete with a base
tray which can easily be removed. The pur­pose of the base tray is that it can be used as
a template to preplumb the appliance before
final fitting.

To remove the base plate from the appliance,
push to release the control panel door, locate
the small tool inside and undo the two screws
securing the front panel to the appliance and
remove. Loosen and undo the Central heating
flow and return unions, cold water inlet union,
hot water outlet union, gas union and safety
valve union.See figs 5 & 9.

Ensure the filling inlet tap is in a horizontal
position. Either slide the base plate out from
the rear of the appliance or slide the appliance
forwards off the base plate. The appliance is
on wheels easing this operation.

The Base Tray Contains:

Central heating valves (2)
Gas service tap (1)
Cold water Filling/Inlet (1)
Hot water outlet Connection (1)

Found packed inside the appliance:

Safety valve outlet pipe (1)
Filling loop hose (1)
Various washers
Base plate screws (2)
Spare front panel door tool (1)
Restrictor ring (1)

Fig. 8

8

Flue kit supplied in separate carton.

Fig. 9

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Fig. 10

Fig. 11a

Rear pipework
reference bar.

Base tray securing screws

Fig. 11

5.3 Siting the Appliance

5.3.1 The appliance is floor standing. Place the

base plate on a smooth firm and level surface.
The back of the base tray can be pushed flush
against the back wall if necessary (this will still
allow piping behind the appliance see figs 5
&10). Special floor protection is not required
and the floor must be capable of supporting
the weight of the appliance See section 3..

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'.

5.3.2 If necessary drill holes through the wall to
allow passage of pipework before final base
plate fixture see fig 10.

5.3.3 Drill and plug the floor for 4 - 1" No. 10 screws
and screw the base tray firmly into position
using rust proof countersunk screws.

5.3.4 Refer to figs.13 for relevant dimensions for
locating the flue hole: Where it is remote from
the boiler take special care to ensure hole is at
the correct level. Drill a 105mm hole through
the wall to allow passage of the flue pipe.

5.3.5 Connecting the Gas and Water

5.3.6 Figs. 5 and 13 show the locations of the

fittings.

5.3.7 When connecting pipework to valves do not
over tighten nuts, use another spanner to
apply counter force to avoid damaging/
moving the valves/baseplate.

5.3.8 Gas Supply

Connecting the gas supply.

Connect a 15mm gas pipe to the gas
service tap and tighten the union nut secur­ing the tap to the appliance.

Pipework from the meter to the appliance
must be of adequate size.

A minimum gas pressure of 20mb (8 in.
w.g.) must be available at the appliance
inlet at full flow rate. See section 3.

DO NOT use pipes of a smaller size than
the appliance inlet connection.

5.3.9 Central Heating

Connect the central heating pipework
(22mm o.d) to the respective valves, right
hand: flow, left hand: return, and tighten the
nuts.

5.3.10 Hot Water

Connect a 15mm pipe to the hot water
outlet connection of the appliance. Tighten
the nut.

If the hot water system does not include a
tap below the hot water outlet connection,
provide a suitable drain tap to permit
draining of the appliance hot water side
during servicing.

Fig. 12

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5.3.11 Cold Water

Connect a 15mm cold water service pipe to
the inlet stopcock of the appliance. Tighten
the nut.

If the cold water supply is liable to high
pressure or large pressure fluctuations, a
flow/pressure regulator should be fitted in
the supply pipe.

Should the appliance be subject to 'mains
knock' it would be advisable to install a non
return valve in the hot water outlet pipe to
prevent unnecessary activation of the
domestic flow switch.

5.3.12 Safety Valve Discharge

Connect a 15mm pipe to the discharge
outlet of the appliance.

The discharge should terminate facing
downwards outside the building in a position
where discharging (possibly boiling) water
will not create danger or nuisance; but in an
easily visible position.

5.3.13 Once all relevant pipework has been installed
and the flue hole has been cut,the appliance
can be slid into position.

If the filling inlet valve is in the off position
(verticaly up) remove the handle from the
valve (this will allow the appliance to slide into
position without fouling the component).

Stand the appliance in front of the base tray
See fig.11. and gently slide into position.

Tighten the nuts from the valves on the base
plate to the corresponding inlet/outlet connec­tions on the appliance using the fibre washers
supplied.

Finally secure the appliance to the base tray
using the 2 screws provided. See fig.11a.

Fit the filling loop hose and safety valve outlet
pipe and replace the filling/inlet valve handle.

Alternatively before the appliance is positioned
the system and supplies can be filled and
pressure tested using the Vokèra pressure
test kit (part no. 401). Pressure test kit instruc­tions supplied with kit.

Note: All pipework can be installed to run up
behind the appliance. Ensure that the pipes
pass behind the reference bar to prevent the
pipes fouling the appliance when it is pushed
into position. See fig. 10.

Remove the knock out panel in the top panel
for pipe clearance See fig.17.

Fig. 13

Fig. 14

10

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Supplied By www.heating spares.co Tel. [phone]

5.4 Installing the flue system

Care should be exercised when determining
the position of the appliance and route of the
flue system with respect to hidden obstruc­tions such as pipes, cables, etc.

5.5 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.

5.5.1 Concentric horizontal flue

(For concentric vertical flue, see 5.5.2)
(For twin flue applications, see 5.5.3)
The appliance flue outlet elbow can be rotated
at 90º intervals on its vertical axis allowing the
flue system to exit the appliance casing at the
rear, to the left, & to the right. In addition the
flue may be extended from the outlet elbow in
the horizontal plane (see 3.4.4), however if the
flue is to be extended and/or additional bends
are to be fitted, a reduction must be made to
the maximum flue length (see table below).

Reductio n i n maximum flue

Bend

lenght for each bend

45° 0,5 metre

90° 1,0 metre

Discard the bend & inner (small) flue clip
supplied with the flue terminal.

Carefully measure the distance from the cen­tre of the appliance flue outlet to the face of the
outside wall (dimension X) and add 34mm to
give you dimension Y (see fig. 15).

Measure from the terminal end of the concen­tric flue pipe and mark off dimension Y. Cut
only the outer flue pipe at this mark.

Mark dimension Y on the inner flue pipe then
add 10mm and cut at the new mark.

This results in the inner flue pipe being 10mm
longer than the outer flue pipe.

Horizontal flue terminal and accessoires

Part No. Descrip tion Min-Max Length
0225700 Horizontal flue kit

For use with add.

Bends & exte nsio ns
0225755 Telescopic extension 35 0 - 500 m m
0225740 0,5 m extension 5 00 mm
0225745 1,0 m extension 1000 mm
0225730 45° bend (pair) N/A
0225735 901° bend N/A
0225760 Wall bracket (5) N/A

900 mm

Using the fig. 13 as a reference, mark and drill
a 115mm hole for the passage of the flue pipe.
The hole should have a 1º drop from the boiler
to outside, to eliminate the possibility of rain­water entering the appliance via the flue.

5.5.1.1 Standard horizontal flue (See 5.5.1.2 for
extending the horizontal flue)

The flue terminal (part no. 0225700) is suitable
for the following wall thickness:

Route Maximum wall thickness
Terminating to the rear 573mm (boiler hard

against rear wall)

Terminating to the left 509mm (boiler with

minimum clea ra nce a t
left hand side )

Terminating to the right 617mm (boiler with

minimum clea ra nce a t
right ha nd si de)

Insert the flue pipe into the previously drilled
flue hole.

Pull it towards the appliance flue bend and
insert the inner flue pipe into the push-fit socket
of the bend until the outer flue pipe butts
against the edge of the appliance flue bend.

Take the outer flue clip, seal, & screws (sup­plied with the flue terminal kit) and secure the
flue pipe to the appliance flue bend.

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

Check that the terminal protrudes past the
finished wall by the correct length (115mm).

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.

5.5.1.2 Extended horizontal flue
(see fig. 15a)

Discard the bend & inner (small) flue clip
supplied with the flue terminal.

Insert the flue terminal into the previously
drilled flue hole.

Connect the required bends and/or extensions
to the flue terminal working back towards the
boiler whilst maintaining a 1°fall (17mm per
1000mm) away from the boiler.

All bends and extensions are push-fit and
require no clips or screws, however care should
be taken to ensure that the correct seal is
made when assembling the flue system.

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Carefully measure the distance between the
appliance flue outlet bend and the 2nd last
extension or bend (dimension X). Add 40mm
to dimension X to give dimension Y (see fig.
15a).

Measuring from the socket end of the last
extension, mark and cut both pipes to suit
dimension Y.

Remove the appliance flue bend from the flue
outlet and insert the inner flue pipe  of the
extension  into the push-fit socket of the bend
until the outer flue pipe butts against the edge
of the appliance flue bend.

Take the outer flue clip, seal, & screws (sup­plied with the flue terminal kit) and secure the
flue pipe to the appliance flue bend.

Connect the assembled bend and extension to
the 2nd last extension or bend and ensure the
correct seal is made.

Finally connect the appliance flue outlet bend
to the appliance flue outlet.

NOTE

When cutting an extension to the required
length, you should ensure that the excess is
cut from the plain end of the extension. Re­move any burrs, and check that both seals are
located properly.

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

Optional
knock-out
panels

Fig.16

5.5.2 Concentric vertical flue
(see fig. 16 & 16a)

The vertical flue terminal should be connected
directly to the appliance flue outlet. If addi­tional bends and/or extensions are fitted, a
reduction must be made to the maximum flue
length (see table below & 3.4.4).

B end R eduction in maximum flu e le ngth for

each bend

45º bend 0.5 metre

90º bend 1.0 metre

Vertical flue terminal and accessories

Part No. Description Length
0225715 Vertical flue

terminal

0225770 Pitched roof

flashing plate

0225765 Flat roof flashing

plate

0225775 Vertical flue

connection kit

0225755 Telescopic

extension
0225740 0.5m extension 500mm
0225745 1.0m extension 1000mm
0225750 2.0m extension 2000mm
0225730 45º bend (pair) N/A
0225735 90º bend N/A
0225760 Wall bracket (5) N/A

IMPORTANT

The vertical flue terminal is 1.0 metre in length
and cannot be cut; therefore it may be neces­sary to adjust the position of the appliance to
suit or use a suitable extension.

Remove and discard the appliance flue outlet
bend.

Remove the knockout panel on the appliance
casing (directly above the appliance flue out­let).

Using the dimensions given in fig. 16a 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.

Insert the boiler top adapter (supplied with the
vertical flue terminal) into the appliance flue
outlet ensuring the correct seal is made. Insert
the vertical flue assembly into the boiler top
adapter 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 top
adapter and vertical flue assembly.

1.0 metre

N/A

N/A

N/A

350mm –500mm

12

Linea Max

Supplied By www.heating spares.co Tel. [phone]

1 5

NOTE;

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

When cutting an extension to the required
length, you should ensure that the excess is
cut from the plain end of the extension. Re­move any burrs, and check that both seals are
located properly.

Fig. 16a

Y = 302 mm

Flashing Plate

Flue Outlet

Spigot

â

â

Collar

● Ensure that the entire flue system is ad-

equately 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.

B end R eduction in maximum flu e le ngth 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

319 Twin adapter kit N/A
0225815 C ondensate 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

Y

0225845 90º bend (pair) N/A
0225850 Twin bracket (5) N/A
0225855 S i ngle bracket (5) N/A

Air Inlet

Spigot

5.5.3 Twin flue system

The Vokera twin flue system enables greater
flue distances to be achieved (see 3.4.4) than
that of the standard concentric flue system,
however the twin flue system must be con­verted to the dedicated concentric flue kit for
termination. It is essential that the installation
of the twin flue system be carried out in strict
accordance with these instructions.

GUIDANCE NOTES ON TWIN FLUE INSTALLATION

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

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

5.5.3.1 Installation of twin adaptor kit (fig. 17)

● 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 one of the blanking plates (located

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

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5.5.3.2 Installation of condensate drain kit (fig. 17a)

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 connec-

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

● Connect the air inlet pipe to the air baffle as

above.

● The twin flue pipes extensions and 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).

5.5.3.3 Horizontal termination (See fig. 17c)

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

● The horizontal terminal is supplied with a

built-in converter box and cannot be short­ened.

● A 130mm hole is required for the passage of

the concentric terminal through the wall.

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

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

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

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

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.

The condensate drain trap must be connected
to the drain in accordance with building Regu­lations or other rules in force.

When cutting an extension to the required
length, you should ensure that the excess is
cut from the plain end of the extension. Re­move any burrs, and check that both seals are
located properly.

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

Twin Flue system

Boiler

Fig. 17c

Concentric to Twin Converter

(Part no 310)

Horizontal

Flue Terminal

Condensate drain kit

Condensate trap

14

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5.5 Electrical Connections

5.5.1 The electricity supply must be as specified

in clause 4.7. If controls external to the
appliance are required, design of the exter­nal electrical circuits should be undertaken
by a competent person.

See Section 10 for further advice.

N.B. IT IS ESSENTIAL THAT ALL EXTER­NAL CONTROL CIRCUITS AND WIRING IS
WIRED FROM THE SAME ELECTRICAL
ISOLATOR AS SERVES THE APPLIANCE.

Factory fitted internal wiring must not be
disturbed when wiring external controls.

5.5.2 To gain access to the electrical terminals

Reposition front control panel by first pulling
it free from 4 locating lugs. Rotate the panel
through 90° degrees and relocate it into the
lower position using the locating hooks as
shown in fig.18 & 19.

Remove electrical cover by releasing nine
securing screws. Fig.19.

The mains input terminal block is now easily
visible (marked 1 - 6).

5.5.3 The electricity supply cable from the isolator
and the appliance terminal block must be 3
core flexible sized 0.75mm² (24 x 0.2mm) to
table 15-16, BS6500.

Wiring to the appliance should be rated for
operation in contact with surfaces up to
90°C.

Fig. 18

Locating hook

Linea Max

Locating hook

Fig. 19

15

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5.5.4 Pass the cable through one of the cord
anchorage points and connect the wires
Brown to L1, Blue to N, and Green/Yellow to

W of the terminal strip. Arrange the cable so

that should the cable slip the anchorage the
current carrying conductors become taut
before the earthing conductor.

5.5.5 Securely tighten all terminal screws and
arrange the cable with slack between the
cable anchor and the terminal block. Tighten
the cord anchorage screw until the cable is
secure.

5.5.6 Neatly arrange the external cable in such a
way that unrestricted opening of the controls
fascia and repositioning is possible without
strain on the cable.

5.5.7 External controls may be wired from termi­nals 1 & 2 or 2 & 3 after removing the
factory fitted link (between 2 & 3) depending
on wiring configuration (see pages 48 - 51
for further details). If a neutral is needed use
the terminal marked N on the terminal strip.

DO NOT CONNECT ANY WIRES TO THE
PRINTED CIRCUIT BOARD TERMINALS.

Section 10 gives details of fitment for exter­nal and internal controls (ie Vokèra time
clock).

If required pass the external controls cable
through the spare cord anchorage and
arrange the cable so that should the cable
slip the anchorage the current carrying
conductors become taut before the earthing
conductor.

Main Burner

Test Point

Incoming Gas

Pressure Test

Point

Fig. 20

Filling
Position

16

Closed
Position

Normal
Operating
Position

Fig. 21

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SECTION 6 COMMISSIONING

6.1 Where the text bears identifying numbers in
brackets, refer to figs. 1 and 2 unless
otherwise instructed.

6.2 Gas Supply Installation

Inspect the entire installation including the
meter. Test for soundness and purge, all as
described in BS6891:1988.

6.3 Central Heating Systems

6.3.1 IMPORTANT DO NOT RELEASE AIR

FROM THE RED SEALED EXPANSION
TANK. It is charged with air at the factory
from .75 - .80 bar (11 - 12psig)

6.3.2 Initial filling of the System

6.3.2.1 See 3.4.3.

6.3.2.2 Open central heating flow and return valves.

Unscrew black cap on automatic air release
valve (26) one full turn. (Leave open perma­nently).

6.3.2.3 Close all air release taps on the central
heating system.

6.3.2.4 Identify the filling/inlet valve found at the
base of the appliance. See fig.5.

The filling loop may have been disconnected
from the filling/inlet valve and heating flow
valve. If so reconnect unscrewing the caps
as necessary.
The filling/inlet valve has 3 positions. (Fig.

21) i) Vertically up - closed position.
ii) Turn to the left to horizontal - filling
position.
iii) Turn to the right to horizontal - normal
operating position.
To fill, slowly turn the handle of the filling/
inlet valve from the closed position towards
the filling position. Mains water will be heard
to enter the system/boiler. As the water
enters the system/boiler the pressure gauge
will be seen to rise. Pressurise to between
1bar & 1.5bar when the system is cold. DO
NOT OVERPRESSURISE.
Once the desired pressure is achieved turn
the filling/inlet valve back to the closed
position.

6.3.2.5 Starting with the lowest radiator open each
air release tap in turn closing it only when
clear water, free of bubbles, flows out. In the
same away release air from any high points

in the pipework.

6.3.2.6 Continue filling the system until at least 1.0
bar registers on the gauge then turn the
handle of the filling/inlet valve back to the
closed position.

6.3.2.7 Inspect the system for water soundness and
remedy any leaks discovered.

6.3.3 Initial Flushing of the Pipework

The whole of the heating system must be
flushed both cold and later hot as detailed in

6.10.1. Open all radiator or heating valves
and the appliance central heating valves.
Drain the boiler and system from the lowest
points. Open the drain valve full bore to
remove any installation debris from the
boiler prior to lighting. Refill the boiler and
heating system as described in 6.3.2.

6.3.4 Setting the System Design Pressure

6.3.4.1 The design pressure should be a minimum

of 1 bar and maximum 1.5 bar.

6.3.4.2 The actual reading should ideally be 1 bar
plus the equivalent height in metres to the
highest point of the system above the base
of the appliance. (Up to the maximum of 1.5
bar total).
N.B. The safety valve is set to lift at 3bar/
30m / 45psig.

6.3.4.3 To lower the system pressure to the re­quired value, pull the lever on the head of
the safety valve to release water until the
required figure registers on the gauge.

6.3.5 Filling the Hot Water System

6.3.5.1 Close all hot water draw-off taps.

6.3.5.2 Turn filling/inlet valve to the normal operat-

ing position (horizontally to the right). See
fig.21

6.3.5.3 Slowly open each draw-off until clear water
is discharged.

6.4 Checking Electricity Supply

6.4.1 Carry out preliminary checks for continuity,

polarity, and resistance to earth (see page

61), gaining access as required according to

5.5.2 in this manual.

6.4.2 Leave the appliance with the control fascia
open and with the mains electricity switched
OFF

6.5 Lighting the Boiler

6.5.1 Ensure flow and return valves are open.

If external and/or internal controls are fitted
(e.g Timeclock and/or Room thermostat)
ensure they call for heat. The commission­ing of the appliance may be easier if the
external/internal controls are disconnected
and terminals 2 & 3 are linked. (For access
procedure turn off electricity and refer to

5.5.2 for instructions).

6.5.2 Switch on the mains electricity and turn the
on / off / mode switch to

6.5.3 Set the c/h control knob to the highest
setting.

6.5.4 The pump only will run for approximately 1
minute, the appliance will then go through
an ignition sequence and the burner will
light.

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6.5.5 If during the ignition attempt period (10 secs
approx.) the boiler fails to light, the ignition
control circuit will go to lockout. This is
indicated by the status LED flashing red
accompanied by a flashing error code 01
shown in the temperature indicator. The gas
valve is de-energised, but leaves the fan
and pump running for approximately 2
minutes after lockout.

6.5.6 In the event of the boiler going to lockout
turn the mode selector switch to the reset
position for approximately 10 seconds, then
back to the original position. The two main
causes of the boiler going to lockout during
commissioning are electrical supply polarity
reversed, or air in the gas supply. Check
polarity and that the gas supply is complete­ly purged of air, and that gas is reaching the
boiler, then repeat from 6.5.2.

6.6 Checking Burner Pressures

6.6.1 The heat inputs for high and low gas rates

are factory set to the maximum values given
in section 3.6 for domestic hot water and
central heating but it is necessary to check
them when commissioning.

6.6.2 Turn off the main electricity supply. Gain
access to the interior by removing front door
panel.

6.6.3 Locate the main burner pressure test point
(Fig. 22) and slacken the screw half a turn in
an anti clockwise direction. Attach a suitable
U gauge tube between the test nipple and
manometer (see fig. 22).

IMPORTANT: Before measuring gas pres­sures it is imperitive that the protective
cover over the gas valve adjustment screw
is removed. (Fig. 33)

Turn on electricity supply and fully open a
domestic hot water tap to operate boiler in
dhw mode. Adjust hot water control knob to
it's maximum setting.

6.6.4 The pressure reading for maximum rate
should be:

10.1mbar
(plus or minus 1.0mbar)

If the pressure is wrong it should be ad­justed as instructed in 8.23 (N.B. Whenever
the maximum rate is adjusted check and
adjust the minimum rate too)

6.6.5 Reduce the domestic water flow rate to
approx. 3-4 litres/min, turn the domestic
control knob slowly to minimum. The boiler
output will reduce to the minimum setting. If
low flame cannot be established in this way,
turn off the electricity supply and remove
one of the grey wires connecting to the
modulator coil on the front of the gas valve.
Switch on the electricity supply. The boiler
will now light at the minimum setting.

6.6.6 When low flame is established, the pressure
reading should be:

1.3mbar
(plus or minus 0.13mbar)

If it is different adjustment should be made
in accordance with the instructions in 8.23.

6.6.7 If the grey wire from the modulator coil was
removed to check the minimum setting, turn
off the electricity supply and replace the wire
onto the modulator coil.

Main burner test point

Gas Valve

Manometer

18

U Gauge Tube

Fig. 22

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6.6.8 Setting the Maximum Rate for Central
Heating

The maximum heat input for the central
heating mode is not adjustable.

6.7 Checking the Flue System

6.7.1 The flue system should be visually checked

for soundness. Check all clamps and fixings
are secure and tight.

6.8 Checking the Heating Thermistor

6.8.1 Allow the system to warm up and manipu-

late the c/h control knob to ensure that the
burner modulates between high and low
and then to off and vice versa (scale range
covers approx. 45° - 85°C).

6.9 Regulating the Central Heating System

6.9.1 Fully open all radiator and circuit valves and

run the appliance in the central heating
mode until heated water is circulating. If
conditions are warm, remove any thermo­static valve heads.

6.9.2 If the burner will not light, ensure that water
is in fact circulating. See 4.6.3.

6.9.3 Adjust radiator return valves and any branch
circuit return valves until the individual
return temperatures are correct and are
approximately equal.

6.9.4 When all is adjusted, progressively close all
radiator valves to ensure that the appliance
still operates when flow through the system
is limited.

If the burner cuts out prematurely due to
lack of water flow through the appliance, the
system should be regulated to ensure a flow
rate of at least 350 litres/h (78 gals/h). This
may mean the addition of a small manual
by-pass being fitted to the system if a fully
TRV system is used.

6.10 Final Flushing of the Heating System

6.10.1 The system should be flushed in accord-

ance with BS7593:1992. Turn on the boiler
for central heating and allow the boiler and
system to reach temperature. Turn off the
boiler and drain the system whilst hot.

Refill the boiler and heating system as
described in 6.3.3.

Although not necessary for correct operation
of the boiler an inhibitor may be added at
this point. Contact the inhibitor manufacturer
for further information concerning applica­tion and required dose.

6.10.2 Inspect the system for soundness. Turn the
appliance off at the mode selector switch.

6.11 Filling, Testing and Regulating the
Domestic Hot Water System

6.11.1 Start with the appliance switched on having

completed the procedures described in 6.4
to 6.10.

6.11.2 Open a domestic hot water tap (Preferably
the bath tap).

Ensure cold water inlet stopcock is fully
open (horizontally to the right) and the dhw
control knob is set at maximum.

6.11.3 The flow of water should activate the do­mestic hot water flow switch (13) and drive
the diverting valve (21) to its hot water
position thus heating the domestic water
flowing through the dhw heat exchanger. At
the same time the pump and fan are acti­vated lighting the burner on maximum rate.

6.11.4 If the burner does not light, check that the
water flow rate is above the minimum
required to operate the domestic hot water
flow switch (13) 2.0 litres/min (0.45 gals/
min).

6.11.5 The temperature of the water will depend on
the rate at which it flows and the amount of
energy stored in the primary store.

The temperature of water at the tap can be
varied by adjusting the water flow rate at the
tap up to the maximum predetermined
quantity.The hot water temperature control
knob will govern the maximum temperature.
When the appliance is being used in hot
water mode the temperature indicator
indicates the temperature of the hot water
leaving the appliance.

6.11.6 It is best to set for the lowest acceptable
temperature since the user can gain higher
temperatures by restricting flow at the tap.

N.B. If the cold supply is subject to large
fluctuations or is above the permitted maxi­mum a suitable pressure/flow regulator
should be fitted in the cold water supply to
the appliance.

6.11.7 Turn the appliance mode selector switch to
the position.

Slowly close the tap to reduce the rate of
draw to above the minimum approx. 2.0
litres/min., (0.45 gal/min.) Rotate the dhw
control knob to ensure the appliance modu­lates at its various setting.

6.11.8 Close the draw-off tap still further. The
burner should stop when the rate falls below
approximately 2.0 litres/min. (0.45 gal/min.),
and the primary store temperature is replen­ished.

6.11.9 The appliance incorporates a hot water
preheat facility. The appliance will therefore
ignite periodically to maintain heat within the
thermal store of the appliance.

6.12 Final Check for Operations

Turn mode selector switch to the OFF/
RESET position, disconnect pressure
gauge, re-tighten screw. Relight boiler.

6.12.1 Re-check for gas soundness

6.12.2 Re examine heating and hot water systems

and cold water supply for water soundness.

6.12.3 Check the appearance of the gas flame to
assess adequacy of combustion air supply.

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6.12.4 Re-check the flue system for soundness and
adequacy of supports.

6.13 Concluding Operations

6.13.1 If external/internal controls have been

disconnected and terminals 2 & 3 temporar­ily linked, remove the link and reconnect the
controls circuit. Check the operation of the
controls.

6.14 Disconnect filling loop, fit filling loop cap.
Leave filling loop in a safe and accessible
place.

6.14.1 Reposition the front control panel and fit the
front boiler casing panel (fig. 18).

SECTION 7 INSTRUCTING THE USER

6.15 Supplementary Instructions for Fitting &
Removing Optional Time Clock and for
Wiring to External Controls.

Section 10 Appendices A and B at the rear
of this manual provides full instruction for
fitting and wiring the optional built-in time
switches and for wiring to external controls.

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

7.1 Hand over the copy of the Users Instructions
and the boiler log book supplied with the
appliance, together with these instructions.
Explain how to operate the boiler correctly
and how to use the timeclock and room
thermostat if fitted.

7.2 Show the user how to switch off the appli­ance and indicate the position of the electric
supply isolator.

7.3 Inform the user of the location of all drain
cocks and air vents.

SECTION 8 SERVICING INSTRUCTIONS

8.1 General

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

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

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

The following instructions apply to the boiler
and its controls, but it should be remem­bered that the central heating and domestic
hot water systems will also require attention
from time to time.

8.2 Important Notes

WARNING: Having carried out preliminary
flame checks and before starting any
servicing work, switch OFF the mains
electricity supply and disconnect the plug at

7.4 Explain how to turn the appliance off for both
short and long periods and advise on the
precautions necessary to prevent damage
should the appliance be inoperative when
freezing conditions may occur.

7.5 Show the user the filling loop position its
function and how to repressurise the system
using the filling/inlet valve.

7.6 Finally, advise the user that, for continued
safe and efficient operation, the appliance
must be serviced by a competent person at
least once a year.

the main isolating switch and socket. (If a
switch is used remove the fuse.)

Turn off gas supply at the gas service tap
fitted to the appliance.

Always test for gas soundness after any
service work and after exchanging any gas
carrying component.

8.3 Recommended Routine Servicing

8.3.1 Annual Servicing

When servicing is required the following
procedures should be carried out.

1. Inspect exterior for signs of damage and
deterioration, particularly of flue pipework
and electrical connections.

2. Turn off mains electricity and remove
front casing (see clause 8.4.).

3. Replace fuse if previously removed (8.2.
above) and turn on electricity. Run the boiler
for a few minutes in the domestic hot water
mode to permit inspection of its operation.
This is accomplished by opening a domestic
hot water draw off tap and inspecting burner
for yellowing of flame tip, flame lift off or
sooting.

20

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4. Ensure central heating valves are open.
See 6.3.2.1.

Observe pressure gauge reading (fig. 1, 19)
which should be approximately 1 bar when
the system is cold See 6.3.4

5. Turn off mains electricity and turn off gas
service tap on the appliance.

6. Gain general access as described in
clause 8.4.

7. Remove main burner (see clause 8.6).
Lightly clean with a soft brush and inspect
for damage. If during initial inspection any
combustion irregularity was suspected,
remove injectors and clean or replace (see
clause 8.7).

8. Place cloth below combustion chamber to
catch debris. Clean heat exchanger using
suitable brushes and rods if necessary.

9. Inspect combustion chamber lining. The
insulating material is easily damaged. Do
not scrape, but clean off lightly.

If any panels are damaged these should be
replaced (see clause 8.11).

10. Replace all parts in reverse order but
leave the controls fascia open and outer
casing off.

11. Undertake a complete commissioning
check as detailed in section 6.

12. Close up control fascia and refix front
casing.

13. Clean off casing using soft cloth and
dilute detergent.

14. Complete details of service undertaken
in the boiler log book.

NOTE: There is a flue gas analysis test
point incorporated in the flue outlet. (see

8.23.6)

8.3.2 Replacement of Parts

1. The life of individual components varies
and they will need servicing as and when
faults develop. The fault finding sequence
charts in section 9 will serve to locate which
component is the cause of any malfunction.
Instructions for removal, inspection and
replacement of the individual parts are given
in the following pages.

2. The domestic hot water heat exchanger
may in certain conditions become partially
blocked by scale deposits. Evidence of this
will be deterioration in performance.

This condition could well be treated using
proprietary descalants following makers'
instructions without dismantling the appli­ance by circulating a fluid through the dhw
coil. To do this, disconnection from hot and
cold services is necessary. Reconnect only
after thorough flushing with clean water.

3. Occasional maintenance of mechanical
working parts will be necessary (three port
valve, flow diaphragm). Service kits are
available from your local Vokèra stockists.
Vokèra Service Kit No.T0019

8.4 To Gain General Access/Assembly

To remove components access to the
interior is essential.

Ensure electricity supply is isolated before
carrying out any servicing.

8.4.1 To remove front casing.

Push to release front door panel and lower
to reveal controls. Found magnetised on the
inside of the door panel will be a small tool.
Using the tool loosen the 2 captive screws
securing the front control panel door to the
appliance, lift away to reveal the inside of
the appliance.

If necessary reposition the front control panel
by first pulling it free from 4 locating lugs.
Rotate the panel through 90° degrees and
relocate it into the lower position using the
locating hooks as shown in fig.18.

Fig. 23

8.4.2 Reassembly is always carried out in reverse

order to dismantling, unless otherwise stated.
Electrical connections must be remade in ac­cordance with the wiring diagram (fig.36).

8.4.3 Where gas control components are re­placed, check the burner pressures and
adjust if necessary. See 8.23.

8.5 Room Sealed Chamber Front Cover

Refer to fig. 23.

Flue gas analysis

test point

Linea Max

Fig. 24

21

Supplied By www.heating spares.co Tel. [phone]

8.5.1 Gain general access as 8.4

8.5.2 Remove room sealed cover plate by releas-

ing two lower retaining clips and easing
cover off the top locating hooks. Inspect
gasket for damage. If damaged, replace.

NOTE: When refitting the combustion
chamber front cover it is essential to cor­rectly seat and secure the cover in place
ensuring both clips are secured in place.

8.6 Main Burner and Spark Electrode

Part No's
Main Burner - 5317
Spark Electrode - 1931
Refer to figs. 25 & 26

8.6.1 Gain general access as 8.4.

8.6.2 Remove room sealed front cover as 8.5

8.6.3 Remove front of combustion chamber by

releasing six screws (fig. 24).

8.6.4 Remove four burner retaining screws (fig.

25). Ease burner forward and rest on
chamber base (fig. 26).

8.6.5 Release electrode and earth retaining
screws & carefully remove electrode.

8.6.6 Trace electrode and earth lead to electronic
ignition control and gas valve and discon­nect.

8.6.7 Remove main burner.

8.6.8 Reassemble in reverse order ensuring

correct location of electrode, and solid
earthing point.

Note: If difficulty is found in relocating the
burner securing screws, easier access can
be gained by removing the two side panels
(fig. 26).

8.8.6 Turn the 3 butterfly primary store isolation
valves to the closed position (handle across
valve body) this isolates the primary store
thus preventing unnecessary draining.

8.8.7 Close heating flow and return valves by
turning ¼ turn until indicating lines are
horizontal. Pull lever on head of safety
valve to drain primary circuit to boiler.

8.8.8 Place cloth under heat exchanger to catch
surplus water.

8.8.9 Unscrew unions on either side of main heat
exchanger fig. 25.

8.8.10 Slide out main heat exchanger, taking care
not to damage insulation panels. Avoid
spillage of water on boiler electrics.

8.8.11 Reassemble in reverse order using new
fibre washers in unions.

Fig. 25

8.7 Main Burner Injectors

8.7.1 Gain general access as 8.4

8.7.2 Remove room sealed front cover plate and

combustion chamber front (8.5 & 8.6.3).

8.7.3 Remove main burner (8.6.4 to 8.6.8).

8.7.4 Unscrew injector(s) from burner bar.

8.8 Main Heat Exchanger

Part No. 28 - 1914
Refer to Fig. 25

8.8.1 Gain general access as 8.4

8.8.2 Remove room sealed front cover plate (8.5).

8.8.3 Remove front of combustion chamber

(8.6.3).

8.8.4 Remove two air baffle plates, 1 screw
securing each (fig.27).

8.8.5 Remove both side panels, 2 screws each
(fig.26)

Fig. 26

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8.9 Flue Fan

Part No. 5911

8.9.1 Remove room sealed front cover plate (8.5)
and front of combustion chamber (8.6.3).

8.9.2 Loosen maintenance clip securing screws
(see fig.27) and slide upwards to clear joint.

8.9.3 Remove silicone pipes from nozzles on
inner flue bend

8.9.4 Remove 3 flue hood retaining screws (see
fig. 27).

NOTE: When removing the two side screws
the two air baffle plates can be removed.

8.9.5 Carefully slide flue hood forward disconnect­ing electrical leads on fan in the process.

8.9.6 Unscrew 4 screws securing fan to flue hood
and remove fan. Transfer aluminium
manifold (two screws) to new fan.

8.9.7 Reassemble in reverse order, replacing
centre hood screw first.

8.10 Flue Pressure Differential Switch

Part No 9232
Refer to Fig. 27

8.10.1 Gain general access as 8.4

8.10.2 Remove room sealed cover (8.5)

8.10.3 Remove 2 screws holding pressure differen-

tial switch to the combustion chamber.

8.10.4 Pull off tab connectors and remove pressure
switch, disconnecting the air pressure pipes
in the process.

8.10.5 Reassemble in reverse order.

See fig. 36 for correct fitting of electrical
connections. When reconnecting the pres­sure pipes the upper nozzle on the inner
flue bend connects to the front nozzle of the
pressure differential switch.

8.11 Combustion Chamber Insulation Boards

8.11.1 Gain general access as 8.4

8.11.2 Remove room sealed front cover 8.5

Remove front of combustion chamber 8.6.3.

Remove Main Heat Exchanger 8.8.

8.11.3 To remove side combustion chamber
insulation boards, gently prise upwards and
pull out.

8.11.4 To remove rear board, gently prise upwards
and pull out.

8.11.5 Fourth panel (front) is replaced complete
with combustion chamber front panel.

Maintenance clip

Air

baffle

plate

Pressure

differential switch

Air
tubes

Air

baffle

plate

Fig. 27

Hood

Retaining

Screws

Linea Max

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8.12 Ignition Control Box

Part No. 099864

8.12.1 Gain general access as 8.4.

8.12.2 Release 1 screw (upper) securing ignition

box to gas valve body.

8.12.3 Disconnect electrode lead from ignition box.

8.12.4 Disconnect ignition control box from gas

valve by sliding out of situ.

8.12.5 Release one screw to release electrical
cover plate on ignition control box.

8.12.6 Remove internal electrical plug-in connector
by gently pulling and releasing.

8.12.7 Reassemble in reverse order ensuring
correct location of electrical plug and
electrode lead.

8.13 Gas Control Valve (complete)

Part No. 099862 fig. 28

8.13.1 Turn off gas service tap.

8.13.2 Remove Ignition control box as 8.12

8.13.3 Pull off silicone tube from gas valve regula-

tor.

8.13.4 Disconnect earth leads from gas valve.

8.13.5 Disconnect wires from modulator coil.

8.13.6 Unscrew gas service tap union & release

from its seating.

8.13.7 Undo union above the gas control valve &
withdraw gas valve.

8.13.8 Undo union from base of gas valve and
transfer supply tube to new gas valve.

8.13.9 Reassemble in reverse order.

8.13.10 Test all joints for gas soundness.

8.13.11 Check burner pressures. As 6.6

If incorrect adjust as instructed in 8.23.

Gas Valve Regulator
Silicon Pipe Connection
Point

Modulator
Coil

Pipe Securing Clip

Pump
Securing
Bracket

Fig. 28

24

Fig. 29

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8.14 Pump

Part No. 088031 Refer to fig.29

8.14.1 Gain general access as 8.4

8.14.2 Turn the 3 butterfly primary store isolation

valves to the closed position (handle across
valve body) this isolates the primary store
thus preventing unnecessary draining.

8.14.3 Close heating flow and return valves
(fig.30), by turning ¼ turn until indicating
lines are horizontal. Pull lever on head of
safety valve to drain primary circuit to boiler.

8.14.4 Place cloth under pump to catch surplus
water.

8.14.5 HEAD ONLY Unscrew the 4 allen screws
around the pump head. Pull head from base
of pump and disconnect electrical leads. If
replacement required, use the head from a
standard 15-60 Grundfos pump.

8.14.6 COMPLETE PUMP Disconnect pipe union
connection at front left corner of combustion
chamber.

8.14.7 Disconnect push fit pipe from pump body by
releasing pump securing clip and pulling
pipe free from body.

8.14.8 Remove screw from pump securing bracket.

8.14.9 Grasp pump and pull upwards with slight

twisting movement to release pump from
manifold.

8.14.10 Disconnect electrical leads from pump.

8.14.11 Reassemble in reverse order.

Reconnect electrical leads Brown to L, Blue
to N and Green to E.

8.15 Domestic Flow Switch

Refer to fig. 30.

8.15.1 Gain general access as 8.4.

8.15.2 Place receptacle or an absorbent pad below

switch to catch trapped water.

8.15.3 Close cold water inlet stopcock. See fig.30

8.15.4 Open lowest draw-off or drain tap on hot

water system.

8.15.5 Disconnect cold water inlet valve from flow
switch by undoing union.

8.15.6 Disconnect union at top of flow switch and
two electrical tab connectors.

8.15.7 Reassemble in reverse order.

8.16 Combined Diverter Valve & Flow Switch
Manifold

Refer to fig. 30

8.16.1 Gain general access as 8.4

8.16.2 Remove Pump as 8.14

8.16.3 Remove motorised valve as 8.21.8.

8.16.4 Release flow microswitch from the hydraulic

group by removing one retaining screw on
bracket.

8.16.5 Disconnect flow tube union and rear union
where they connect onto the hydraulic
group.

8.16.6 Disconnect expansion vessel pipe.

8.16.7 Unscrew pressure gauge connection retain-

ing screw and pull out pressure gauge
connnection.

8.16.8 Disconnect safety valve discharge pipe and
heating valve unions.

8.16.9 Remove retaining allen screw securing
hydraulic group to frame.

8.16.10 Withdraw hydraulic group from appliance.
See fig. 31 for further disassembly.

8.16.11 Reassemble in reverse order ensuring that
washers are replaced in all union connec­tions.

Motorised Valve

Safety

Valve

Heating flow

and return valves

Diverter Valve
& Flow Switch

Assembly

Domestic
Heat
Exchanger

Linea Max

Domestic Hot
Water Flow Switch

Cold Water

Inlet Stopcock/

filling valve

Gas Valve
& Ignition Control
Box

Fig. 30

25

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8.17 Removal of Domestic Hot Water Heat
Exchanger

Refer to figs. 30

8.17.1 Gain General access 8.4

8.17.2 Place receptacle or an absorbent pad below

heat exchanger to catch trapped water.

8.17.3 Close cold water filling/inlet valve. See fig.
21

8.17.4 Open lowest draw-off or drain tap on hot
water system.

8.17.5 Turn the 3 butterfly primary store isolation
valves to the closed position (handle across
valve body) this isolates the primary store
thus preventing unnecessary draining.

8.17.6 Close heating flow and return valves (fig.30)
by turning ¼ turn until indicating lines are
horizontal. Pull lever on head of safety
valve to drain primary circuit to boiler.

8.17.7 Undo 4 unions and withdraw heat ex­changer.

8.17.8 Reassemble in reverse order, using new
washers if required.

8.18 Diverter Valve

8.18.1 Gain general access as 8.4.

8.18.2 Turn the 3 butterfly primary store isolation

valves to the closed position (handle across
valve body) this isolates the primary store
thus preventing unnecessary draining.

8.18.3 Close heating flow and return valves (fig. 6)
by turning ¼ turn until indicating lines are
horizontal. Pull lever on head of safety
valve to drain primary circuit to boiler.

8.18.4 Remove motorised valve. See 8.21.8

8.18.5 Remove front of diverter valve by unscrew-

ing six retaining bolts.

8.18.6 See Fig.31 for further disassembly and
location of components.

8.18.7 Reassemble in reverse order.

8.19 Checking/Replacing Main Expansion
Vessel

8.19.1 The expansion vessel is factory pressurised

0.8 bar (12psig) and should be checked
during servicing. Should it have lost pres­sure it can be repressurised in situ. Turn the
3 butterfly primary store isolation valves to
the closed position. Drain the boiler. Fit a
suitable pump and gauge (i.e. car foot pump
and gauge) to the valve on the side of the
expansion vessel, and pressurise to 0.8bar
(12psig) and remove the pump.

If the vessel cannot be repressurised or if
pressure loss is very frequent the expansion
vessel will require changing. Alternatively, a
new vessel can be fitted in the return to the
appliance, and the old vessel isolated in
situ.

8.19.2 Switch OFF mains electricity and gain
general access. Disconnect electricity
supply and wiring for external controls from
the appliance. See 5.5.7

8.19.3 Turn the 3 butterfly primary store isolation
valves to the closed position (handle across
valve body) this isolates the primary store
thus preventing unnecessary draining.

8.19.4 Close heating flow and return valves (fig.30)
by turning ¼ turn until indicating lines are
horizontal. Pull lever on head of safety
valve to drain primary circuit to boiler.

8.19.5 Disconnect pipe union at the base of the
expansion vessel.

8.19.6 Withdraw expansion vessel from appliance
easing away from retention clip, taking care
not to spill water retained inside vessel.

8.19.7 Reassemble in reverse order, using new
fibre washer.

26

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8.20 Safety Valve

Part No. 1806 Refer to fig.30

8.20.1 Gain general access as 8.4.

8.20.2 Turn the 3 butterfly primary store isolation

valves to the closed position (handle across
valve body) this isolates the primary store
thus preventing unnecessary draining.

8.20.3 Close heating flow and return valves (fig.

30) by turning ¼ turn until indicating lines
are horizontal. Pull lever on head of safety
valve to drain primary circuit to boiler.

8.20.4 Disconnect safety valve discharge pipe.

8.20.5 Loosen grub screw at base of safety valve

and pull forwards releasing valve from O'
ring seal.

8.20.5 Replace in reverse order.

8.21 Removal of Electrical Components

8.21.1 Ensure electricity is switched off at main

isolator and gain general access as 8.4.

8.21.2 Flow Microswitch

Fig. 35l

8.21.3 Gain general access.

8.21.4 Release microswitch from hydraulic group

by removing one securing screw.

8.21.5 Remove electrical cover plate by removing
6 screws.

8.21.6 Trace the electrical wires back to where
they connect into the plug on the circuit
board. Release the plug from the circuit
board and remove wires by inserting a small
screwdriver or spike into the lower part of
the plug releasing the retaining lug.

8.21.7 Reassemble in reverse order ensuring
correct location of electrical connections.
(see fig.36 for electrical connections)

Diverter Valve
and Flow Switch
Manifold

Diverter
Valve
Bobbin

Diverter
Valve
Cover

Fig.31

Flow Switch Diaphragm

Safety Valve

Motorised Valve

Linea Max

27

Supplied By www.heating spares.co Tel. [phone]

8.21.8 Motorised Valve Part No 2905

8.21.9 Gain general access as 8.4

8.21.10 Release motorised valve by removing

retaining clip.

8.21.11 Remove electrical plug in connector.

8.21.12 Reassemble in reverse order.

8.21.13 Printed Circuit Board

Part No. 48898

8.21.14 Gain general access as 8.4 & 8.4.1

8.21.15 Remove electrical cover plate by removing

6 screws.

8.21.16 Pull out 9 multi plug connectors and one
earth lead from the printed circuit board.

8.21.17 Remove 2 screws securing circuit board to
front panel and remove board.

8.21.18 Reassemble in reverse order ensuring
correct location of electrical connections.
(see fig. 36 for electrical connections)

NOTE: It will also be necessary to check/
adjust the c/h minimum gas pressure as

8.23.3

8.21.19 Display Printed Circuit Board

8.21.20 Remove printed circuit board as 8.21.13 to

8.21.18. Part No 48899

8.21.21 Remove three control knobs from front
control panel (pull off).

8.21.22 Remove the two screws securing the circuit
board to the front panel.

8.21.23 Pull out two multi-plug connectors.

8.21.24 Replace in reverse order.

8.21.25 Safety Thermostat

Part No 8367 (Refer to fig. 32)

8.21.26 Gain general access as 8.4.

8.21.27 Remove room sealed chamber front cover

as 8.5 and R/H side panel (fig. 26).

8.21.28 Pull off the two electrical connections on the
back of the thermostat.

8.21.29 Release stat from flow pipe by unscrewing 2
retaining screws.

8.21.30 Reassemble in reverse order ensuring
correct location of electrical connections.
(see fig. 36 for electrical connections)

8.21.31 Thermistor Sensors

Part No. 8484 Refer to fig.32

8.21.32 Gain general access as 8.4.

8.21.33 Remove room sealed chamber front cover

as 8.5. Remove R/H side panel as fig.26

8.21.33a PRIMARY
Turn the 3 butterfly primary store isolation
valves to the closed position (handle across
valve body) this isolates the primary store
thus preventing unnecessary draining.

Close heating flow and return valves (fig. 5)
by turning ¼ turn until indicating lines are
horizontal. Pull lever on head of safety valve
to drain primary circuit to boiler.

8.21.33b DOMESTIC HOT WATER
Close cold water inlet stopcock. See fig.5

Open lowest draw-off or drain tap on hot
water system.

8.21.34 Pull off electrical plug connection from
thermistor.

8.21.35 Unscrew thermistor from pocket.

8.21.36 Reassemble in reverse order.

8.22 Pressure Gauge

Part No 078139

8.22.1 Gain general access as 8.4 & 8.4.1

8.22.2 Turn the 3 butterfly primary store isolation

valves to the closed position (handle across
valve body) this isolates the primary store
thus preventing unnecessary draining.

8.22.3 Close heating flow and return valves (fig.5)
by turning ¼ turn until indicating lines are
horizontal. Pull lever on head of safety
valve to drain primary circuit to boiler.

8.22.4 Remove electrical cover plate by removing
6 screws.

8.22.5 Trace capillary from back of pressure gauge
to connecting point on brass manifold.

8.22.6 Unscrew the retaining screw beside the
capillary tube entry to the manifold.

8.22.7 Pull out capillary tube from manifold.

8.22.8 Squeeze plastic locking lugs behind fascia

and press gauge from aperture.

8.22.9 Reassemble in reverse order following
original route for capillary tubes and ensur­ing locking lugs are located in the grooves.

Flow Pipe

Primary
Thermistor

Safety Thermostat

Fig. 32

28

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8.23 Setting Gas Pressures

ALL SETTINGS DONE WITH A SUITABLE
MANOMETER CONNECTED TO GAS
VALVE AS INSTRUCTED IN 6.6.

8.23.1 Setting Maximum Rate

Turn off electrical supply to boiler and follow
instructions in section 8.4 & 8.4.1 to gain
access.

Refer to Fig. 22 & 33.

Turn on the electricity supply and the appli­ance mode selector switch to Remove gas

pressure adjustment protective cover (fig. 33).
Turn on fully a domestic draw off tap.

The boiler will now light at full flame. Screw the
outer nut (a) on the end of the modulator coil
slowly clockwise until the burner lights.

Adjust the nut until the correct pressure is
obtained on the gauge. The correct reading
should be:

(N/G)

10.1 mbar.
plus or minus 1.0 mbar.

8.23.2 Setting Minimum Rate (DHW)

Remove one of the grey wires connecting to
the modulator coil. The gas pressure will now
be at the minimum rate.

Turn the inner minimum adjusting screw (b)
anti clockwise to decrease the pressure, or
clockwise to increase the pressure until the
minimum gas pressure is achieved, (ensure
when adjusting the inner screw the outer nut
(a) is held in position) the correct reading
should be:

(N/G)

1.3 mbar.
plus or minus 0.13 mbar.

Replace the grey wire back onto the modula­tor coil together with the protective cover.

8.23.3 Setting Minimum Rate (C/H)

Turn off the hot water draw off tap.

Remove electrical cover plate by removing
6 screws. (Fig. 19).

Turn the mode selector switch to the
position, ensure that the room thermostat
and/or timeclock (if fitted) are calling for
heat. Turn the heating thermostat to maxi­mum and ensure the appliance ignites.

Identify minimum adjustment button on pcb
(fig. 34).

Press the minimum adjustment button once,
the boiler will operate in central heating
mode at a minimum gas pressure. An LED
on the PCB will flash red to confirm the
appliance is in central heating minimum
mode.

The gas pressure should now be:

(N/G)

1.6 mbar.
plus or minus 0.16 mbar.

If the reading is incorrect it should be adjusted
as follows:

Identify the minimum adjustment potentiometer
on the PCB fig. 34.

With the boiler still in central heating mode and
the burner at the minimum rate, using a small
screwdriver turn the potentiometer clockwise
to increase & anti-clockwise to decrease the
minimum gas pressure.

When all is adjusted, press the minimum
adjustment button once (the appliance will
return to normal operation). Turn the appli­ance off.

8.23.4 Soft Light Ignition

The Linea range incorporates a fully auto­matic soft light ignition sequence which is non
adjustable.

When ignition is called for the gas valve is
energised and at the same time 20 m/A is
applied to the modulator coil for a period of
approximately 3 seconds. During this 3 sec­onds the appliance will ignite.

After the initial 3 seconds power to the modu­lator coil is gradually increased to a maximum
power of 120 m/A.

120 m/A is applied to the modulator coil for a
further second. If the appliance is operating in
hot water mode the maximum heat input will
be automatically adjusted depending on the
temperature of the appliance.

If the appliance is operating in central heating
mode see 8.23.5.

8.23.5 Maximum Rate in Central Heating Mode.

After initial ingnition (8.23.4), the Linea Max
range does not require any adjustment to
maximum heat requirement of the system
load.

Should the appliance fail to achieve sufficient
temperature rise within this 15 minute period,
the appliance will increase its maximum heat
input to further increase the temperature of the
system.

Once achieved the appliance will modulate to
suit system load.

8.23.6 Combustion Analysis

Incorporated on the appliance is a combustion
switch (fig.1, 35). Once the gas pressures
have been set activation of the combustion
switch automatically fires the appliance at
maximum rate in central heating. The appli­ance will be held at maximum rate until the
maximum temperature of the appliance is
achieved. The appliance will not modulate
during this period.

Linea Max

29

Supplied By www.heating spares.co Tel. [phone]

8.23.6.1 Remove electrical cover plate by removing
6 screws.

8.23.6.2 To use the combustion switch it is important
that the gas pressures are set accurately as
described in 8.23.1 - 8.23.3.

8.23.6.3 Remove combustion switch cap on front con­trol panel by turning ¼ turn to disengage.

8.23.6.4 Unscrew flue gas analysis test point Fig.24.
Set up flue gas analyser and insert probe into
test point.

8.23.6.5 Using a screwdriver lightly press the black
toggle behind the combustion switch cap once
only. The appliance will light at maximum rate.
At this point the digital display will show CO to
confirm the appliance is in combustion test
mode.

8.23.6.6 Analyse flue gasses on analyser.

8.23.6.7 Once the analysis is complete lightly press the

black toggle once to disengage the combus­tion mode. The display will revert to showing
appliance temperature on the digital display.

NOTE:

The combustion switch can also be used
when gas rating the appliance.

8.24 End of Servicing

Run through the general commissioning as
described in Section 6 as far as they apply.

Refit casing and clean up.

Fig. 33

Maximum pressure
adjustment screw (a)

Gas pressure adjustment
protective cover

Minimum pressure ad­justment screw (b)

Minimum
Adjustment
Button

Fig. 34

30

Minimum
Adjustment
Potentiometer

Linea Max

Supplied By www.heating spares.co Tel. [phone]

SECTION 9 OPERATIONAL CHECKS AND WIRING DIAGRAMS

9.1 On completion of any service/fault finding
task which has required the breaking and
remaking of electrical connections, the
checks Earth Continuity, polarity and
Resistance to Earth must be repeated.

The following flow diagrams suggest the
logical sequence of steps for fault finding.

They are not exhaustive but cover all that
can reasonably be carried out on site by the
installer.

Acquaintance with the functional sequence
will prove helpful for some, and this is
included for reference. As further help, the
role of each part is briefly described.

Also included in this section are wiring
diagrams and schematics to assist in fault
location and servicing as described in the
text.

9.2 Sequence of Functions

When following this sequence, refer to fig

36. It is assumed that the mode selector
switch is in the

9.2.1 Rest (No demand for central heating or hot
water)

With no demand for heating or hot water the
appliance will periodically light to preheat
the thermal store. (This operation takes
place approx. once every 3 hours if there
has been no demand for hot water). This is
done to ensure that when a demand is
made for domestic hot water the appliance
is not cold, thereby reducing the wait for hot
water, and energy is present in the store for
better hot water production.

Once every 19 hours the appliance will
automatically activate and deactivate the
pump and motorised valve (provided the
electrical supply is on to the appliance).
This will help prevent these components
becoming stuck if the appliance is not used
for long periods.

The temperature indicator will always
display the temperature of the boiler unless
domestic hot water is drawn where it will
indicate the temperature of the hot water
leaving the appliance.

9.2.2 Domestic Hot Water Mode

Turning on a tap will cause the domestic hot
water flow switch to activate.

Activation of the domestic hot water flow
switch operates the motorised valve. Opera­tion of the motorised valve mechanically
diverts the primary water to the thermal
store and domestic heat exchanger. The
pump is started simultaneously and with
sufficient primary water circulation around
the appliance the flow switch is operated.
Once the flow switch has activated the fan
starts which results in a changeover of the
pressure differential switch. Once these
actions have

position.

been proven the gas valve will be energised
and the electrode will start to spark.

If a flame is detected during the ignition
attempt time (8-12 seconds) the sparking
will cease, the gas valve will remain ener­gised and the appliance will produce hot
water as described below.

If a flame is not detected the appliance will
go to lockout (failure to detect a flame
during ignition attempt time). The gas valve
will be de-energised and the sparking will
stop. (See self diagnostic error codes)

To reset the appliance after lockout turn the
mode selector switch to the reset position
for approximately 10 seconds then back to
original position.

The temperature rise of primary water and
domestic hot water in the appliance is
sensed by thermistors on the flow tube and
hot water outlet. An increase in temperature
will in turn decrease the voltage reaching
the modulator coil, causing the gas rate to
be lowered. If the temperature rise is too
great the gas valve can turn off completely.

Conversely a fall in temperature of the
primary and domestic hot water will in­crease the low voltage to the modulator coil
and this in turn increases the gas rate
accordingly.

Temperature of the domestic hot water
leaving the appliance is shown at the
temperature indicator whenever hot water is
drawn.

Constant monitoring of the temperature of
the primary and domestic hot water by the
thermistors will regulate the gas rate to
maintain an average heat input.

NOTE 1: As the thermistor senses the
temperature of the primary water leaving the
main heat exchanger, the amount of heat
transferred from the primary water to the
dhw water depends upon the temperature
differential between them.

NOTE 2: With maximum thermal storage
temperature, the temperature rise to the hot
water will depend upon the flow rate and
length of use. It is possible to use all the
energy within the thermal store therefore the
maximum hot water performance will reduce
to 28kW output (11.4l/min at 35°C rise).

When the dhw water draw off rate drops
below the permitted minimum (2.0 l/min) the
domestic hot water flow switch is deacti­vated, and the appliance either reverts to
the 'Rest' mode where the fan may overrun
to remove residual heat, or the appliance
will continue to operate to replenish heat
within the thermal store, or if there is a call
for heating to the mode described.

Linea Max

31

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9.2.3 Central Heating Mode

In this mode the mode selector switch must
be turned to the position.

With all controls calling for heat the motor­ised valve returns, mechanically diverting
primary water to the central heating circuit.
The pump will run and provided sufficient
primary water is circulating the flow switch
is activated.

The fan will run and the pressure differential
switch will be activated. This in turn will
energise the electronic ignition control box.
The gas valve will be energised and the
electrode will start to spark.

If a flame is detected during the ignition
attempt period, (8-12 seconds) the sparking
will cease and the gas valve will remain
energised.

The temperature rise of the primary water is
sensed by the thermistor on the flow pipe.

As the temperature of the primary water
approaches that set on the c/h temperature
control, the voltage to the modulator coil will
decrease and thus lower the gas rate.

On reaching the set temperature the gas
valve is de-energised and the burner is
extinguished.

The appliance has an inbuilt delay timer and
re-ignition will not be attempted for approxi­mately 3 minutes. This can be deactivated.
See page 53.

Conversely a fall in temperature of the
primary water will increase the voltage to
the modulator coil therefore increase the
gas rate.Constant monitoring of the tem­perature of the primary water by the ther­mistor will regulate the gas rate to maintain
an average heat input.

When the appliance has reached the set
temperature and the burner is off, the pump
will continue to run to circulate the primary
water around the c/h system.

Temperature of the central heating is
shown at the temperature indicator when­ever the central heating is on.

If supply to the appliance is broken (e.g. by
a room thermostat or timeclock) the burner
is extinguished the pump stops, the motor­ised valve is energised into the hot water
mode waiting for pre-heat or demand for hot
water. However, the fan will continue to run
until the primary water temperature is below
80°C.

Should there be a restriction in the heating
circuit reducing the flow rate to below 350 l/
hour (1.28 gpm) the flow switch could
deactivate and de-energise the gas valve.

Self Diagnostic Error Codes

The temperature indicator also serves as an
error code indicator. Should an error occur
the status LED (which is normally green)
will flash red. This will be accompanied by
the temperature indicator flashing an error
code of 01 - 08. Check code and proceed
as follows:

01: Failure to ignite (see 6.5.5). To re-set
turn mode selector switch to re-set position
for approximately 10 seconds, then back to
original position.

02: Overheat - Normally associated with
either poor or lack of primary water circula­tion. Wait for appliance to cool then re-set
as described for code 01.

03: Problem with fan/flue. Re-set as de­scribed for code 01.

04: Insufficient water pressure or poor flow
in system. Check pressure gauge reading,
if low restore pressure (see 6.3.3) then re­set as described in code 01. If the pressure
gauge reading is correct check for sufficient
primary water movement or correct opera­tion of flow switch. Re-set as described for
code 01.

05: Re-set as described for code 01.

06: Hot water thermistor open circuit.

07: Primary thermistor open circuit.

08: Re-set as described for code 01.

FAULT FINDING GUIDES

On the following pages are the fault finding guides. Be sure to read the notes below before
begining any fault finding

NOTES:

1. To ensure correct fault diagnosis it is important that these guides are carried out in the set order.

2. Check the electrical supply polarity is correct before carrying out fault finding (lockout will occur if the

polarity is reversed).

3. To ensure that internal/external controls (if fitted) do not interfere with fault finding, disconnect the wires
from terminals 2 & 3 (labelling them in the process to ensure correct reconnection) and provide a solid
link between 2 & 3.

32

Linea Max

Supplied By www.heating spares.co Tel. [phone]

VOKERA

Linea Max

Test A: Checking operation of electronic control board at start up

NO

3 way valve
in the DHW

position

230 V

on 3 way

NO

valve between

terminals M11.1 &

M11.3 on

Replace control

board

PCB

YES

Turn on hot tap

Check &/or

replace 3 way

valve assembly

running

Is the

YES

Is the
pump

YES

YES

Start

Switch on/off

Selector to

DHW position

Green

led

alight

NO

A2

NO

Replace board

NO

Replace control

board

Is

there 5 VDC

between terminals

M5.5 & M5.6

on PCB

YES

Check wiring and

connections or DHW

switch

230 V

on pump

connector M15.1 &

M15.2

YES

NO

between terminals

NO

NO

Is

there 0 VAC
M5.5 & M5.6

on PCB

YES

there 24 VDC

between terminals

M3.5 & M5.3 on

Is

PCB

connector M12.1

NO

Is the

fan

running

NO

230 V

on fan

& M12.2

YES

Replace fan

YES

A

YES

230 V on

fan

NO

Check &/or

replace wiring

and connections

Replace wiring

NO

230 V

on pump

YES

Replace pump

Replace control

board

or connections

Linea Max

YES

Air

pressure switch

off

YES

Replace air

pressure switch

NO

Replace wiring
or connections

33

Supplied By www.heating spares.co Tel. [phone]

YES

Check wiring

and connections

YES

Check wiring

and connections

YES

A1

Is

there 24

VDC between

terminals M5.4 on PCB &

black wire on air

pressure

switch

terminals M5.4 on PCB &

NO

Is

there 24 VDC

between terminals

M5.4 on PCB & red wire on

hight limit thermostat

NO

Is

there 24

VDC between

terminals M5.4 on PCB &

white wire on hight

limit thermostat

NO

Is

there 24

VDC between

red wire on air

pressure

switch

YES

Does

the air pressure

switch turn

on

NO

Are the

Venturi tube

and the silicone air

tubes clean

YES

YES

Check wiring and

connections, air
pressure switch

and control board

NO

Check/clean

the Venturi tube

and silicone air

tubes

Reset the high

limit thermostat

Green

led alight

YES

Restart the test

NO

Is there

24 VDC between

terminals M5.4 and

M3.3 on PCB

YES

Check wiring

and connections

NO

Check wiring and
connections, high

limit thermostat or

PCB

NO

Replace the

control board

Is the

air DP >

11 mmCH2O

NO

Check the fan

and /or flue gas

tube

YES

Check replace

air pressure

switch

34

Linea Max

Supplied By www.heating spares.co Tel. [phone]

A2

5 VDC

between terminals

M2.1 & M2.2 on dislay

board

YES

YES

Digital

display

showing 01

Red led

flashes

Replace the

Bicoloured

assembly OK

YES

NO

NO

Digital

display

showing

YES

Bicoloured

assembly OK

YES

Replace the

display board

Switch on/off

selector to off

position

NO

terminals M9.1 &

M9.2 on control

between M16.L &

M16.N on control

between blue &

brown wires at boiler

terminal strip

Replace wiring or

connections terminal

strip and control board

NO

5 VDC

between

board

NO

230V

present

board

NO

230V

present

YES

Replace the

display board

YES

Check and/or
replace wiring or
connections with

display board

YES

Check fuses
F1 and F2 on
control board

NO

Recheck supply

fuse &

connectors to

boiler terminals

Digital

display

showing 02

A4

YES

Restart the high

limit lock

Green

led alight

Check wiring and

connections high

limit thermostat

and control board

Switch on/off

selector to DHW

position

Green

led alight

YES

YES

Restart the

test

NO

Replace the

control board

Ignition

box OK

NO

Replace Ignition

box

YES

YES

Fuse

OK

NO

Replace Fuse

Restart the

test

Replace the

control board

Linea Max

35

Supplied By www.heating spares.co Tel. [phone]

VOKERA

Linea Max

Test B: Check control in DHW mode

Start

Switch on boiler and select

mode to summer.

DHW thermostat to max

YES

Is

there a

voltage >10 VDC

between terminals

M4.1 & M4.2 on

PCB

NO

Is the

resistance of

modulation coil

about 80

OHM

NO

Replace

modulator coil

Replace control

board

YES

Wait for water flow

temperature to be

<60°C

NO

temperature

YES

NO

Is

water flow

<60°C

Turn on tap

Does

the burner

light

YES

Is

voltage across

terminals of modulator

coil > 10 VDC

YES

Turn the DHW

thermostat to

min

NO

Check boiler

startup: test A

Is there

a voltage >

10VDC between

terminals of modulator

coil

NO

Replace wire

and connections

YES

Is water

flow temperature

> 60°C

YES

Replace

modulator coil

Wait for water

flow temperature

to be< 60°C

NO

NO

YES

Turn DHW

thermostat to

max

Do the

burner and fan

switch on

Do the

burner and

fan switch

off

NO

Is

water flow

temperature

>50°C

YES

Replace

control board

YES

Wait for water

flow temperature

to be> 50°C

NO

B

Replace control

board

36

Linea Max

Supplied By www.heating spares.co Tel. [phone]

Start

Switch on boiler and

select mode to

winter. C/H

thermostat to max

Make a

link between 2 & 3

at boiler terminal

strip

VOKERA

Linea Max

Test C: Check control in C/H mode

YES

Does

the burner

light

YES

Is

voltage across

terminals of modulator

coil < 5VDC

NO

Is

voltage across

terminals of modulator

coil > 10VDC

YES

Replace control

board

Is the 3

way valve on

C/H position?

NO

Check boiler

startup test A

YES

C

NO

NO

YES

Check &/or

replace 3 way

valve

YES

0 VAC

present

between pin M16.TA

and M16.TA on

control board

230 V

present

between pin M11.1

and M11.2 on control

board

contol board

Is

there a

voltage >5 VDC

between terminals

M4.1 & M4.2 on

PCB

NO

Is the

resistence of

the modulator coil

about 80

OHM

NO

Replace

modulator

coil

YES

YES

Replace

NO

Check/replace wire

and connections

between terminal

strip and control

board

NO

Has the

hot water

preheat cycle

finished

NO

Wait for hot water

preheat cycle to

finished

YES

Is the

wiring and

connections between

modulator coil and

control board

OK

NO

Replace wire

and

connections

YES

Replace contol

board

Linea Max

Replace

modulator

coil

37

Supplied By www.heating spares.co Tel. [phone]

A

END

YES

NO

Spark

at electrode

YES

Ignition

YES

Lockout

after ignition

YES

Check electrode

and lead OK

Electrode

and lead OK

NO

NO

Is

there 230V

between terminals

M14.1 & M14.2

on PCB

NO

YES

Is

there 230V

between terminals L

& N on Ingnition

box

YES

Check electrode and

lead or replace

ingnition box

NO

Check wiring

and

connections or

air pressure

switch

Replace

ingition box

electrode and

Replace

ingition box

Replace

Gas valve

NO

Replace

lead

NO

NO

Ingition
box OK

YES

Gas

valve OK

YES

Check Gas

NO

A1

Is

there 0 VDC

between terminals

M5.3 & M5.4 on

PCB

YES

Is

there 24 VDC

between terminals

M3.5 & M5.4 on

PCB

NO

0 VDC

on Pressure

switch

YES

Pressure

switch OK

NO

A3

YES

Replace

ingition box

NO

Check wiring

and

connections

YES

Check Water

38

Linea Max

Supplied By www.heating spares.co Tel. [phone]

A3

A4

Digital

display

showing 03

Digital

display

showing 04

Digital

display

showing 05

YES

YES

Replace control

YES

board

Does

the diaphragm

shaft go

out

YES

Does

the boiler

pressure switch

go on

YES

Check the wiring

AND/OR the contol

board

NO

Check AND/OR replace

the diaphragm. Check

the correct water dp

check the water circuit.

Check if the pump is on

speed 3

NO

Check and/or replace

the boiler pressure

switch

NO

Digital

display

showing 06

NO

Digital

display

showing 07

NO

Replace control

board

YES

Check DHW

NTC sensor or

connection

YES

Check Flow

NTC sensor or

connection

Linea Max

39

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B

Turn OFF Tap

YES

END

NO

Replace DHW

pressure switch

Do

burner, fan

and pump switch

Off

NO

Is

water flow

temerature

>78°C

NO

Is

DHW

pressure switch

OK

YES

YES

NO

Do

burner pump

switch Off

YES

Does

the fan

RUN

YES

Is

water flow

temperature

<78°C

NO

Is

DHW

pressure switch

OK

YES

Replace

control board

NO

Is DHW

NTC OK

YES

Replace

control board

NO

DHW Flow

switch

NO

Replace

DHW NTC

YES

Does

NO

the fan

switch

OFF

Is DHW

NTC OK

YES

Replace

control board

NO

Replace DHW

NTC

40

YES

END

Linea Max

Supplied By www.heating spares.co Tel. [phone]

C1

END

YES

Do the

burner and

fan switch

ON

YES

Remove link
between pin
M16.TA and

M16.TA on control

board

Wait 30 sec.

Do

the burner,

fan and pump

switch OFF

NO

Is

water flow

temperature

>78°C

YES

NO

Is the

water flow

temperature

>80°C

NO

Replace

control board

Do

the burner

and fan switch

OFF

YES

Does

pump

RUN

Wait for the

water flow

temperature to

be <80°C

YES

NO

Replace

control board

NO

NO

NO

water flow

NO

Does

the pump

RUN

temperature

Replace

control

YES

board

NO

Is flow

NTC OK

YES

NO

the pump

switch OFF

Replace

flow NTC

Replace

control

board

Linea Max

YES

Is the

<78°C

YES

Does

YES

END

Is Flow

NTC OK

YES

Boiler

in LOCK OUT

state

YES

Switch OFF

boiler. Wait

about 10 secs.

then restart test

NO

Replace flow

NTC

NO

Replace

control board

41

Supplied By www.heating spares.co Tel. [phone]

C

Wait 1 min.

Is

voltage across

terminals of modulator

coil >10 VDC

NO

YES

Switch C/H

thermostat to min

Do the

burner and fan

switch OFF

YES

Switch C/H

thermostat to

max

NO

Replace

control board

Is

water flow

temperature

>40°C

YES

Replace

control board

Wait for water

flow temperature

to be >40°C

NO

Do the

burner and fan

YES

switch ON

NO

timer jumper

Wait 3 min.

control board

C1

42

Is

ON

NO

Replace

YES

Remove

jumper

Restart the

test

Linea Max

Supplied By www.heating spares.co Tel. [phone]

SECTION 10 APPENDIX

Instructions for (A) Fitting Vokèra 24 Hour Time Switch (Part No. 201)

and Vokèra Digital 7 Day Time Switch (Part No. 202)

(B) Wiring to external Time Switches and Room Thermostat
(C) Wiring for 'S' & 'Y' Plan Installations.

A. Installation of the Vokèra time switches (24 Hr and 7 Day)

Gain general access to electrical panel as 5.5.2.

Remove the clock aperture blanking plate (1) fig.1 by
squeezing the 4 lugs on the rear of the plate together
and push the plate out.

Remove the central circular disk from the plate (some
force is necessary to break the holding nibs).

Remove the clock from its box.

Wire the clock as shown in fig. 2. The wiring loom to
the clock comes complete with 4 spade connectors
(for connection to the clock terminals), and a multi­plug for connection to the clock loom pre assembled
on the appliance.

Replace the clock blanking plate back into the fascia
of the appliance.

Insert the clock into the aperture from the back of the
control panel, and secure the clock to the front
control panel using the four screws provided.

Brown

Blue

Identify the internal clock wiring loom. Push fit the
multi-plug onto the multi-plug connector connected to
the time clock. The multi-plug connector is polarised,
it is therefore only possible to connect the multi-plugs
one way.

When all electrical connections are made replace
electrical cover.

NO EXTERNAL OR INTERNAL CONTROLS

The loop between terminals 2 & 3 remains when no

Fig. 2

external or internal controls are used (as fig. 4).

INTERNAL TIME CLOCK ONLY

Remove the loop between terminals 2 & 3 and
reconnect it between terminals 1 & 2 (as fig. 5)

ROOM THERMOSTAT (Without clock)

Remove the loop between terminals 2 & 3 and
connect room thermostat between 2 & 3 (as fig. 6).

ROOM THERMOSTAT (With clock)

Remove the loop between terminals 2 & 3 and con­nect room thermostat between 1 & 2 (as fig. 7)

1

23

Fig. 1

1

White

Red/White

Spare

45

Linea Max

Vokera room

thermostat

Link 1 &
4 in r/stat

1

3

2

4

5

6

Fig. 3

Live

Load

Neutral

43

Supplied By www.heating spares.co Tel. [phone]

Fig. 4

Fig. 5

To internal
timeclock
multiplug con­nector (unused)

Fig. 4 Showing 230v input electrical con­nection without room thermostat or inter­nal time clock
(Internal wiring loom for timeclock and link
between 2 & 3 remains)

Link between
terminals 1 & 2.

Fig. 6

Fig. 7 Showing 230v input electrical con­nection and internal timer without room
thermostat.
NOTE: Remove link between terminals 2
& 3 and replace between terminals 1 & 2.

Internal
time clock

Room thermostat

Fig. 6 Showing 230v input electrical con­nection and room thermostat without in­ternal time clock. Remove link between 2
& 3 room thermostat connected between
terminals 2 & 3.
Should the room thermostat require a
neutral or earth, connect neutral to the
terminals marked N, and the earth to the
earth terminal.
Note: Room thermostat contact rated at
230v.

Fig.7

Room thermostat

Internal
time clock

44

Fig. 7 Showing 230v input electrical con­nection internal timer and room thermo­stat. Remove link between terminals 2 &

3. Room thermostat connected between
terminals 1 & 2.
Should the room thermostat require a
neutral or earth, connect neutral to the
terminals marked N, and the earth to the
earth terminal.
Note: Room thermostat contact rated at
230v.

Linea Max

Supplied By www.heating spares.co Tel. [phone]

B. Wiring to External Time Switches and Thermostats.

(i) General Schematic Diagram.

Room

Thermostat

Earths have been
omitted for clarity

External

Time Switch

(ii) ACL Time Switch and Typical Room Thermostat

COMMON

LOAD

13456

2

Remove

Link between

2 & 3

Earths have been
omitted for clarity

ACL Lifestyle

LP111 or LP711

Do not link L & 1

Appliance

Terminal

Block

Room

Thermostat

123

4

Remove link between 2 & 3

(iii) Randall Time Switch and Vokèra Room Thermostat.

Room

Thermostat

LOAD

COMMON

12345 Appliance Terminal Block

6

Remove link between 2 & 3

Appliance

6

5

Terminal

Block

Earths have been
omitted for clarity

Randall
Time switches
103
103E
103E7

Do not link
terminals 3 & 6
in time switch

Linea Max

45

Supplied By www.heating spares.co Tel. [phone]

C. Wiring for 'S' Plan Installations.

APPLIANCE TERMINAL BLOCK

1

2

ROOM

THERMOSTAT

LOAD

REMOVE

LINK

3

546

CYLINDER

THERMOSTAT

SATISFIED

CALLING

LIVE

3 Amp Fuse

Mains Supply

230v 50Hz

N
L
E

OFF

C/H

ON

OFF

H/W

ON

DOUBLE CHANNEL

PROGRAMMER

MODE SELECTOR SWITCH MUST BE IN THE POSITION.

Wiring for 'Y' Plan Installations.

COMMON

N

E

L

2

1

3456

7

REMOTE JUNCTION BOX

H/W 2 PORT ZONE VALVE

ORANGE

GREY

BROWN

BLUE

GREEN/YELLOW

ORANGE

GREY

BROWN

BLUE

GREEN/YELLOW

M

M

C/H 2 PORT ZONE VALVE

ROOM

THERMOSTAT

Mains Supply

230v 50Hz

DOUBLE CHANNEL

PROGRAMMER

LOAD

LIVE

N

L

E

APPLIANCE TERMINAL BLOCK

132

54

6

CYLINDER

THERMOSTAT

REMOVE

LINK

3 Amp Fuse

NL

E

4

3

567

REMOTE JUNCTION BOX

2

1

SATISFIED

CALLING

COMMON

DIVERTER VALVE

ORANGE

GREY

WHITE

GREEN/YELLOW

OFF

ON

OFF

ON

C/H

H/W

ADD THIS WIRE IF PROGRAMMER

BLUE

HAS A HEATING ONLY POSITION.

NOTE: WHEN USING A 'Y' PLAN INSTALLATION THE MODE SELECTOR

SWITCH WILL BE OVERRIDEN BY THE CONTROL CIRCUIT.

3 WAY

46

Linea Max

Supplied By www.heating spares.co Tel. [phone]

Fig.35a Gas Assembly

R5317

R5317

R1931

R102929

R102411

R102866

R102930

R102868

R102934

R7721

R100068

R102397

R102291

R102392

R102935

R102405

Linea Max

77085

77086

48897

R102936

R102937

R102399

R102938

R102847

R100057

R102254

Fig.35b Front Panel

47

Supplied By www.heating spares.co Tel. [phone]

Fig.35c cover

R2374

R2374

R1920

R5072

R3139

Fig.35d Inlet Assembly

R101954

R103317

R103318

R101319

R102330

R102956

R102955

R102947

R103319

48

Linea Max

Supplied By www.heating spares.co Tel. [phone]

Fig.35e Expansion Vessel

R102957

R103320

R100035

R103321

R102960

R102964

R100035

R100035

R102924

R100035

R102961

Fig.35f Circulating pump and pipes

R100035

R102962

R100035

R102961

R102963

R100035

R102927

R100035

Fig.35g Pipes

Linea Max

R102931

R100035

R102961

49

Supplied By www.heating spares.co Tel. [phone]

Fig.35h Thermal Store & Flue Fig.35i Thermal store & insulation

R102921

R102923

R103322

R102991

R102804

R102906

R102928

Fig.35j Base tray

R103317

R103323

R103324

Complete Kit : Part No 48945

R102950

R103327

R103319

R103326

R102946

R102947

R103325

50

R103318

Linea Max

Supplied By www.heating spares.co Tel. [phone]

Fig.35k Domestic heat exchanger & pipes Fig.35l Hydraulic Manifold

R101319

R103329

R102947

R103323

R103328

R100030

R103325

R102953

R102954

R101319

R102330

R102956

R102955

R103316

R102859

48913

48912

R0182

Fig.35m Hydraulic Manifold

(Exploded Diagram)

R4611

R5042

R4612

R6862

R2909

R6865

R1806

R6872

R6867

R6888

R6853

R5184

R6860

R5041

R2904

R6895

R2910

R6887

R2913

R8444

R7134

Linea Max

R2906

R5041

R5184

R6919

R2905

51

Supplied By www.heating spares.co Tel. [phone]

Fig.35n Outer casing

R102796

R100939

R101821

R102768

R102915

R102848

R102919

Fig.35o Sealed Case

R100940

R102914

R102785

R102918

R5922

R5964

R5927

R2073

R8085

R8086

R5923

R9805

R9232

R100953

R1835

52

Linea Max

Supplied By www.heating spares.co Tel. [phone]

Fig.35p Combustion chamber

R8083

R5916

R7948

R6985

R6492

R5917

R7280

R1912

R5907

R5316

R6028

R5271

R1914

R5315

R5909

Linea Max

53

Supplied By www.heating spares.co Tel. [phone]

SHORT SPARE PARTS LIST (Refer to figs.35)

Code Fig No. Description

099862 35a Gas Valve Complete

08665 35i Auto Air Vent

1914 35p Main Heat Exchanger

1931 35a Spark Electrode

088031 35f Grundfos UPS 15-60 Pump (complete)

5911 35p Fan

088120 35d Domestic Flow Switch

9232 35o Pressure Differential Switch

5317 35a Main Burner

099864 35a Ignition Control Box

088125 35j Gas Service Cock

088124 35j Cold Water filling/Inlet valve

088042 35e Expansion Vessel

077939 35m Thermistor

078139 35b Pressure Gauge

088155 35k &m Domestic Heat Exchanger

088127 35j Heating Flow Valve

088126 35j Heating Return Valve

1806 35l Safety Valve

ABLING AND DISABLING ELECTRONIC FUNCTIONS

Certain electronic functions on the Linea
range of appliances can be abled or disa­bled according to customer preference. The
selections can be made by the addition or
removal of jumper tags situated on the
printed circuit board. Refer to fig. 36 for
jumper positions on printed circuit board.

Pre-heat

To disable pre-heat facility add jumper to
JP9 and remove from JP4

Jumpers JP1, JP2, JP3, JP5 and JP7 also
exist on the printed circuit board DO NOT
under any circumstances add or remove
jumpers at these points.

Spare jumpers are available from Vokera
stockists. Part no. 7232.

54

Linea Max

Supplied By www.heating spares.co Tel. [phone]

GENERAL LAYOUT & ILLUSTRATED WIRING DIAGRAM

Fig. 36

Key
F2 Fuse (2A F)
F1 Fuse (T100MA)
SAN H/W Flow Switch
PF Air Pressure Switch
R1 ,2 & 3 Relay

V Fan
P Pump

TL High Limit Thermostat
3V Motorised Valve

Linea Max

E.A./R. Electrode
ACF Ignition Control Box
MOD Modulator Coil
SR/SS Thermistor Sensor
PTR C/H Temperature Control
PTS D/H/W Temperature Control
CO10 Time Clock Connector
SEL Mode Selector Switch
DIS Digital Display
SP Combustion Switch
OPE Solenoid Operators

55

Supplied By www.heating spares.co Tel. [phone]

PRELIMINARY ELECTRICAL SYSTEM CHECKS

A. EARTH CONTINUITY CHECK - appliance must

be electrically disconnected - meter set on W (ohms)
x 1 scale and adjust zero if necessary.

a) Test leads from any appliance earth point to earth
pin on plug - resistance should be less than 0.1 W
(ohm).
If the resistance is greater than 0.1 W (ohm) check all
earth wires for continuity and all contacts clean and
tight.

B. SHORT CIRCUIT CHECK - appliance electrically
disconnected, all switches ON (including stats) ­a) meter set on W (ohms) x 1 scale.
Test leads from L to N in appliance terminal strip/
block - if meter reads 0 then there is a short circuit.

b) meter set on W (ohms) x 100 scale
Repeat test with leads from L to E. If meter reads
less than µ (infinity) there is a fault.

NOTE - Should it be found that the fuse has failed but
no fault is indicated, a detailed continuity check (i.e.
by disconnecting and checking each component) is
required to trace the faulty component. It is possible
that a fault could occur as a result of local burning/
arcing but no fault could be found under test.
However, a detailed visual inspection should reveal
evidence of burning around the fault.

D. RESISTANCE TO EARTH CHECK

Appliance must be disconnected from mains supply
and meter set on W (ohms) x 100 scale. All switches,
including stats, ON - Test leads from L to E - if meter
reads other than infinity (µ) there is a fault which
should be isolated. A detailed continuity check is
required to trace the faulty component.

IMPORTANT - This series of checks are the first
electrical checks to be carried out during a fault
finding procedure. On completion of the service/fault
finding task which has required the breaking and
remaking of electrical connections then the checks ­A. Earth Continuity. C. Polarity and D. Resistance to
Earth - must be repeated.

C. POLARITY CHECK

Appliance connected to mains supply and meter set
on 300V ac scale. Test at appliance terminal strip:-

a) Test leads from L to N - meter reads approx
230V ac
b) Test leads from L to E (W) - meter reads approx
230V ac
c) Test leads from N to E (W) - meter reads from
O-15V ac*

Thus the terminal marked L is the live terminal. If the
low* V ac reading is given on terminals other than N
to E (W) there is an electrical fault.

Repeat the test at the appliance plug/inlet spur to
check the wiring system up to the appliance and
rectify any fault. If necessary repeat the test at the
supply system socket/spur - if the fault also occurs at
this stage then there is a house system fault which
requires attention by the ELECTRICITY AUTHORITY.
The customer should be warned not to use the
appliance until this examination has been carried out.

56

Linea Max

Supplied By www.heating spares.co Tel. [phone]

SECTION 11 L.P.G. INSTRUCTIONS

11.1 Gas Rates (LPG)

Linea Max

Min. Gas Rate

Max. Gas Rate

11.2 Burner Details (LPG)

1.63 litres/h

4.85 litres/h

Main Burner

Main Burner Injectors

Burner Pressure Max. Rate

Burner Pressure Min. C/H

Burner Pressure Min. DHW

Burner Pressure Soft Light

11.3 RELATED DOCUMENTS

BS 6891 1988 Low pressure installation pipes
BS 6798 1987 Boilers of rated input not exceeding 60kW
BS 5449 Part 1 1990 Forced circulation hot water systems
BS 5546 1990 Installation of gas hot water supplies for

BS 5440 Part 1 1990 Flues
BS 5482 Part 1 1994 Domestic Butane & Propane Gas burners in

11.4 GAS SUPPLY

A gas supply should be connected to the
boiler by a competent L.P.G. installer and
should be of sufficient size to supply the
boiler at its maximum output.

Polidoro NP14

14 x 0.77

36.0 mbar

5.5 mbar

4.3 mbar

16.7 mbar

domestic purposes (2nd family gases)

permanent dwellings

11.6.4 Locate the main burner pressure test point
(fig. 20) and slacken the screw half a turn in
an anti clockwise direction. Attach a suitable
pressure gauge as described at 6.6.3.

An existing supply should be checked by
the installer or L.P.G. supplier to ensure
that it can deal with the rate of gas supply
required for all the appliances when they are
in use at the same time.

11.5 GAS SUPPLY INSTALLATION

11.5.1 Inspect the entire installation including the

meter, test for soundness and purge.

11.6 CHECK BURNER PRESSURE

11.6.1 The heat inputs for high and low gas rates

are factory set to the maximum values given
in section 11.2 but it is necessary to check/
adjust this when commissioning the appli­ance.

11.6.2 Turn off the main electrical supply. Gain
access to the interior.

11.6.3 Gain access to the electrical terminals as

5.5.2. Ensure the Jumper at point JP8 is
removed.

IMPORTANT: Before measuring gas
pressures it is imperative that the protective
cover over the gas valve adjustment screw
is removed. (Fig. 33)

Turn on electricity supply. Turn mode
selector switch to the position and fully

open a domestic hot water tap to operate
boiler in dhw mode. Adjust hot water control
knob to its maximum setting.

11.6.5 The pressure reading for maximum output
should be :

36.0mbar.
(Plus or minus 3.6mbar.)
If the pressure is wrong it should be ad­justed as instructed in 8.23. (N.B. Whenever
the maximum rate is adjusted check and
adjust the minimum rate too).

11.6.6 Reduce the domestic water flow rate to
approximately 3-4 litres/min. Turn the
domestic control knob slowly to minimum
the boiler output will reduce to the minimum
setting. If low flame cannot be established in
this way, turn off the electricity supply, and

Linea Max

57

Supplied By www.heating spares.co Tel. [phone]

disconnect a grey wire from the modulator
coil. Switch on the electricity supply, the
boiler will now light at the minimum setting.

11.6.7 When low flame is established the pressure
reading should be :

4.3mbar.
(Plus or minus 0.43mbar.)
If it is different adjustment should be made
in accordance with the instructions in 8.23.

11.6.8 If a grey wire was disconnected from the
modulator coil to check the minimum
setting, turn off the electricity supply and
reconnect the wire.

11.7 Maximum Rate in Central Heating Mode

The Linea range does not require any
adjustment to the maximum heat require­ment of the system load. See 8.23.5.

11.8 Setting the Minimum Rate for Central
Heating

Turn off the main electrical supply.

Gain access to the electrical terminal blocks
(5.5.2) Fig. 19.

11.9 Soft light ignition and range rating for central
heating is fully automatic, no adjustment is
necessary.

11.10 Turn mode selector to the OFF position, dis­connect pressure gauge, re-tighten screw.
Relight boiler.

11.11 Re- check for gas soundness.

11.12 Replace electrical controls panel.

11.13 Refix the boiler casing.

Turn the mode selector switch to the
position, ensure that the room thermostat
and/or timeclock (if fitted) are calling for
heat. Turn the heating thermostat to maxi­mum and ensure the appliance ignites.

Identify minimum adjustment button on pcb
(fig. 34).

Press the minimum adjustment button once.
The boiler will operate in central heating
mode at a minimum gas pressure. An LED
on the PCB will flash red to confirm the
appliance is in central heating minimum
mode.

The gas pressure should now be:

5.5 mbar.
plus or minus 0.55 mbar.

If the reading is incorrect it should be
adjusted as follows:

Identify the minimum adjustment
potentiometer on the PCB (fig. 34).

With the boiler still in central heating mode and
the burner at the minimum rate, using a small
screwdriver turn the potentiometer clockwise
to increase & anti-clockwise to decrease the
gas pressure.

When all is adjusted, press the minimum ad­justment button once (the appliance will return
to normal operation). Turn the appliance off.

58

Linea Max

Supplied By www.heating spares.co Tel. [phone]

Supplied By www.heating spares.co Tel. [phone]

VER 09/00

(Cod.066612)

PUTTING THE ACCENT ON QUALITY

Vokèra Ltd.

Web: www.vokera.co.uk

Southern Region: Morson Road, Enfield, Middlesex EN3 4NQ. Sales: 020 8216 6300. Fax: [phone].

Parts: 020 8216 6310. Technical HeIpIine: 01274 866110. Customer Services: 0870 333 0220.

E-mail: [e-mail]

Northern Region: Stubs Beck Lane, West 26 Business Park, Whitehall Road, Cleckheaton, West Yorkshire BD19 4TT. Sales: 01274 866100.

Fax: [phone]. Parts: 01274 866140. Technical HeIpIine: 01274 866110. CustomerServices: 0870 3330220.

E-mail: [e-mail]

Scottish Region: Shuna Street, Maryhill, Glasgow G20 9NW. Sales: 0141 945 6800. Fax: [phone].

Parts: 0141 945 6820. Technical HeIpIine: 0141 945 6810. Customer Services: 0870 333 0220.

E-mail: [e-mail]

Vokèra (Ireland) Ltd: West Court, CaIIan, Co. Kilkenny, Ireland. Sales/Parts: 056 55055.

Fax: [phone]. Technical HeIpIine/ Customer Services: 056 55057.

E-mail: [e-mail]

Vokèra Ltd. reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected.