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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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

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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

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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

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Locating hook

Fig. 19

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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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