VOKERA Linea ONE Installation & Servicing Instructions Manual

Installation & Servicing Instructions

THESE INSTRUCTIONS TO BE RETAINED BY USER

Linea ONE

High efficiency combi boiler

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

6.5 Pump assembly 18

6.6 Safety valve 19

6.7 Bottom automatic air release valves 19

6.8 Water pressure sensor/gauge 19

6.9 Primary thermistors 19

6.10 Return thermistors 19

6.11 Printed circuit board 19

6.12 Gas valve 19

6.13 Electrode and condense sensor 20

6.14 Flue fan & mixer 20

6.15 Burner 20

6.16 Main heat exchanger 20

6.17 Flow restrictor 21

6.18 DHW flow meter 21

6.19 DHW heat exchanger 21

6.20 Valve actuator 21

6.21 Divertor valve assembly 21

6.22 DHW thermistor 21

6.23 Automatic by-pass & DHW non-return valve 21

6.24 Expansion vessel 21

6.25 Condense trap removal 21

6.26 Flue collector removal 22

Checks, adjustments and fault finding Page

7.1 Checking appliance operation 23

7.2 Appliance mode of operation 23

7.3 Service mode & parameters 25

7.4 Adjustments 27

7.5 Combustion analysis test 28

7.6 Checking the expansion vessel 28

7.7 External faults 28

7.8 Electrical checks 28

7.9 Fault finding 28

7.10 Temporary fault codes 28

7.11 Final fault codes 28

Wiring diagrams Page

8.1 External wiring 30

8.2 Typical control applications 30

8.3 Vokera room thermostat 30

8.4 Other devices 30

Exploded diagrams Page

9.1 Table 1 33

9.2 Table 2 34

9.3 Table 3 35

9.4 Table 4 36

9.5 Table 5 37

L.P.G. instructions Page

10.1 Related documents 38

10.2 Technical data 38

10.3 Converting the appliance gas type 38

10.4 Gas supply 38

10.5 Gas supply installation 38

10.6 Adjusting the gas valve 38

Benchmark 39-40

Contents

Design principles & operating sequence Page

1.1 Principle components 3

1.2 Mode of operation 3

1.3 Mode of operation (Heating) 3

1.4 Mode of operation (DHW) 3

1.5 Safety devices 3

1.6 Optional accessories 3

Technical data Page

2.1 Central heating 4

2.2 Domestic hot water 4

2.3 Gas pressure 4

2.4 Expansion vessel 4

2.5 Dimensions 4

2.6 Clearances 4

2.7 Connections 4

2.8 Electrical 4

2.9 Flue details (concentric) 4

2.9A Flue details (twin pipes) 4

2.9B Flue details (80/125) 4

2.10 Efficiency 4

2.11 Emissions 5

2.12 Range rated 5

2.13 Pump duty 5

General requirements (UK) Page

3.1 Related documents 7

3.2 Location of appliance 7

3.3 Gas supply 7

3.4 Flue system 7

3.5 Air supply 7

3.6 Water circulation 7

3.7 Electrical supply 8

3.8 Timber framed buildings 8

3.9 Inhibitors 8

3.10 Showers 8

General requirements (EIRE) Page

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

Installation Page

4.1 Delivery 10

4.2 Contents 10

4.3 Unpacking 10

4.4 Preparation for mounting the appliance 10

4.5 Fitting the flue 10

4.6 Connecting the gas & water 13

4.7 Electrical connections 14

Commissioning Page

5.1 Gas supply installation 15

5.2 The heating system 15

5.3 Initial filling of the system 15

5.4 Initial flushing of the system 15

5.5 Filling the hot water system 15

5.6 Pre-operation checks 15

5.7 Initial lighting 15

5.8 Final flushing of the heating system 15

5.9 Setting the boiler operating temperature 15

5.10 Setting the system design pressure 16

5.11 Regulating the hot water 17

5.12 Final checks 17

5.13 Instructing the user 17

Servicing Page

6.1 General 18

6.2 Routine annual servicing 18

6.3 Replacement of components 18

6.4 Component removal procedure 18

RANGE RATED

This boiler can be adapted to the heating requirements of the system, it is possible to change the maximum output in central heating. Refer to chapter “Adjustments” for calibration. After setting the desired output (parameter 23 maximum heating) report the value in the table on the back cover of this manual, for future references.

INTRODUCTION

General layout (fig. 1)

1 Water pressure sensor /trasducer 2 Drain valve 3 Three port valve actuator 4 DHW heat exchanger 5Pump 6 Bottom auto air vent (AAV) 7 Pressure gauge 8 Condense trap 9 Return sensor 10 Fumes sensor 11 Flue gas analysis test point 12 Flue outlet & air intake 13 Ignition transformer 14 Limit thermostat 15 Flow temperature sensor 16 Top AAV 17 Sensing electrode 18 Spark electrode 19 Cylindric Burner 20 Condensate level sensor 21 Main heat exchanger 22 Fan assembly 23 Mixer 24 Expansion vessel 25 Injector 26 DHW temperature sensor 27 Gas valve 28 Flow meter

R Heating return connection F Heating flow connection G Gas connection O Hot water outlet I Cold water inlet

There are no banned substances used in the manufacture of these appliances.

The Linea ONE is a high-efficiency combination boiler with inputs to heating 30 kW & DHW of 38 kW. Each appliance – by design – incorporates electronic ignition, circulating pump, expansion vessel, safety valve, water pressure sensor and automatic by-pass. The Linea ONE is produced as room sealed, category II2H3P appliances, suitable for internal wall mounting applications only.

It is provided with a fan powered flue outlet with an annular co-axial combustion air intake that can be rotated – horizontally – through 360 degrees for various horizontal or vertical applications. The Linea ONE can also be used with the Vokera twin flue system. The Linea ONE is approved for use with B23P-B53P-C13-C23C33-C43-C53-C63-C83 type flue applications. These appliances are designed for use with a sealed system only; consequently they are not intended for use on open vented systems nor are they intended for external applications.

Fig. 1

IOG

INSTALLATION AND SERVICING INSTRUCTIONS

MAIN FEATURES

- Fully automatic modulating circulation pump

- High performances in DHW mode, 3 stars according EN 132031 (flow meter and larger DHW heat exchanger)

- Combustion Range Rated, output adjustable according the designed home energy requirement

- Premix fully condensing combustion

PRIMARY INFORMATION

CONTROLS INTERFACE

1 Info button

Enables the function that allows the access to some information regarding the boiler operation.

2 Memory button

Enables the Memory function.

3 Heating temperature adjustment button

Allows the access to the adjustment of the heating water temperature by using the selector.

4 ON/OFF/RESET button

Allows you to:

● switch on the boiler

● switch off the boiler

● restart the boiler after a fault stop.

5 Heating ON/OFF button

Enables/disables the heating function

6 Dedicated to the Technical Assistance Service

Enables or disables the boiler’s self-operation.

7 Encoder (adjustment selector)

Allows you to increase or decrease the preset values.

8 Comfort button

Enables Comfort function.

9 DHW temperature adjustment button

Allows the access to the adjustment of DHW temperature by using the selector.

SECONDARY INFORMATION

DISPLAY

1 Reset symbol

Indicates when it is necessary to restart the boiler (please read page 42 for details).

2 Key symbol

Indicates the presence of a fault (please read page 42 for details).

3 Drop symbol

Displaying that the system pressure is under the correct level

4 Displaying the operating temperature (DHW or heating). 5 Memory symbol

It is displayed when Memory function is on.

6 Heating symbol

Flashing, indicates a heating request in the room.

7 Heating layer

Indicates the position of the set heating temperature (position relative to the maximum and minimum).

8 When the heating flame is on, it indicates that the burner is on

following a heat request in the room.

9 Anti-freeze symbol

It is displayed when the anti-freeze function is on.

10 External probe symbol

It is displayed when the external probe is connected.

11 Remote control panel

It is displayed when a remote control panel is connected.

12 Service icon

Indicates the boiler is self-operating.

13 Pressure value of the heating installation. 14 Comfort symbol

It is displayed when the Comfort function is on.

15 DHW symbol

Flashing, indicates a DHW request.

16 DHW layer

Indicates the position of the DHW temperature set (position relative to the maximum and minimum).

17 When the DHW flame is on, it indicates that the burner is on

following a DHW request.

°C

fig. 2

1.1 PRINCIPLE COMPONENTS

- A fully integrated electronic control board featuring electronic temperature control, anti-cycle control, pump over-run, self-diagnostic fault indicator and premix burner control

- Low-water-content, aluminium heat exchanger

- Electronic ignition with flame supervision

- Integral high-head pump

- Fan

- Expansion vessel

- Water pressure sensor/gauge

- Two-stage gas valve

- Condensate level sensor

- Safety valve

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

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

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

- HEATING ON- Heating and DHW functions enabled with TOUCH & GO function and SARA function active

- HEATING OFF - DHW only enabled, TOUCH & GO function active

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

modes.

1.3 MODE OF OPERATION (Heating)

When there is a request for heat via the programmer/time clock and/ or any external control, the pump and fan are started, the fan speed will modulate until the correct signal voltage is received at the control PCB. At this point an ignition sequence is enabled. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry increases the gas rate to 75% for a period of 15 minutes (adjustable, see parameter 28, cap. 7.3.1). Thereafter, the boiler’s output will either increase to maximum or modulate to suit the set requirement. When the appliance reaches the desired temperature the burner will shut down and the boiler will perform a five-minute anti-cycle (timer delay). When the request for heat has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

1.4 MODE OF OPERATION (DHW)

When there is a request for DHW via a hot water outlet or tap, the pump and fan are started, the fan speed will modulate until the correct signal voltage is received at the control PCB. At this point an ignition sequence is enabled. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry increases the gas rate to maximum or will modulate output to stabilise the temperature. In the event of the appliance exceeding the desired temperature (set point) the burner will shut down until the temperature drops*. When the request for DHW has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

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

1.5 SAFETY DEVICES

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

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

- 2 temperature sensors that control and prevent the over-heating of the circuit, interrupting the operation of the burner;

- a differential temperature protection circuit which interrupts the burner if the temperature differential is too high or inverted;

- a fan speed sensor that checks the correct operation of the fan, thereby allowing safe operation of the burner;

- a sensor that interrupts the operation of the appliance if the condense pipe becomes blocked;

- a safety valve which releases excess pressure from the primary circuit.

1.6 OPTIONAL ACCESSORIES

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

- external sensor that enables the appliance to automatically adjust its outlet flow temperature in response to the outside temperature

- RF wireless room thermostat.

Fig. 3

flow

DHW

outlet

return

Domestic cold water inlet

safety

valve

expansion

vessel

pump

diverter

valve

return

temperature

sensor

top AAV

flow

temperature

sensor

main heat

exchanger

water pressure sensor

& gauge

DHW

heat exchanger

DHW

temperature

sensor

transducer

automatic

by-pass

DHW

flow

meter

flow regu-

lator

DHW

non-return

valve

SECTION 1 - DESIGN PRINCIPLES AND OPERATING SEQUENCE

2.1 Central Heating Linea ONE

Heat input (kW) 30.0 Maximum heat output @ 60/80 °C (kW) 29.3 Maximum heat output @ 30/50 °C (kW) 32.0 Minimum heat output @ 60/80 °C (kW) 6.8 Minimum heat output @ 30/50 °C (kW) 7.5 Minimum working pressure 0.50 bar Maximum working pressure 3 bar Minimum flow rate 1000 litres per hour

2.2 Domestic Hot Water

Maximum input (kW) 38.0 Maximum output (kW) 38.0 Minimum input (kW) 7.0 Flow rate (35 °C rise) 15.6 Maximum inlet pressure 6.0 bar Minimum inlet pressure 0.15 bar Minimum flow rate 2.0 l/min

2.3 Gas Pressures

Inlet pressure (G20) 20.0 mbar Maximum CH gas rate (m3/hr) 3.17 Maximum DHW gas rate (m3/hr) 4.01 Minimum gas rate (m3/hr) 0.74 Injector size 1 x Ø 7.0mm Fan speed @ max output (rpm) DHW 6.300 Fan speed @ max output (rpm) HTG 5.000 Fan speed @ min output (rpm) 1.400

2.4 Expansion Vessel

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

2.5 Dimensions

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

2.6 Clearances (see fig. 6A)

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

2.7 Connections

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

2.8 Electrical

Voltage (V/Hz) 230/50hz Power consumption (W) 153 Internal fuse 2A External fuse 3A

2.9 Flue details (concentric)

Maximum horizontal flue length (60/100mm) 3.85m Maximum vertical flue length (60/100mm) 4.85m

2.9A Flue details (twin pipes)

Maximum horizontal flue length (80mm+80mm) 30m+30m Maximum vertical flue length (80mm+80mm) 30m+30m

2.9B Flue details (80/125mm)

Maximum horizontal flue length (80/125mm) 10m Maximum vertical flue length (80/125mm) 12 m

2.10 Efficiency

SEDBUK (%) 90.1 (A) NOx class 5

SECTION 2 - TECHNICAL DATA

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

1,8

2,0

2,2

2,4

2,6

2,8

3,0

3,2

3,4

3,6

3,8

4,0

4,2

4,4

4,6

4,8

5,0

5,2

5,4

5,6

5,8

6,0

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

Residual head (m.c.a.)

Plant flow rate (l/h)

2.11 Emissions Linea ONE

NOx (max-min) 71 - 44 mg/kWh CO (max-min) 215 - 32 mg/kWh CO2 (max-min) 9,5 - 9,5 % CO/CO2 ratio (max) 0,002 to 1 CO/CO

ratio (min) 0,0003 to 1

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

2.13 PUMP DUTY

Linea ONE boilers are fitted with a variable speed circulation unit that is already connected up in terms of plumbing and electrics, and the usable performance it provides is shown in the graph. The boilers are fitted with an anti-blocking system that starts an operating cycle every 24 hours when not used, irrespective of the position of the function selector.

The “anti-blocking” function is only active when the electrical power supply to the boiler is on.

Operating the circulation system without any water is strictly forbidden.

VARIABLE SPEED CIRCULATION UNIT

The modulating circulating function is only active for the heating function. When switching the three ways on the plate heat exchanger, the circulation unit is set at maximum speed. The modulating circulation function applies only to the boiler circulation unit and not to circulation units on any external devices connected to it (e.g. booster circulation unit). Any of 4 operating modes can be chosen, depending on situations and the type of plant. By accessing parameter 90 in the technical menu, one of the following possibilities can be chosen:

1 - VARIABLE SPEED CIRCULATION UNIT WITH

PROPORTIONAL MODE (41 <= P90 <= 90)

2 - VARIABLE SPEED CIRCULATION UNIT WITH

CONSTANT DT MODE (2 <= P90 <= 40)

3 - VARIABLE SPEED CIRCULATION UNIT WITH MAXIMUM

FIXED MAXIMUM SPEED MODE (P90 = 1)

4 - EXCEPTIONAL USE OF A STANDARD CIRCULATION

UNIT WITHOUT SPEED ADJUSTMENT (P90 = 0)

1 - VARIABLE SPEED CIRCULATION UNIT WITH PROPORTIONAL MODE (41 <= P90 <= 90)

In this mode the boiler’s board determines what flow rate curve to adopt according to the instantaneous power supplied by the boiler. The boiler controller breaks down the power range within which the boiler operates in heating mode into various levels. Depending on the power level in use when heating, one of the speeds available is selected automatically according to a linear logic: Maximum power = high speed, minimum power = low speed. This is used on all types of plants where the machine’s power has been correctly balanced with the plant’s real needs.

Operationally:

- Access parameter 90

- Set the parameter = 41 Note: The parameter 90 = 41 setting is recommended by the manufacturer. Values exceeding 41 are used in specific cases.

2 - VARIABLE SPEED CIRCULATION UNIT WITH CONSTANT DT MODE (2 <= P90 <= 40)

In this mode the installer sets the ΔT value to be maintained between the delivery and return (e.g. if a value of 10 is entered, the circulation unit’s speed will change to implement a plant flow rate aimed at maintaining the ΔT between upstream and downstream of the heat exchanger at 10°C). By periodically sampling the values provided by the boiler delivery/ return sensors, the board increases or decreases the circulation unit’s speed and therefore the plant’s flow rate. If the sampling shows a ΔT value lower than that set, the speed is reduced until the ΔT increases to the value set. Vice-versa is sampling is higher than the value set, the speed is increased. This is used for direct high temperature plants (typical of replacement), where the boiler is not thermostatically controlled, and where a calculated ΔT can be set. When working with a constant delivery temperature and attainment of stabilising the ambient conditions, the average temperature of the

2.12 Range rated (parameter 23) Input fan speed (rpm) CO (ppm) - less than

8 kW 1500 35 10 kW 1750 55 12 kW 2100 75 14 kW 2400 92 16 kW 2750 110 18 kW 3100 130 20 kW 3400 140 22 kW 3650 155 24 kW 4050 170 26 kW 4400 180 28 kW 4700 190 30 kW 5000 200

Key Location Minimum distance

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

F Below balcony, car-port roof, etc. 25 mm G To the side of a soil/drain-pipe, etc. 25 mm (60mm for 80/125 - 5” flue) H From internal/external corner 25 mm (60mm for 80/125 - 5” flue)

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

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

P From a structure to the side of the vertical terminal 300 mm

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

of the vertical terminal

R To the side of a boundary 300 mm

S To the side of an opening or window on a pitched roof 600 mm T Below an opening or window on a pitched roof 2000 mm V From a vertical terminal to an adjacent opening (window, air-brick, etc.) (call Vokera technical for advice)

W From a vertical terminal to an adjacent vertical terminal 300 mm (only if both terminals are the same hight)

Fig. 4

radiators tends to increase. By keeping ÄT constant, the reduction in the flow rate is obtained by changing the operating curve, which produces a lower return temperature that in turn favours high boiler performance and the reduction of electricity consumption. Operationally:

- Access parameter 90

- Set the parameter at a value between 2 and 40 (normally between 10 and 20).

3 - VARIABLE SPEED CIRCULATION UNIT WITH MAXIMUM FIXED MAXIMUM SPEED MODE (P90 = 1)

In this mode the modulating circulation unit works constantly at maximum speed. It is used on plants with a high load loss in which the boiler’s head must be used as much as possible in order to guarantee sufficient circulation (plant flow rate at maximum speed lower than 600 litres per hour). This is used when bottles of mixture are involved, with high flow rates in the circuit downstream. Operationally:

- Access parameter 90

- Set the parameter = 1

4 – EXCEPTIONAL USE OF A STANDARD CIRCULATION UNIT WITHOUT SPEED ADJUSTMENT (P90 = 0)

This mode must be used in exceptional cases in which the boiler is to be used with a traditional circulation unit without a speed adjustment. It presupposes that the adjustable speed circulation unit has been removed and replaced with a non-adjustable speed circulation unit. Warning !!!! the BE06 board connected to

connector CN9 must be removed and replaced with a connector with a jumper to be inserted into connector CN9. This latter connection is obligatory and if not formed may cause the system to malfunction. Operationally:

- Access parameter 90

- Set the parameter = 0

HIGH

TEMPERATURE

(radiators)

LOW

TEMPERATURE

(floor)

ΔT constant (2  P90  40)

EXTERNAL SENSOR YES

(TERMOREGULATION)

PROPORTIONAL (P90 = 41)

EXTERNAL SENSOR NO

(NO TERMOREGULATION)

PROPORTIONAL (P90 = 41)

CONFIGURATIONS RECOMMENDED BY THE MANUFACTURER

SECTION 3 - GENERAL REQUIREMENTS (UK)

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

3.1 RELATED DOCUMENTS

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

3.2 LOCATION OF APPLIANCE

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

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

3.3 GAS SUPPLY

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

3.4 FLUE SYSTEM

The terminal should be located where the dispersal of combustion products is not impeded and with due regard for the damage and discoloration that may occur to building products located nearby. The terminal must not be located in a place where it is likely to cause a nuisance (see fig. 4). In cold and/or humid weather, water vapour will condense on leaving the terminal; the effect of such pluming must be considered. If installed less than 2m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material.

BS 5440 PART 1 FLUES BS 5440 PART 2 FLUES & VENTILATION BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW BS 6891 LOW PRESSURE INSTALLATION PIPES BS 7074 PART 1 APPLICATION, SELECTION, AND INSTALLTION OF EXPANSION VESSELS

AND ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS

The guard must be fitted centrally over the terminal. Refer to BS 5440 Part 1, when the terminal is 0.5 metres (or less) below plastic guttering or 1 metre (or less) below painted eaves.

3.5 AIR SUPPLY

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

3.6 WATER CIRCULATION

Detailed recommendations are given in BS 5449 Part 1 and BS

6798. The following notes are for general guidance only.

3.6.1 PIPEWORK

It is recommended that copper tubing to BS 2871 Part 1 is used in conjunction with soldered capillary joints. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and that water flows naturally to drain cocks. Except

where providing useful heat, pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing. Particular attention should be paid to pipes passing through ventilated areas such as under floors, loft space and void areas.

3.6.2 AUTOMATIC BY-PASS

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

3.6.3 DRAIN COCKS

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

3.6.4 AIR RELEASE POINTS

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

3.6.5 EXPANSION VESSEL

The appliance has an integral expansion vessel to accommodate the increased volume of water when the system is heated. It can accept up to 8 litres of expansion from within the system, generally this is sufficient, however if the system has an unusually high water content, it may be necessary to provide additional expansion capacity (see 6.18).

3.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. directly from the mains supply, is provided (see fig. 5). This method of filling complies with the current Water Supply (Water Fittings) Regulations 1999 and Water Bylaws 2000 (Scotland). If an alternative location is preferred, it should be connected as detailed in fig. 5.

3.6.7 LOW PRESSURE SEALED SYSTEM

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

Make-up vessel or tank

Automatic air-vent

Non-return

valve

Stopcock

5.0 metres minimum

Heating return

Fig. 5

Fig. 6

Fig. 6A

Fig. 6B

Default screws position of fixing jig: No. 3

3.6.8 FREQUENT FILLING

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

3.7 ELECTRICAL SUPPLY

The appliance is supplied for operation on 230V @ 50Hz electrical supply; it must be protected with a 3-amp fuse. The method of connection to the mains electricity supply must allow for complete isolation from the supply. The preferred method is by using a double-pole switch with a contact separation of at least 3,5mm (3° high-voltage category). The switch must only supply the appliance and its corresponding controls, i.e. time clock, room thermostat, etc. Alternatively an un-switched shuttered socket with a fused 3-pin plug both complying with BS 1363 is acceptable.

3.8 TIMBER FRAMED BUILDINGS

If the appliance is to be fitted in a timber framed building, it should

be fitted in accordance with the Institute of Gas Engineers publication (IGE/UP/7) ‘Guide for Gas Installations in Timber Frame Buildings’.

3.9 INHIBITORS

Vokèra recommend that an inhibitor - suitable for use with aluminium heat exchangers - is used to protect the boiler and system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers instructions*. *Water treatment of the complete heating system - including the boiler - should be carried out in accordance with BS 7593 and the Domestic Water Treatment Association’s (DWTA) code of practice.

3.10 SHOWERS

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

Hot water outlet

Cold water inlet

stopcock/filling

valve

Gas

cock

Filling loop

C/H flow

valve

C/H return

valve

Safety

valve outlet

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

3A.1 RELATED DOCUMENTS

The installation of this boiler must be in accordance with the relevant requirements of the local building regulations, the current ETCI National Rules for Electrical Installations and the bylaws of the local water undertaking. It should be in accordance also with any relevant requirements of the local and/or district authority.

3A.2 LOCATION OF APPLIANCE

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

3A.3 GAS SUPPLY

The gas meter – as supplied by the gas supplier – must be checked to ensure that it is of adequate size to deal with the maximum rated input of all the appliances that it serves. Installation pipes must be fitted in accordance with I.S. 813. Pipe work from the meter to the appliance must be of adequate size. Pipes of a smaller size than the appliance gas inlet connection must not be used. The installation must be tested for tightness in accordance with I.S. 813. If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time.

3A.4 FLUE SYSTEM

The terminal should be located where the dispersal of combustion products is not impeded and with due regard for the damage and discoloration that may occur to building products located nearby. The terminal must not be located in a place where it is likely to cause a nuisance (see I.S. 813). In cold and/or humid weather, water vapour will condense on leaving the terminal; the effect of such pluming must be considered. If installed less than 2m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material. The guard must be fitted centrally over the terminal. Refer to I.S. 813, when the terminal is 0.5 metres (or less) below plastic guttering or 1 metre (or less) below painted eaves.

3A.5 AIR SUPPLY

3A.6 WATER CIRCULATION

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

3A.6.1 PIPEWORK

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

SECTION 3A - GENERAL REQUIREMENTS (EIRE)

3A.6.2 AUTOMATIC BY-PASS

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

3A.6.3 DRAIN COCKS

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

3A.6.4 AIR RELEASE POINTS

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

3A.6.5 EXPANSION VESSEL

3A.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. is provided (

see fig. 5). You should ensure this

method of filling complies with the local water authority regulations.

3A.6.7 LOW PRESSURE SEALED SYSTEM

3A6.8 FREQUENT FILLING

3A.7 ELECTRICAL SUPPLY

The appliance is supplied for operation on 230V @ 50Hz electrical supply; it must be protected with a 3-amp fuse. The method of connection to the mains electricity supply must allow for complete isolation from the supply. The preferred method is by using a double-pole switch with a contact separation of at least 3,5 mm (3° high-voltage category). The switch must only supply the appliance and its corresponding controls, i.e. time clock, room thermostat, etc.

3A.8 TIMBER FRAMED BUILDINGS

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

3A.9 INHIBITORS

Vokèra recommend that an inhibitor - suitable for use with aluminium heat exchangers - is used to protect the boiler and system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers instructions*. *Water treatment of the complete heating system - including the boiler - should be carried out in accordance with I.S. 813 and the Domestic Water Treatment Association’s (DWTA) code of practice.

3A.10 SHOWERS

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

3A.11 DECLARATION OF CONFORMITY

A Declaration of Conformity (as defined in I.S. 813) must be provided on completion of the installation. A copy of the declaration must be given to the responsible person and also to the gas supplier if required.

4.1 DELIVERY

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

4.2 CONTENTS

Contained within the carton is:

• the boiler

• the wall bracket & fixing jig

• template

• carton template

• an accessories pack containing appliance service connections

and washers

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

4.3 UNPACKING

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

4.4 PREPARATION FOR MOUNTING THE APPLI-

ANCE

The appliance should be mounted on a smooth, vertical, noncombustible surface, which must be capable of supporting the full weight of the appliance. Care should be exercised when determining the position of the appliance with respect to hidden obstructions such as pipes, cables, etc. When the position of the appliance has been decided – using the template supplied – carefully mark the position of the wall-mounting bracket and flue-hole (if applicable). If you intend to run the pipe-work vertically behind the boiler, move

the screws on the fixing jig from the default position (No. 3) to position No. 5. You will also require a spacer kit, part No. 435 (see 4.6).

4.5 FITTING THE FLUE

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

4.5.1 CONCENTRIC HORIZONTAL FLUE

(For concentric vertical flue, see 4.5.2). (For twin flue applications, see 4.5.3). The appliance can be used with either the Vokèra condensing 60/ 100mm concentric flue system or the optional 80/125mm concentric flue system.

NOTE

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

Reduction for additional bends

Bend Reduction in maximum flue length for each bend

45º bend 0.5 metre

90º bend 1.0 metre

SECTION 4 - INSTALLATION

FITTING THE HORIZONTAL FLUE KIT

Carefully measure the distance from the centre of the appliance flue outlet to the edge of the finished outside wall (dimension X). Add 65mm to dimension X to give you Dimension Y (see fig 7B). Measure dimension Y from the terminal end of the concentric flue pipe and cut off the excess ensuring any burrs are removed. Pass the concentric flue pipe through the previously drilled hole. Fit the flue bend to the boiler flue outlet and insert the concentric flue pipe into the flue bend ensuring the correct seal is made. Using the clamp, gasket, and screws supplied, secure the flue bend to the appliance flue spigot.

NOTE

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

Fig. 7

Terminal or extension

Outer clamps

“X”

Fig. 7A

Horizontal flue terminals and accessories

Part No. Description Length

29450120 Horizontal flue kit 900mm 29450121 Telescopic flue kit 350/530mm

522 Plume management kit 1370mm 29450123 90-degree bend N/A 29450124 45-degree bends (pair) N/A 29450125 500mm extension 500mm 29450126 1000mm extension 1000mm 29450127 2000m extension 2000mm 29450128 Telescopic extension 350/730mm 529 Wall bracket pack (5) 208mm

Using the template provided, mark and drill a 115mm level hole for the passage of the flue pipe. Note that if extending the flue, the hole should be drilled at a higher position taking into account the 1-3 degree fall back of extension pipes (fig.7A). The fixing holes for the wall-mounting bracket/fixing jig should now be drilled and plugged, an appropriate type and quantity of fixing should beused to ensure that the bracket is mounted securely. Once the bracket has been secured to the wall, mount the appliance onto the bracket.

30mm

1-3 degree

“Y”

0 degree

“X” + 65mm = “Y”

Fig. 9

“X”

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

“X”

28/32/36 HE = 218 mm

“X”

Fig. 8

EXTENDING THE FLUE

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

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (see fig. 7-

8). Remove any burrs, and check that all seals are located properly. You must ensure that the entire flue system is properly supported and connected. Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The interior and exterior trim can now be fitted.

4.5.2 CONCENTRIC VERTICAL FLUE

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

NOTE

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

Reduction for bends Bend Reduction in maximum flue length for each bend

45º bend 0.5 metre 90º bend 1.0 metre

Vertical flue terminal and accessories Part No. Description Length

29450122 Vertical flue terminal 1000mm 531 Pitched roof flashing plate N/A 532 Flat roof flashing plate N/A

29450123 90-degree bend N/A

29450124 45-degree bends (pair) N/A

29450125 500mm extension 500mm

29450126 1000mm extension 1000mm

29450127 2000mm extension 2000mm

29450128 Telescopic extension 350/730mm 529 Wall bracket pack (5) 208mm

Using the dimensions given in fig. 7A as a reference, mark and cut a 125mm hole in the ceiling and/or roof.

Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing. The fixing holes for the wall-mounting bracket should now be drilled and plugged, an ‘appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely. Once the bracket has been secured to the wall, mount the appliance onto the bracket.

IMPORTANT

The vertical flue terminal is 1.0 metre in length and cannot be cut; therefore it may be necessary to adjust the height of the appliance to suit or use a suitable extension. Connect the vertical flue assembly to the boiler flue spigot using the 100mm clip, gasket & screws (supplied), ensuring the correct seal is made. The flue support bracket (supplied with the vertical flue kit) can now be fitted. If the vertical flue requires extension/s or additional bend/s, connect the required number of flue extensions or bends (up to the maximum equivalent flue length) between the boiler and vertical flue assembly. Ensure that any horizontal sections of the flue system have a minimum 1º; maximum 3º fall back to the boiler (1º = 17mm per 1000mm).

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension. Remove any burrs, and check that any seals are located properly. You must ensure that the entire flue system is properly supported and connected.

4.5.3 TWIN FLUE SYSTEM

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

GUIDANCE NOTES ON TWIN FLUE INSTALLATION

• The flue must have a have a minimum 1º; maximum 3º (1º = 17mm per 1000mm) fall back to the appliance to allow any condensate that may form in the flue system to drain via the condensate drain.

X= Measured distance from flue spigot to hole drilled

Y= Measured hight from bracket to centre of hole drilled

X= terminal only X= 2m X= 3m X= 3.85 m

min 114mm 132mm 149mm 164mm

max 114mm 166mm 219mm 265mm

Fig. 7B

Consideration must also be given to the fact that there is the possibility of a small amount of condensate dripping from the terminal.

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

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

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

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

Reduction for bends

Bend Reduction in maximum flue length for

each bend

45º bend 1.0 metre 90º bend 1.0 metre

Twin flue accessories Part No. Description Length

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

MOUNTING THE BOILER

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

INSTALLATION OF TWIN ADAPTOR KIT (fig. 10 & 11)

• Insert the exhaust connection manifold (A) onto the appliance flue outlet.

• Remove the blanking plate (located to the left of the appliance flue outlet) and – using the same screws – install the air inlet plate (B).

• Using the hole in the exhaust connection manifold as a guide, drill a 3mm hole in the appliance flue spigot and secure the exhaust manifold connection to the flue spigot using the screw provided (C).

• Using the two holes in the air inlet plate as a guide, drill a 3mm hole in each and secure the air inlet pipe/bend using the screws provided.

The twin flue pipes extensions and accessories 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).

Fig. 10

Fig. 11

HORIZONTAL TERMINATION (fig. 12)

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

• The horizontal terminal is supplied with a built-in converter box and cannot be shortened.

• A 130mm hole is required for the passage of the concentric terminal through the wall.

• The air inlet pipe must always be level with or below, that of the exhaust pipe.

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

Mark and drill a level 130mm hole for the passage of the horizontal flue terminal. 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

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.

VERTICAL TERMINATION (fig. 13)

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

• The vertical terminal is supplied with a built-in converter box and cannot be shortened.

• A 130mm hole is required for the passage of the concentric terminal through the ceiling and/or roof.

Depending on site conditions it may be preferable to install the terminal assembly prior to fitting the twin flue pipes. Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing. Push-fit the twin flue pipes onto the concentric to twin converter ensuring that the exhaust pipe connects to the exhaust connection on the concentric to twin converter. If necessary cut the plain ends (male) of the twin flue pipes to allow connection to the concentric to twin converter.

NOTE

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

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

• Ensure that any horizontal sections of pipe have a 1º fall towards the appliance (17mm per 1000mm).

Fig. 13

Fig. 14

Hot water outlet

Cold water inlet

stopcock/filling

valve

Gas

cock

Filling loop

C/H flow

valve

C/H return

valve

Safety

valve outlet

Fig. 12

4.6 CONNECTING THE GAS AND WATER

IMPORTANT - REAR SPACER KIT

If you intend to run the pipework vertically behind the appliance, it will be necessary to use the rear spacer kit (part code

435). It will also be necessary to adjust the pitch of the fixing jig to compensate for the increase in the depth of the appliance. The appliance is supplied with a fixing jig that includes service valves (fig. 14). The service valves are of the compression type. The accessories pack contains sealing washers etc, for use with the service valves. When connecting pipe work to the valves, tighten the compression end first then insert the sealing washers before tightening the valve to the appliance.

The appliance is supplied with an accessory pack that includes service valves. The service valves are for welding. The accessory pack contains sealing washers’ etc, for use with the service valves.

NOTE

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

4.6.1 GAS (fig. 14)

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

NOTE

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

4.6.2 FLOW & RETURN (fig. 14)

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

NOTE

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

4.6.3 COLD WATER INLET (fig. 14)

The appliance is supplied with a 15mm combined stopcock and double check-valve, connect a 15mm pipe to the inlet of the stopcock and tighten both nuts.

4.6.4 HOT WATER OUTLET (fig. 14)

The appliance is supplied with a 15mm outlet connection, connect a 15mm pipe to the outlet connection and tighten both nuts.

4.6.5 SAFETY VALVE (fig. 14)

Connect a discharge pipe to the fixing jig connection and tighten. The discharge pipe must have a continuous fall away from the appliance to outside and allow any water to drain away thereby eliminating the possibility of freezing. The discharge pipe must terminate in a position where any water – possibly boiling – discharges safely without causing damage or injury, but is still visible.

4.6.6 CONDENSE PIPE

During normal operation the boiler produces condense which is collected in a trap located in the lower part of the boiler. A flexible pipe (condense outlet pipe) is connected to the outlet of the trap. The flexible pipe must be connected to a plastic waste pipe only. The plastic waste pipe must have a minimum of a 3º fall towards the drain. Any external run of pipe should be insulated to prevent the risk of freezing.

CONNECTING THE CONDENSATE OUTLET

Gently pull the condense outlet pipe down from its location inside the boiler until it protrudes from the underside of the boiler. Connect a suitable plastic (not copper) pipe (no less than 20mm diameter) to the outlet pipe and ensure it discharges in accordance with building regulations or other rules in force (see fig. 15A for examples).

4.6.7 CONNECTING THE CONDENSATE OUTLET

Gently pull the condense outlet pipe down from its location inside the boiler until approximately 100mm protrudes from the underside of the boiler. Connect a suitable plastic (not copper) pipe (no less than 20mm diameter) to the outlet pipe and ensure it discharges in accordance with building regulations or other rules in force.

4.7 ELECTRICAL CONNECTIONS

The electrical supply must be as specified in section 3/3A. A qualified electrician should connect the electrical supply to the appliance. If controls – external to the appliance – are required, a competent person must undertake the design of any external electrical circuits, please refer to section 8 for detailed instructions. ANY EXTERNAL CONTROL OR WIRING MUST BE SERVED FROM THE SAME ISOLATOR AS THAT OF THE APPLIANCE. The supply cable from the isolator to the appliance must be 3-core flexible sized 0.75mm to BS 6500 or equivalent. Wiring to the appliance must be rated for operation in contact with surfaces up to 90 °C.

4.7.1 CASING REMOVAL (fig. 15)

Remove transit screws C once the boiler has been mounted on the wall. To gain internal access to the appliance you must first remove the casing, proceed as outlined below:

- locate and remove the screw A;

- remove the cover from the underside of the appliance casing;

- locate and remove the 2 screws B located at the Left & Right of the

underside of the casing;

- lift the casing upward to disengage it from the top locating hooks and then remove;

- store the casing and screws safely until required. Re-fit in the reverse order.

4.7.2 APPLIANCE TERMINAL BLOCK

The appliance terminal block is located on the rear of the control fascia. Remove the casing as described in 4.7.1. Lift the control fascia upward and lower it. Locate the terminal block covers (see fig. 16).

NOTE

The appliance comes with a factory fitted link to allow basic operation of the boiler via the mode selector switch. If it is anticipated that external controls will be required please refer to the wiring diagrams in section 8 for more detailed information.

4.7.3 CONNECTING THE MAINS (230V) INPUT (see fig. 17)

Locate and remove the screw securing the right terminal block cover (230V). Pass the cable through the cable anchorage point. Connect the supply cable wires (LIVE, and NEUTRAL) to their corresponding terminals on the appliance terminal block. Connect the EARTH wire to the EARTH block (see fig. 17) ensuring that it’s

left slightly longer that the others, this will prevent strain on the EARTH wire should the cable become taut. Do not remove the link wire unless additional external controls are to be fitted (see section 8). The securing screw on the cable anchorage should now be tightened. This must be done before the control fascia is re-fitted in the upright position. The appliance casing, screws, and lower cover can now be re-fitted.

Fig. 15

cover

Fig. 16

Optional de-

vices (24V)

terminal block

Mains (230V)

terminal block

Fig. 17

link

wire

ME3

ME6

Fig. 15A

5.1 GAS SUPPLY INSTALLATION

Inspect the entire installation including the gas meter, test for tightness and purge. Refer to BS 6891 for specific instruction

5.2 THE HEATING SYSTEM

The appliance contains components that may become damaged or rendered inoperable by oils and/or debris that are residual from the installation of the system, consequently it is essential that the system be flushed in accordance with the following instructions.

5.3 INITIAL FILLING OF THE SYSTEM

Ensure both flow and return service valves are open, remove appliance casing as described in 4.7.1, identify the automatic air release valves (AAV) and loosen the dust cap/s by turning the cap anti-clockwise one full turn.

IMPORTANT, THERE ARE NO MANUAL AIR RELEASE VALVES LOCATED ON THE APPLIANCE. Ensure all manual air release valves located on the heating system are closed.

Connect the filling loop as shown in fig. 3, slowly proceed to fill the system by firstly opening the inlet valve connected to the flow valve, and then turning the lever on the combined stopcock and check valve, to the filling position (see fig. 18). As water enters the system the pressure gauge will begin to rise. Once the gauge has reached 1 BAR close both valves and begin venting all manual air release valves, starting at the lowest first. It may be necessary to go back and top-up the pressure until the entire system has been filled. Inspect the system for water tightness, rectifying any leaks.

5.4 INITIAL FLUSHING OF THE SYSTEM

The whole of the heating system must be flushed both cold and hot as detailed in 5.8. Open all radiator or heating valves and the appliance flow & return service valve. 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 5.3.

5.5 FILLING THE HOT WATER SYSTEM

Close all hot water outlets, turn appliance stopcock to the normal operating position (fig. 18), slowly open each outlet until air has been expelled and clear water is discharged. Check pipe-work etc. for water tightness.

5.6 PRE-OPERATION CHECKS

Before attempting the initial lighting of the appliance, the following checks must be carried out:

- ensure all gas service valves from the meter to the appliance are open and the supply pipe has been properly purged;

- ensure the proper electrical checks have been carried out, (see

7.8) particularly continuity, polarity, and resistance to earth;

- ensure the 3 AMP fuse – supplied with the appliance – has been fitted;

- ensure the system has been filled, vented, and the pressure set to 1 BAR;

- ensure the flue system has been fitted properly and in accordance with the instructions;

- ensure all appliance service valves are open.

5.7 INITIAL LIGHTING

Ensure the electrical supply to the appliance is switched on. Press the ON/OFF switch to switch the appliance ON (indicated by active display), ensure any external controls are switched to an ‘ON’ position and are calling for heat.

After being powered, the boiler begins an automatic vent cycle lasting approximately 2 minutes. The display indicates “sf” and the “function selection indicators” light up in sequence. Press the MODE button to interrupt the automatic vent cycle.

Press the heating button, the appliance will now operate in the

Winter

mode as described in 1.2. Should the appliance fail to ignite, refer to 5.6 and/or section 7 (mode of operation, parameter setting, & faultfinding).

5.7.1 CHECKING GAS PRESSURE AND COMBUSTION ANALYSIS

The appliance is factory set and requires no additional adjustment once installed.However to satisfy the requirements of GSIUR 26/9 (I.S. 813 ROI), it will be necessary togas rate the appliance using the gas meter that serves the appliance.If the installation does not include a gas meter (for example LPG) and there are nomeans by which to calculate the gas rate, then a combustion analysis test must becarried out in accordance with BS 7967 (UK) to ensure the appliance is left workingsafely and correctly.Additionally, if the gas valve has been adjusted, replaced, or the appliance has beenconverted for use with another gas type, then it becomes necessary to carry out acombustion analysis/check to ensure that correct combustion is occurring.If there are no means to gas rate the appliance and/or carry out a combustion analysischeck, then it will not be possible to complete the commissioning procedure. Details on how to carry out the combustion analysis can be found in section 7.

IMPORTANT

It’s imperative that a sufficient dynamic – gas – pressure is maintained at all times.Should the dynamic gas pressure fall below an acceptable level, the appliance maymalfunction or sustain damage

5.8 FINAL FLUSHING OF THE HEATING SYSTEM

The system shall be flushed in accordance with BS 7593. Should a cleanser be used, it must be suitable for Copper and Aluminium heat exchangers. It shall be from a reputable manufacturer and shall be administered in strict accordance with the manufacturers’ instructions and the DWTA code of practice.

NOTE

Chemicals used to cleanse the system and/or inhibit corrosion must be pH neutral, i.e. they should ensure that the level of the pH in the system water remains neutral. Premature failure of certain components can occur if the level of pH in the system water is out-with normal levels.

5.8.1 INHIBITORS

See Section 3 “General Requirements”.

5.9 SETTING THE BOILER OPERATING TEMPERATURE

The flow outlet temperature can be adjusted between 39 °C - 80 °C via the “Heating temperature adjustment button” (see fig.2).

5.9.1 SETTING THE DOMESTIC HOT WATER TEMPERATURE

The DHW outlet temperature can be adjusted between 35 °C - 60 °C via the “DHW temperature adjustment button” (see fig. 2).

5.9.2 INFORMATION MODE

By pressing the

key, the InFO word appears on display. By turning the selector A, the display shows, one by one, the information described below.

Info list (fig. 19)

Info 1 displays the external temperature recorded by the probe,

only if an external probe is connected

Info 2 displays the system pressure, accompanied by the filling

symbol

normal operating position

filling position

closed position

Fig. 18

SECTION 5 - COMMISSIONING

Info 3 displays the set heating temperature Info 4 displays the set domestic hot water temperature.

If you don’t make any selection within 10 seconds, the boiler automatically exits the function; if you want to exit immediately, press the

key.

5.9.3 INFORMATION MODE SERVICE

It is possible to display information that can be helpful for the Service Engineer. Press for 10 seconds the button : the INF2 will be displayed. Every pressing corresponds to a different information.

5.9.4 ADJUSTING APPLIANCE PARAMETERS

The appliance is delivered with pre-set parameters. Some parameters can be changed or adjusted if required. For further details, please refer to section 7.

5.10 SETTING THE SYSTEM DESIGN PRESSURE

The design pressure should be a minimum of 0.5 BAR and a maximum of 1.5 BAR. The actual reading should ideally be 1 BAR plus the equivalent height in metres (0.1 BAR = 1 metre) to the highest point in 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 3 BAR/30 metres/45 psig. To lower the system pressure to the required value, drain off some water from the appliance drain valve until the required figure registers on the pressure gauge (see fig. 1).

Fig. 19

Step Description Unit

01 Temperature at flow sensor °C 02 Temperature at return sensor °C 03 Temperature at hot water outlet sensor °C 04 Unused 05 Unused 06 Unused 07 Flow meter speed lt/min 08 Fan speed/100 rpm

10-17 Historical alarms

18 Time metering cleaning heat exchanger

Lista INF2

5.11.1 CHANGING THE FLOW RESTRICTOR

Refer to 6.17 for detailed instruction on changing the flow restrictor.

5.11.2 REGULATING THE CENTRAL HEATING SYSTEM

Fully open all radiator and circuit valves and run the appliance for both heating and hot water until heated water is circulating. If conditions are warm remove any thermostatic heads. Adjust radiator return valves and any branch circuit return valves until the individual return temperatures are correct and are approximately equal.

5.12 FINAL CHECKS

- ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS VALVE ARE TIGHT AND CHECKED FOR TIGHTNESS.

- ENSURE THE APPLIANCE FLUE SYSTEM IS FITTED CORRECTLY AND IS PROPERLY SECURED.

- ENSURE ALL PIPE WORK IS RE-CHECKED FOR TIGHTNESS.

- RE-FIT APPLIANCE CASING.

- COMPLETE BENCHMARK CHECKLIST.

FOR UK ONLY

Complete details of the boiler, controls, installation and commissioning in the Benchmark checklist at the back of this book. It is important that the Benchmark checklist is correctly completed and handed to the user. Failure to install and commission the appliance to the manufacturers instructions may invalidate the warranty.

5.13 INSTRUCTING THE USER

Hand over all documentation supplied with this appliance – including these instructions – and explain the importance of keeping them in a safe place. Explain to the user how to isolate the appliance from the gas, water and electricity supplies, and the locations of all drain points. Show the user how to operate the appliance and any associated controls correctly. Show the user the location of the filling valve and how to top-up the system pressure correctly and show the location of all manual air release points. Explain to the user how to turn off the appliance for both long and short periods and advise on the necessary precautions to prevent frost damage. Explain to the user that for continued safe and efficient operation, the appliance must be serviced annually by a competent person.

IMPORTANT

To validate the appliance warranty, it’s necessary to register the appliance details with us. The warranty can be registered in several ways:

- by completing the warranty registration card and posting to us using the pre-paid envelope supplied

- online at: vokera.co.uk

- for UK residents by calling: 0844 391 0999

- for ROI residents by calling: 1850 221121.

13-litre 14-litre 15-litre

(olive) (pink) (green) Spare Fitted Spare

Linea ONE

5.11 REGULATING THE HOT WATER

The appliance is fitted with a flow rate restrictor that limits the maximum flow rate that can be drawn through the appliance. The restrictor eliminates the need to manually adjust the DHW flow rate. However if it is felt necessary to further increase or decrease the available flow rate, spare restrictors are included in the accessory pack. The spare flow rate restrictors can be fitted to either increase or decrease the maximum flow rate. The tables overleaf denote the size of restrictor fitted and the spare restrictors supplied in the accessory pack. Each restrictor is colour-coded to enable identification.

6.1 GENERAL

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

To ensure correct and safe operation of the appliance, it is essential that any worn or failed component be replaced only with a genuine Vokera spare part. It should be remembered that although certain generic components may look similar, they will be specific to an individual appliance or product range. Use of non-genuine Vokera spare parts could invalidate your warranty and may pose a potential safety hazard. The frequency of servicing will depend upon the particular installation conditions, but in general, once per year should be sufficient. It is the law that any servicing work is carried out by competent person such as a Vokera engineer, an approved service agent, British Gas, GAS SAFE registered personnel or other suitably qualified personnel. The following instructions apply to the appliance and its controls, but it should be remembered that the central heating and the domestic hot water systems would also require attention from time to time.

6.2 ROUTINE ANNUAL SERVICING

- Check the operation of the appliance and ensure it functions as described in section 7.

- Compare the performance of the appliance with its design specification. The cause of any noticeable deterioration should be identified and rectified without delay.

- Thoroughly inspect the appliance for signs of damage or deterioration especially the flue system and the electrical apparatus.

- Check and adjust – if necessary – all burner pressure settings (see 7.4).

- Check and adjust – if necessary – the system design pressure (see 5.10).

- Carry out an analysis of the flue gases (see 7.5), and visually check the condition of the entire flue assembly.

- Compare the results with the appliance design specification. Any deterioration in performance must be identified and rectified without delay.

- Check that the burner and main heat exchanger are clean and free from any debris or obstruction.

- Check and clean – if necessary – the condense trap to ensure correct operation.

6.3 REPLACEMENT OF COMPONENTS

Although it is anticipated that this appliance will give years of reliable, trouble free service, the life span of components will be determined by factors such as operating conditions and usage. Should the appliance develop a fault, the fault finding section will assist in determining which component is malfunctioning.

6.4 COMPONENT REMOVAL PROCEDURE

To remove a component, access to the interior of the appliance is essential. Isolate the appliance from the electrical supply and remove the fuse. And when necessary, close all service valves on the appliance, remove the appliance casing as described in section 4.7.1 and drain the water content from the appliance via the drain valve. Ensure some water absorbent cloths are available to catch any residual water that may drip from the appliance or removed component. Undertake a complete commissioning check as detailed in section 5, after replacing any component. ALWAYS

TEST FOR GAS TIGHTNESS IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED OR DISTURBED.

6.4.1 AIR BOX FRONT COVER REMOVAL (fig. 21)

Locate the two clips and remove air box front cover. If necessary to remove the air box side cover, locate and remove the 4 screws.

6.5 PUMP ASSEMBLY (fig. 22)

Carry out component removal procedure as described in 6.4. Locate and remove the 2 securing screws (A) at the rear of the pump assembly. Disconnect the flow pipe (B) from the combustion chamber connection, slacken the pipe at the hydraulic assembly and swing/rotate clear of the pump assembly. Disconnect and remove the pump outlet pipe (C) from the pump assembly/ combustion chamber connection. Remove the expansion pipe locking pin from the top of the pump assembly and withdraw the flexible pipe (D). Disconnect the electrical wiring from the pump’s electrical connection point (E). Remove locking pin (F) from pump base and lift pump assembly clear of the hydraulic manifold. The pump assembly can now be removed from the appliance. Replace carefully in the reverse order.

Fig. 21

SECTION 6 - SERVICING INSTRUCTIONS

X= Measured distance from flue spigot to hole drilled

Y= Measured hight from bracket to centre of hole drilled

X= terminal only X= 2m X= 3m X= 3.85 m

min 114mm 132mm 149mm 164mm

max 114mm 166mm 219mm 265mm

Fig. 22

Fig. 20

6.6 SAFETY VALVE (fig. 23)

Carry out component removal procedure as described in 6.4. Disconnect the outlet pipe (A) from the safety valve, remove safety valve locking pin (B) from the hydraulic manifold. Replace in the reverse order.

6.7 BOTTOM AUTOMATIC AIR RELEASE VALVES (fig. 22)

Carry out component removal procedure as described in 6.4. Remove the expansion pipe locking pin (D) from the pump assembly and remove the expansion pipe. Locate and remove the AAV locking pin (G) from the pump assembly and remove the AAV assembly (H). Replace in the reverse order.

6.7.1 TOP AAV (fig. 24)

Carry out component removal procedure as described in 6.4. Remove the locking pin (A). Unscrew the top AAV (B). Replace in the reverse order.

6.8 WATER PRESSURE SENSOR AND GAUGE (fig. 23)

Carry out component removal procedure as described in 6.4. Locate and remove the locking pin (C) from the water pressure gauge assembly (D). Remove the wiring. Carefully withdraw the assembly. Replace in the reverse order.

Carry out component removal procedure as described in 6.4. Locate and remove the locking pin (E) from the water pressure sensor assembly (F). Remove the wiring. Carefully withdraw the assembly. Replace in the reverse order.

6.9 PRIMARY THERMISTOR (fig. 1)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber front cover. Unclip the primary thermistor from the flow outlet pipe. Disconnect thermistor electrical plug. Replace in the reverse order.

6.10 RETURN THERMISTOR (fig. 1)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber front cover. Unclip the return thermistor from the return inlet pipe. Disconnect thermistor electrical plug. Replace in the reverse order.

6.11 PRINTED CIRCUIT BOARD (fig. 25)

Carry out component removal procedure as described in 6.4. Lift the control fascia upward and rotate it. Locate and remove the screws (A) which secure the PCB cover, push the clips (B) and remove cover, after carefully taking note of all wiring connections, disconnect all wiring from the PCB, locate and remove the PCB securing screws, remove the required PCB. Replace in the reverse order.

6.12 GAS VALVE (fig. 14 & 26)

Carry out component removal procedure as described in 6.4. The gas valve must be changed as complete unit. Disconnect the electrical plug and leads from the gas valve, lacken and unscrew gas valve inlet (gas cock, fig. 14) and outlet (A, fig. 26) connections. Please note, the sealing washers (B) must be discarded and replaced with new sealing washers. Disconnect the compensation pipe (C). Locate and remove gas valve retaining screws (D) on the underside of the boiler if required, the gas valve can now be removed. Replace in the reverse order. Check and adjust burner pressure settings.

WARNING, A GAS TIGHTNESS CHECK MUST BE CARRIED OUT.

6.12.1 INJECTOR (fig. 26)

Carry out component removal procedure as described in 6.4. Unscrew and remove gas pipe connections (A & E). Locate and remove the injector (F) inside the pipe. Replace in the reverse order. Check and adjust burner pressure settings.

WARNING, A GAS TIGHTNESS CHECK MUST BE CARRIED OUT.

Fig. 25

Fig. 26

Fig. 24

Fig. 23

6.13 ELECTRODE & CONDENSE SENSOR (fig. 27)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber front and RH side covers. Disconnect the electrode lead and ancillary wiring from their respective connectors. Remove the 2 retaining screws (A) for electrode (B) and remove. Remove the retaining nut (C) for condense sensor (D) and remove.

6.14 FLUE FAN & MIXER (fig. 28)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber front and the RH side covers. Slacken the gas pipe (A) at the air box connection and swing/rotate of the fan assembly. To remove the mixer (B) locate and remove the three screws (C). To remove the fan (D), disconnect the electrical connections attached to the fan, locate and remove the four screws (E). Gently ease the fan from its location. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.15 BURNER (fig. 29)

internal nuts (B) which

secure the fan assembly in position (C) to the heat exchanger (D). Gently ease the fan assembly out of its location. Once the assembly has been removed, the burner (E) can be withdrawn from the heat engine. Ensure the seal (F) is in good condition, taking care to ensure it is replaced correctly. Replace in the reverse order.

6.16 MAIN HEAT EXCHANGER (fig. 30 & 31)

Carry out component removal procedure as described in 6.4. Unclip and remove the three air chamber covers (front, LH, RH sides). Disconnect all the wiring connections.

Fig. 30: Slacken the gas pipe (A) at the air box connection and swing/ rotate of the fan assembly.Disconnect the flow (B), return (C) and condense connections on the heat exchanger. Locate and remove the 4-screws that secure the heat exchanger to the combustion chamber (D). Move the heat exchanger to the right and disconnect it from the flue collector (E). The heat exchanger can now be lifted up and withdrawn from the appliance.

Fig. 31: To remove the fan burner assembly (A) locate and remove the 3

external nuts (B).

Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

Fig. 27

Fig. 28

Fig. 29

Fig. 30

6.17 FLOW RESTRICTOR (fig. 32)

Carry out the component removal procedure as described in 6.4. Disconnect the cold water inlet pipe at the DHW flow meter (A). Using a small screwdriver, gently ease the flow restrictor (B) from its seating. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.18 DHW FLOW METER (fig. 32)

Carry out component removal procedure as described in 6.4. Remove the locking pin (C). Disconnect and remove the cold water inlet pipe from the DHW flow meter & DHW heat exchanger. Disconnect the wiring to the DHW flow meter. Lacken and unscrew the inlet connection (cold water inlet stopcock, fig. 14). Unscrew the nut (D). Lift the DHW flow meter housing from its seating. If necessary remove the locking pin (E) from the DHW flow meter, taking care not to lose the float contained within the housing. It is possible to clean internally the flow meter removing the locking pin. Replace in the reverse order ensuring that the housing is firmly inserted onto its seating. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.19 DHW HEAT EXCHANGER (fig. 23)

Carry out component removal procedure as described in 6.4. Locate and remove the screws (G) that secure the heat exchanger to the DHW manifolds. Carefully remove the heat exchanger from its location taking care not to spill any residual water. Replace in the reverse order ensuring that the heat exchanger ‘O’ ring seals are correctly inserted into the DHW manifolds. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.20 VALVE ACTUATOR (fig. 33)

Carry out component removal procedure as described in 6.4. Remove the locking pin (F) that secures the actuator (G) to the heating manifold. Disconnect the electrical plug from the actuator. Replace in the reverse order.

6.21 DIVERTOR VALVE ASSEMBLY (fig. 33)

Carry out component removal procedure as described in 6.4. Remove the valve actuator as described in 6.20. Locate and re-

move the locking pin (A) that secures the valve housing cover to the hydraulic manifold. Gently prise the valve assembly from the manifold. Replace in the reverse order ensuring that the seating assembly is inserted properly. Ensure all seals are in good condition, taking care to ensure they are replaced correctly

6.22 DHW THERMISTOR (fig. 34)

Carry out component removal procedure as described in 6.4. Locate and remove the thermistor locking pin (H). Gently ease the thermistor assembly (I) from the hydraulic manifold. Replace in the reverse order.

6.23 AUTOMATIC BY-PASS & DHW NON-RETURN VALVE (fig. 34)

Carry out component removal procedure as described in 6.4. Remove the locking pin (A) that secures the cover (B) to the hydraulic manifold. Using a hooked piece of wire, carefully withdraw the by-pass cartridge (C) and/or DHW non-return cartridge (D). Ensure all seals are in good condition, taking care to ensure they are replaced correctly. Replace in the reverse order ensuring the cartridge is facing the correct way.

6.24 EXPANSION VESSEL (fig. 1)

Should the removal and replacement of the expansion vessel be deemed impractical, an external expansion vessel may be fitted to the return pipe as close to the appliance as possible.

6.24.1 EXPANSION VESSEL REMOVAL (with sufficient clearance above, fig. 22 & 35)

Carry out component removal procedure as described in 6.4. Disconnect the flue from the appliance. Disconnect the expansion vessel from the flexibleexpansion pipe. Disconnect the flexible expansion pipe from the vessel. Unscrew the nut that secures the vessel to the frame (I, fig. 22). Locate and remove the 6 screws (A, fig. 35) that secure the vessel top holding plate (B, fig. 35), remove the plate. The expansion vessel can now be removed. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.25 CONDENSE TRAP REMOVAL (fig. 36)

Carry out component removal procedure as described in 6.4. Disconnect the 2 upper rubbers condense pipe (A). Remove the pin (B) tah secures the trap to the air box plate. Disconnect the lower

Fig. 31

Fig. 32

Fig. 33

Fig. 34

rubber condense pipe (C) from the condense trap. Carefully remove the condense trap. Replace in the reverse order.

6.26 FLUE COLLECTOR REMOVAL (fig. 37)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber front and left side covers. Locate and remove the screw (A) that secures the flue gas analysis test point cover (B). Remove the clip and the fumes thermostat. Gently pull down and to the left and ease the flue collector from its location. Replace in the reverse order.

Fig. 35

Fig. 36

Fig. 37

7.1 CHECKING APPLIANCE OPERATION

When carrying out any repairs or servicing to the appliance, the relevant commissioning procedure must be undertaken to ensure the continued safe operation of the appliance. Particular attention should be made to ensure gas tightness, water tightness, and the electrical integrity of the appliance.

7.2 APPLIANCE MODES OF OPERATION NOTE

There must be sufficient system water pressure (min. 0.5 bar) to ensure the water pressure switch is activated. If there is insufficient system pressure the pump and fan will be prevented from operating and the low-pressure fault indicator will be displayed.

7.2.1 SELECTOR SWITCH IN THE OFF POSITION

When the boiler is in the STANDBY position, (see fig. 2) are displayed.

Active functions:

● Frost-protection system

● Pump anti-block

●●

● Valve actuator anti-block.

7.2.2 BOILER “ON” IN HEATING MODE

When boiler is in the

Heating

position (see fig. 2) and the appliance

is active for both heating and DHW requests. Active functions:

● DHW pre-heat

● Booster function

● Frost-protection system

● Pump anti-block

●●

● Valve actuator anti-block.

7.2.4 BOILER “OFF” IN HEATING MODE

When the function switch is in the

DHW

position, (see fig. 2) and the

appliance is active for DHW requests. Active functions:

● TSC function

● Frost-protection system

● Pump anti-block

●●

● Valve actuator anti-block.

7.2.6 APPLIANCE FUNCTIONS

●●

● Comfort button: by pressing the button, Comfort function

enables and the correspondent symbol is displayed. By pressing the

button, domestic hot water is supplied at the ideal temperature for shower; the standard temperature set is actually 40 °C. It is possible to modify Comfort temperature from 35 °C to 45 °C with a 0,5 °C correction. In order to change this temperature, after selecting the function, press the

button and turn the selector A.

The set temperature is displayed. Comfort function avoids searching for the right mix between hot and cold water in order to obtain the right temperature for shower.

Note

The value set is memorized by the boiler, so that, the next time

you select Comfort button, the boiler should be ready to supply the water at the desired temperature.

●●

● Memory key: by pressing the button, Memory function

enables and the correspondent symbol is displayed. Memory function simultaneously enables a double electronic intelligence:

• domestic hot water intelligence

• heating intelligence.

DHW Memory

By enabling Memory button, the intelligence of the machine begins to memorize the usage habits of the user. After only one week, Memory function would have already learned the user’s habits of using domestic hot water and therefore should be able to pre-heat it for each request. The pre-heating is performed in the half hour before the request made in the day and at the hour memorized the week before.

Example

Thursday 15th at 7.00 a.m. a domestic hot water request is made. Next Thursday, the 22

, at 6.30 a.m., the boiler performs the preheating of domestic hot water. When the user makes the hot water request at 7.00 a.m., finds the water already at the desired temperature. If it is necessary to have pre-heated water besides the usual habits, please use the Touch & Go function. In case the boiler lacks power supply, the data memorized by this function will be lost. When the boiler is power supplied again, Memory function restarts to memorize the habits. In order to benefit by the advantages off Memory function, you have to wait for one week to pass.

CH Memory

By enabling Memory button, the boiler takes in consideration the time that passes from ignition and after 10 minutes increases the delivery temperature memorized with 5 °C. Memory repeats the cycle until the room temperature set on the room thermostat is reached or until the maximum temperature allowed is reached. Due to this automatic function, it is possible to select lower delivery temperatures and at the same time to reduce the time for reaching the set room temperature.

●●

● SARA function: while adjusting the heating temperature, from

the minimum value 40°C to the maximum value 80°C, the field where the H.T.C. system enables is met: Heating Temperature Control (from 55°C to 65°C). The H.T.C. system autonomously manages the delivery temperature, adapting the boiler’s operation to meet the dwelling’s real needs. When the heat need extends, the delivery temperature increases allowing a faster heating of the environment. Once the desired comfort is reached, the system restores the delivery temperature to the value set at the beginning. All this assures minor consumptions, minor limestone deposits in the boiler and minor thermal ranges in the radiators.

SECTION 7 - CHECKS, ADJUSTMENTS AND FAULT FINDING

Comfort button

Memory button

SARA function

Fig. 38

●●

●

Touch & Go Function: if you don’t wish to keep the Memory function always enabled or if you need hot water to be ready fast besides the usual habits memorized, it is possible to perform the domestic hot water pre-heating only a few moments before the request. Due to Touch & Go function, by turning on and off the tap the instantaneous pre-heating function enables, which prepares hot water only for that request.

●●

● Frost-protection: this function is only active when there are no

requests for heating or HW. Should the temperature of the primary thermistor drop below 7°C, the valve actuator will motor to the heating position. Should the temperature of the primary thermistor exceed 10°C during this period, the cycle will be aborted. If the temperature drops below 4°C, the boiler will operate on minimum power until the temperature of the primary thermistor reaches 30°C. Thereafter the pump & fan will over-run for 30seconds.

●●

● Pump/actuator anti-block cycle: when there has been no

heating or HW request for 24-hours, the anti-block cycle is activated. The valve actuator will motor from the DHW position to the heating position for a period of 10-seconds and then motor back to the DHW position. Thereafter the pump will be activated for a period of 1-minute. If the selector switch is in the Heating & HW position, the fan will also be active for 1-minute.

7.2.7 HEATING MODE

Press the button to select the heating mode: the display will show boths layers. The valve actuator will motor to the heating position and the pump

and fan will be activated via the flow temperature sensor. When the fan is sensed to be operating correctly, the ignition sequence commences. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry allows 75% 0f the full gas rate through the appliance. After 15 minutes (adjustable, see parameter 28, cap. 7.3.1) the gas rate is increased to maximum (100%). The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow temperature sensor, consequently a high temperature at the flow sensor results in a lower fan speed. As the water temperature increases, the temperature sensors – located on the flow pipe of the boiler – reduce the fan speed via the electronic circuitry. Depending on the load, either the water temperature will continue to rise until the set point is achieved or the water temperature will fall whereby fan speed will increase relative to the output required. When the boiler has reached the set point, the burner will switch off. The built-in anti-cycle device prevents the burner from re-lighting for an adjustable period of time (factory default is 5 minutes). When the temperature of the flow sensor falls below the set-point, the burner will re-light.

NOTE

If the spark/sensing electrode does not sense ignition the appliance will re-attempt ignition a further 4-times then go to lockout.

When the set-point has been reached (the position of the heating temperature selector) as measured at the primary thermistor, the appliance will begin the modulation phase whereby the fan and gas valve will continuously modulate to maintain the set-point. If the temperature continues to rise and exceeds the set-point by 6°C, the burner will shut down. A new ignition sequence will be enabled when the 5-minute anti-cycle has been performed and the temperature at the primary thermistor has dropped 6°C below the set-point.

NOTES

Any DHW request will always have priority over the heating request.

When the request for heating has been satisfied, the appliance pump and fan may continue to circulate to dissipate any residual heat within

the appliance.

7.2.8 DHW MODE

Press the key to select the DHW mode: the display will show only the DHW layer. The valve actuator will motor to the HW position (if a heating request was active) and the pump and fan will be activated via the flow temperature sensor. When the fan is sensed to be operating correctly, the ignition sequence commences. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry modulates the appliance output in order to achieve the DHW setpoint (the position of the DHW temperature selector) as measured at the DHW thermistor. When the set-point has been reached, the appliance will begin the modulation phase whereby the fan and gas valve will continuously modulate to maintain the set-point. If the temperature continues to rise and exceeds the set-point by 5°C, the burner will shut down until the temperature drops to setpoint + 4°C, whereby a new ignition sequence will be enabled. If the TSC function is active the set point will be overridden until/ unless the appliance reaches the maximum operating temperature. When the request for DHW has been satisfied, the appliance fan may continue to operate to dissipate any residual heat from within the appliance.

7.2.9 ADJUSTING HEATING TEMPERATURE WITH AN EXTERNAL PROBE CONNECTED

When an external probe is connected, the value of the delivery temperature is automatically chosen by the system which rapidly adjusts the room temperature according to the variations in external temperature. The external probe symbol appears on display and just the central segment of the heating bar lights up. If you want to adjust the temperature value, by increasing or increasing it given the value automatically calculated by the electronic board, proceed as follows:

- press the heating temperature adjustment key

, the number

corresponding to the set comfort level will appear on the two digits B (standard setting)

- turn the selector A to increase or decrease the comfort level (the

number corresponding to the selected comfort level will appear on the two digits +1, +2 etc or -1, -2 etc). The illuminated segment of the heating bar will increase or decrease. Correction tolerance lies between - 5 and + 5 comfort.

These corrections are very important between seasons, when the value calculated by the curve could result too low and therefore the time for reaching the set room temperature could be too long. After 3 seconds from the last adjustment, the value is automatically memorized and the display shows again the value recorded instantaneously by the probe.

Adjusting domestic hot water temperature

- Press the

key and turn the selector A to select desired

domestic hot water temperature. The big digits will light up on display, indicating the selected temperature value. After a few seconds the display will show again the delivery temperature, effectively recorded by the boiler’s probe.

Fig. 39

Fig. 40

ENTER

ESCAPE

7.3 SERVICE MODE & PARAMETERS

This boiler is equipped with a new generation of electronic boards, which allow a better personalization by setting / adjusting the machine’s operating parameters, in order to answer the installation and/or usage needs. The programmable parameters are indicated in the table at page 24.

The parameters programming must be done with the boiler on OFF position. Press the key until you see “ENERGY FOR LIFE” scrolling on display.

During the parameters programming, the key assumes the function of ENTER (confirm) and the key the function of ESC (exit).

If you don’t confirm the setting within 10 seconds, the value is not memorized and the boiler returns to the value previously set.

Setting the password

By holding down the key and then pressing the key for about 3 seconds, you may access the parameters programming. The display will show the word PROG and immediately after CODE. Press ENTER to confirm. Enter the password code for accessing the parameters adjusting function by turning the selector to obtain the value required. Confirm password by pressing ENTER. The password for accessing the parameter programming function is located on the back side of the control panel.

Modifying parameters

- Turn the selector A to scroll the two number codes of the

parameters indicated in the table.

After identifying the parameter you wish to modify, proceed as follows:

- press ENTER access the parameter value adjustment function. When you press ENTER the value previously set is flashing

- turn the selector A to select the value desired

- confirm the new value by pressing ENTER. The digits will stop flashing

- exit the function by pressing ESCAPE.

The boiler will go back to off mode, to resume operation press the

key.

Fig. 41

PARAMETER

N° PARAMETER UNITÀ MIN MAX DEFAULT

PAR. INSTALLAT

SETTING

1 This parameter is not used on this model. Do not modify 1 2 This parameter is not influential 10 (10kW) 30

16 (16kW) 20 (20kW) 26 (25kW) 30 (30kW) 34 (35kW) 50 (50kW)

70 (70kW) 3 Building structure min 5 20 5 10 DHW-type 0 (OFF) 1

1 Instant water heater (combi)

2 N/A 3 N/A 4 N/A 5 N/A

6 N/A 11 Max set-point for DHW ° C 40 60 60 12 This parameter is not used on this model. Do not modify 60 13 This parameter is not used on this model. Do not modify 80 14 This parameter is not used on this model. Do not modify 5 20 Central heating type 0 (OFF) 1

1 (ON)

2 N/A

3 N/A

4 N/A

5 N/A

6 N/A

7 N/A

8 N/A 21 Max flow temperature 1st CH ° C 40 80 80 22 Min flow temperature 1st CH ° C 20 39 20 23 Max output CH (fan speed) rpm MAX

24 Min output CH (fan speed) rpm MIN

25 Differential heating positive ° C 2 10 6 26 Differential heating negative ° C 2 10 6 28 CH timer: force burner 75% after CH-start min 0 20 15 29 CH timer: blocking time CH min 0 20 5 30 CH timer on/off selection - 0 (NO) 1 (SI) 0 31 Max flow temperature 2nd CH ° C 40 80 45 32 Min flow temperature 2nd CH ° C 20 39 25 40 DHW thermostat 0 (OFF) 1

1 (AUTO)

2 (ON)

41 DHW Memory 0 (OFF) 1

1 (AUTO)

2 (ON)

42 S.A.R.A. Function 0 (OFF) 1

1 (AUTO)

43 CH Memory 0 (OFF) 1

1 (AUTO)

44 1st CH circuit climatic Thermo-regulation

0 (OFF) 1

1 (AUTO)

45 Climatic curve selection on 1st CH circuit

- 2,5 40 20

46 2

CH circuit climatic Thermo-regulation

1 - 2

0 (OFF) 1

1 (AUTO)

Climatic curve selection on 2nd CH circuit

1 - 2

- 2,5 40 10 48 This parameter is not used on this model. Do not modify 50 Touch & Go function 0 (OFF) 1

1 (AUTO) 51 This parameter is not used on this model. Do not modify 0 52 This parameter is not used on this model. Do not modify 0 61 DHW frost protection temperature °C 0 10 4 62 CH frost protection temperature °C 0 10 6 63 This parameter is not used on this model. Do not modify 6 65 External probe reactivity 0 (fast)

255 (low)

20 85 This parameter is not used on this model. Do not modify 0 86

Pressure value alarm

(ON

)

bar 0.4 1.0 0.6 87 This parameter is not used on this model. Do not modify 90 Modulating pump - 0 100 41 92 Condensate or condensate sensor (D). - 0 1 0 93 Condensate or condensate sensor (T) - 1 255 5 94 Condensate sensor or open circuit (D) - 0 1 0 95 Condensate sensor or open circuit (T) - 0 1 0

NG LPG

50(*) 50(*)

NG LPG

14(*) 14(*)

Only with 2nd CH circuit

Working only if an external sensor is fitted

* The value is shown on the display as rpm/100 (i.e. 3700/100 = 37)

7.4 ADJUSTMENTS

If adjustments are required again, for example after ordinary maintenance you need to replace the gas valve or after converting from natural gas to LPG or from LPG to natural gas, proceed as follows.

Maximum and minimum power, minimum and maximum heating, must be adjusted in the indicated sequence and only by qualified personnel from the Technical Assistance Service.

- Turn off the general system power switch

- Remove the casing (fig. 15)

- Move forward and then upwards the lower part of the casing to unhook it from the support plate

- Lift up the panel and then turn it forward

- Loosen the gas pressure check downstream from the gas valve by about two turns and connect the pressure gauge to it

- Remove the protection cover of the adjustment screws, using a screw

- Disconnect the compensation pipe connection from the air chamber.

CALIBRATION & SERVICE operations must be performed with the boiler on OFF position. To do this, press the

key

until you see “ENERGY FOR LIFE” scrolling on display. During the parameters adjustment operations, the

key

assumes the function of ENTER (confirm) and the

key the function of ESC (exit). If you don’t confirm the setting within 10 seconds, the value is not memorized and the boiler returns to the value previously set.

Setting the password

By holding down the

key and then pressing the key for about 3 seconds, you may access the parameters programming. The display will show the word PROG and immediately after CODE. Press ENTER key to confirm. Enter the password code for accessing the parameters adjusting function by turning the selector to obtain the value required. Confirm password by pressing ENTER. The password for accessing the parameter programming function is located on the back side of the control panel.

Calibration phases

By turning the selector the CALIBRATION & SERVICE phases scroll one by one:

- 1 gas type

- 2 boiler power

- 10 DHW mode

- 3 building insulation level (displayed only if an external probe

is connected)

- 45 thermoregulation curve slope (displayed only if an external

probe is connected)

- HH boiler at maximum power

- LL boiler at minimum power

- 23 maximum heating adjustment

- 24 minimum heating adjustment

GAS TYPE - 1

Adjust the set value as fallows:

- press ENTER to access the parameter value programming.

When you press ENTER the digits start flashing, pointing out the value previously set

- turn the selector to select desired value (1 MTN - 2 LPG)

- confirm the new set value by pressing ENTER. The digits will

stop flashing.

ABSOLUTE MAX FAN SPEED - HP

Select the parameter HP by turning the encoder; push ENTER button, it is possible to set the absolute max fan speed that is related to gas type and boiler output. Modify this parameter only if strictly necessary. The value is shown on the display as rpm/100 (i.e. 3600/100 = 36).

The set value automatically modifies the min value of parameter 23.

ABSOLUTE MIN FAN SPEED - LP

Select the parameter LP by turning the encoder; push ENTER button, it is possible to set the absolute min fan speed that is related to gas type and boiler output. Modify this parameter only if strictly necessary.

The value is shown on the display as rpm/100 (i.e. 3600/100 = 36). The set value automatically modifies the min value of parameter 24.

START-UP FAN SPEED - SP

Select the parameter SP by turning the encoder; push ENTER button, it is possible to set the start-up fan speed. Modify this parameter only if strictly necessary. The value is shown on the display as rpm/100 (i.e. 3600/100 = 36).

GAS VALVE MAXIMUM SETTING - HH

Select the HH parameter by turning the encoder; the boiler starts at the maximum power, the CO

reading should be as shown in the

table below(for LPG see 9.2. If the CO

reading is correct, pass to gas valve minimum setting (7.4.7). If the CO2 reading is incorrect, the maximum gas pressure must be adjusted as follows: using a 2,5mm Allen key, very slowly turn the maximum adjustment screw (see fig. 42) – clockwise to decrease, counter clockwise to increase – until the correct value is displayed on the CO

analyser (allow time for the analyser to

stabilise).

GAS VALVE MINIMUM SETTING - LL

Select the LL parameter by turning the encoder. The boiler starts at the minimum power, the CO

reading should be as shown in the table above. If the CO

reading is correct, pass to gas valve final setting (7.4.8).

If the CO

reading is incorrect, the minimum gas pressure must be adjusted as follows: using a 4mm Allen key, very slowly turn the minimum adjustment screw (see fig. 42) – clockwise to increase, counter clockwise to decrease - until the correct value is displayed on the CO

analyser (allow time for the analyser to stabilise).

RANGE RATED MAXIMUM OUTPUT CH (FAN SPEED) - 23

Select the parameter 23 by turning the encoder. Push ENTER button and modify the maximum fan speed as indicated in the range rated table by turning the encoder. Push ENTER button to store the value.

The values just setted must be recorded on the last page of this manual.

MINIMUM OUTPUT CH (FAN SPEED) - 24

Select the parameter 24 by turning the encoder. Push ENTER button, it is possible to modify the minimum fan speed by turning the encoder. Push ENTER button to store the value.

Exit the CALIBRATION & SERVICE functions by pressing ESCAPE. The boiler will go back to off mode, ENERGY FOR LIFE scrolling

on displa

- Reconnect the compensation pipe connection to the air chamber

- Disconnect the pressure gauge and screw back the gas pressure

check screw.

To resume operation, press the

key.

After adjusting the gas valve, always seal it with sealing wax.

LINEA ONE 50 50 rpm

(G31)(G20)

MAX NR FAN SPEED CH

LINEA ONE 14 14

(G31)(G20)

MIN NR FAN SPEED

LINEA ONE CO2 max 9,5 10,5 %

(G 31)

(G 20)

LINEA ONE 63 63 rpm

(G31)

(G20)

MAX NR FAN SPEED DHW

Note An existing boiler with a measured CO/CO2 ratio of 0.004/1

or less can be deemed as operating satisfactorily, with a measured CO/CO2 ratio of greater than 0.004/1 can be deemed as at risk, with a measured CO/CO2 ratio of greater than 0.008/1 can be deemed as immediately dangerous.

LINEA ONE CO2 min 9,5 10,5 %

(G 31)(G 20)

Symptom

No ignition

No hot water

No central

heating

Possible causes

Check wiring. Check electrical supply

Check hot/cold pipe work is not reversed

Check wiring of time clock and/or room thermostat

Fault code

Possible causes

Gas supply problem. Gas line requires purging.

Reversed polarity. Broken, internal flue joint

Insufficient water pressure. Air in boiler

7.5 COMBUSTION ANALYSIS TEST

A combustion analysis check can easily be carried out on the appliance via the test points located on the top of the appliance, however you must check that the CO

values are set correctly (see 7.4).

- Insert the flue gas analyser probe into the flue gas test point (see fig. 37).

- Operate the boiler in HH - LL and compare the values with those shown in 7.4.6. If different adjust the gas valve according to 7.4.6. and 7.4.7.

7.6 CHECKING THE EXPANSION VESSEL

Carry out the component removal procedure as described in 6.4. You must ensure that the boiler is completely drained of water. Using a suitable pressure gauge, remove dust cap on expansion vessel and check the charge pressure. The correct charge pressure should be 1.0 bar ± 0.1 bar. If the charge pressure is less, use a suitable pump to increase the charge.

NOTE

You must ensure the drain valve is in the open position whilst recharging takes place. Replace the dust cap and carry out the relevant commissioning procedure (section 5).

7.7 EXTERNAL FAULTS

Before carrying out any faultfinding or component replacement, ensure the fault is not attributable to any aspect of the installation.

7.7.1 INSTALLATION FAULTS

7.8 ELECTRICAL CHECKS

Any electrical checks must be carried out by a suitably qualified person.

7.8.1 EARTH CONTINUITY TEST

Isolate the appliance from the electrical supply, and using a suitable multi-meter carry out a resistance test. Connect test leads between an appliance earth point and the earth wire of the appliance supply cable. The resistance should be less than 1 OHM. If the resistance is greater than 1 OHM check all earth wires and connectors for continuity and integrity.

7.8.2 SHORT CIRCUIT CHECK

Isolate the appliance from the electrical supply, and using a suitable multi-meter, carry out a short circuit test between the Live & Neutral connections at the appliance terminal strip. Repeat above test on the Live & Earth connections at the appliance terminal strip.

NOTE

Should it be found that the fuse has failed but no fault is indicated, a detailed continuity check will be required to trace the fault. A visual inspection of components may also assist in locating the fault.

7.8.3 POLARITY CHECK

With the appliance connected to the electrical supply and using a suitable multimeter, carry out the following voltage tests:

- connect test leads between the Live & Neutral connections at the appliance terminal strip. The meter should read approximately 230V ac. If so proceed to next stage. If not, see 7.8.4.

- connect test leads between the Live & Earth connections at the appliance terminal strip. The meter should read approximately 230V ac. If so proceed to next stage. If not, see 7.8.4.

- connect test leads between the Neutral & Earth connections at the appliance terminal strip. The meter should read approximately 0 – 15Vac. If so polarity is correct. If not, see 7.8.4.

7.8.4 REVERSED POLARITY OR SUPPLY FAULT

Repeat the above tests at the appliance isolator, if testing reveals correct polarity and/or supply at the isolator, re-check wiring and connections between the isolator and the appliance. If tests on the isolator also reveal reversed polarity or a supply fault, consult the local electricity supplier for advice.

7.8.5 RESISTANCE TO EARTH CHECK

Isolate the appliance from the electrical supply, and using a suitable multi-meter carry out a resistance tes. Connect test leads between the Live & Earth connections at the appliance terminal strip (fig. 17). If the meter reads other than infinity there is a fault that must be isolated, carry out a detailed continuity check to identify the location of the fault.

IMPORTANT

These series of checks must be carried out before attempting any faultfinding procedures on the appliance. On completion of any task that required the disconnection and re-connection of any electrical wiring or component, these checks must be repeated.

7.9 FAULT FINDING

Before attempting any faultfinding, the electrical checks as detailed in 7.8 must be carried out.

Isolate the appliance from the electrical supply. Disconnect any external controls from terminal plug M6, and insert a link-wire between the two Black wires at terminal plug M6.

NOTE

Restore the electrical supply to the boiler and turn the selector switch to the on position. The boiler should now function as described in section 7.2. Should the boiler fail to respond, the internal fuses and connectors should be checked to ensure integrity and continuity. If the boiler still fails to respond, refer to the detailed faultfinding flowcharts overleaf.

7.10 TEMPORARY FAULT CODES

The built-in fault diagnostic system automatically displays a unique faul code that can be used to determine why the boiler has temporarily locked out. When the boiler displays a temporary fault code, the appropriate code is shown flashing on the display, accompanied by the symbol .

7.11 FINAL FAULT CODES

When the boiler displays a final fault code, the appropriate code is shown flashing on the display, accompanied by the symbol (RESET).

7.11.1 CODE ERROR +

(RESET) ONLY

To reset the boiler, push

button. If the boiler starts without any

problems, the lock-out is probably due to an accidental situation.

7.11.2 CODE ERROR + (RESET) + Refer to the following section and the detailed fault finding flow-

charts overleaf.

DHW MINIMUM

ADJUSTMENT

RED SCREW

MAXIMUM POWER

ADJUSTMENT

NUT

Fig. 42

Code Reason

10 no flame detected 14 check the wiring harness 15 false flame 20 high limit thermostat/fume thermostat 21 check the wiring harness 22 check the wiring harness 24 high limit flow temperature probe 26 high limit return temperature probe 28 flow/return ΔT error 29 check the wiring harness 34 fan error (start-up) 37 fan error (high rpm) 40 low water pressure 42 pressure transducer fault 50-59 internal PCB failure 70 flow NTC error (2

CH)

72 return NTC error (2

CH)

79 flow/return ΔT error (2

CH) 80-83 internal fault 91 condensing heat exchanger cleaning requirement

Code Reason

11 false flame 12 restart ignition 13 check the wiring harness 23 check the wiring harness 25 high limit flow temperature probe 27 high limit return temperature probe 41 low water pressure 60 DHW NTC error 71 flow NTC error (2

CH)

77 over heat underfloor thermostat (2

CH)

78 flow/return ΔT error (2

CH)

Alarm 91 - Contact the Technical Assistance

The boiler has a self-diagnosis system which, on the basis of the hours totalised in particular operating conditions, signals the need for maintenance or cleaning of the primary exchanger (alarm code

91).

8.1 EXTERNAL WIRING

The appliance comes with a factory fitted link to allow basic operation of the boiler via the mode selector switch. If external controls are to be added to the system, they must be connected to the appliance as shown in the following diagrams. For advice on controls that are not featured in this book, please contact Vokera technical on 0844 391 0999.

8.2 TYPICAL CONTROL APPLICATIONS

The appliance can be used with the following controls:

- Vokera room thermostat (part no. 011)

- Vokera external sensor. (Part no. 2359259)

- Single-channel, voltage-free time clocks

- Programmable room thermostats. In addition, the appliance can be used in conjunction with a typical ‘S’-Plan system, please contact Vokera technical for further detailed instruction.

NOTE

This appliance is not suitable for use with ‘Y’-Plan systems.

8.3 VOKERA ROOM THERMOSTAT

Connect the Vokera room thermostat to the appliance as detailed in fig. 45.

The Vokera room thermostat can be used as detailed in fig. 45.

8.4 OTHER DEVICES

Fig. 47 details typical devices that are suitable for this appliance:

- TBT: low temperature thermostat for underflow heating, a safety

device that prevent overheating

- SE: outside sensor, a NTC sensor that automatically calculates

the flow temperature according to the outside temperature

- P2: external pump, a supplementary pump that can be managed

directly from the boiler in order to satisfy larger systems with high flow rate or high pressure drop (i.e. underfloor heating).

Fig. 45

Contact the controls manufacturer and/or Vokera technical department should you require more specific information on the suitability of a particular control. Further guidance on the recommended practice for the installation of external controls, can be found in CHeSS – HC5/HC6 (www.energy-efficiency.gov.uk).

Fig. 43

Fig. 44

Fig. 46

ME2

ME10

F= Fuse 3,15AF

SECTION 8 - WIRING DIAGRAMS

FUNCTIONAL DIAGRAM

Fig. 47

Key

AE02X Main PCB

TR1 Main transformer

F1-F2 Fuse 4A F

J1-J24 Connettors

CN1-CN12 Connettors

C.S. Condensate sensor

F.S. (2) Flame sensor

AF0X Display board

D.H.W.TDomestic hot water temperature

F.M. Flow meter

WPS Water pressure switch

F Hv Fan power supply 230 V

F Lv Fan signal control

FS Flue sensor

F.O.H.T Flow over heat thermostat

BE06 Drivers PCB (PWM)

PWM Modulating pump

FT Flow thermistor (NTC)

RS Return thermistor (NTC)

3W 3 way motor

M2 Terminal strip connection secondary

pump

P2 Supplementary external pump

OPE Gas valve solenoids

TSC2 Ignition transformer

S.E. (1) Spark electrode

M10 Terminal strip for electrical connection

low power

E.S External sensor

M3-M6 Terminal strip for electrical connection

hight power

F External fuse 3,15A F

PCB

Gas valve

Fan

Condense sensor

Flow sensor

Return sensor

Pump

External transformer

Hot water outlet sensor

External sensor (if fitted)

Actuator

230V connection for time clock

or room thermostat

Flow meter

Water pressure sensor

Ignition transformer

PLUG or CONNECTION

OPE

C.S.

F.S.

R.S.

DHWT

O.S.

3W (M)

R.T.

DHW F.S.

WPS

TSC2

DESIGNATION

Plug J3 on AE01X

Plug CN02 on MOT2B

Plug CN1 on AE01X Plug CN1 on AE01X Plug CN1 on AE01X

Plug J8 on AE01X

Plug CN01 on MOT2B

Plug CN2 on AE01X

Plug J15 on AE01X

Plug J9 on AE01X Plug J3 on AE01X

Plug J3 on AE01X Plug J3 on AE01X Plug J3 on AE01X

PCB

MOT2B MOT2B MOT2B

PLUG or CONNECTION

CN01 CN02

CN03-CN04

DESIGNATION

External transformer connection

Fan connection

Connection to main PCB

Strip

High voltage High voltage High voltage

Low voltage

PLUG or CONNECTION

M3 M6 M2

M10

DESIGNATION

Incoming 230V supply

Heat request, 230V clock supply

Supplementary external pump

Outside sensor, underflow system overheat

temperature

PCB

AE01A-P2X

AE01X

AE01X AE01X AE01X AE01X AE01X AE01X

PLUG or CONNECTION

CN1 CN2

CN3 CN4 CN5 CN8 CN9

CN10

DESIGNATION

Flow, return, condense sensor

DHW sensor, DHW flow meter, water

pressure sensor

Underflow system overheat temperature

RS232 PC interface

Display board connection

Unused Unused Unused

PCB

AE01X AE01X AE01X AE01X AE01X AE01X AE01X AE01X AE01X

AE01X

AEO1X

AE01X AE01X

PLUG or CONNECTION

J1 J2 J3 J4 J5 J6 J7 J8 J9

J10 J12

J11-J13-J14

J15

DESIGNATION

Earth

Unused

Incoming 230V supply, heat request

Unused

Unused 230V sparking transformer Earth sparking transformer

230V pump

230V 3-way valve, supplementary external

pump

230V gas valve

Fume thermostat/Water overheat thermostat

Unused

Outside sensor

POS. DESCRIPTION Linea ONE

1 Frame assembly R01005365 18 Cover assembly R10026239 20 Printed circuit board 20016283 25 Cover R10025842 26 Control panel 20026585 31 Case Assembly 20026589 34 Fixing flange R10026671 38 Printed circuit board 20024205 89 Detector R1582 90 Fuse R3478 226 Clip R5128 300 Electric connection band R10026686 301 Wiring harness R10026330 302 Wiring harness 20026587 303 Low tension cable 20016279

SECTION 9 - EXPLODED DIAGRAMS

226

300

301

302

303

Tabl e 1

438

265

385

353

366

351

350

328

351

328

288

436

353

366

351

328

435

288

439

432

444

443

290

442

435

288

432

441

436

266

201

433

288

521

433

201

434

438

439

433

105

432

600

POS. DESCRIPTION Linea ONE

1 Exchanger R10023482 2 Connection R10030114 4 Non return valve R10025056 6 By-pass casing R10024641 7 Heating by-pass valve 20007783 9 3-way heating manifold and cartridge 20021496 10 Cartridge 20017597 11 Actuator 20017594 12 Clip 20017598 22 Safety valve R10025055 24 Flow governor R10026046 24 Flow governor R10026041 24 Flow governor R10026042 25 Pipe R10025839 26 Dhw actuator 20013968 27 Heating cock R1789 28 Connection R1790 30 Cock R10023567 34 Cock R10023566 35 Flexible pipe R10023570 37 Pipe R10025840 47 Cover for by-pass assembly R10024643 48 Cock R10024646 50 Cover R10026384 61 Non return valve R10023569

62 Cock R10023568 63 Pipe R10026228 105 Pressure transductor 20024559 201 Washer R5026 265 Washer R5236 266 Washer R5237 288 Ring R6898 290 Clip R2165 351 Nut R1823 353 Nut R1824 366 Clip R1820 432 Clip R10024958 433 Clip R10024986 434 Nipple R10024985 435 Fitting/union R10025059 436 Clip R10025062 438 O ring R10024988 439 Washer R10025067 441 Clip R10025063 442 O ring R10025065 443 O ring R10025064 444 Washer R10025066 521 NTC sensor R10027351 600 Hydraulic control cable 20025883

Tab l e 2

200

290

372

512

343

200

633

476

477

287

633

201

200

247

290

538

477

476

700

288

702

432

701

594

595

703

704

432

288

POS. DESCRIPTION Linea ONE

1 Expansion vessel R2573 2 Pipe R10025188 3 Pump 20025880 6 Pipe R10026264 7 Pipe R10026267 9 Pipe assembly 20020179 10 Pipe 20025881 17 Air vent valve 20019768 25 Condensate reservoir R10028405 26 Flexible pipe R10027191 27 Flexible pipe R10027192 66 Flexible pipe R10026272 69 Pressure gauge R10027135 71 Pipe 20020178 72 Vent plug R10023235 73 Cock R10028431 200 Washer R5023 201 Washer R5026

247 Washer R5203 287 High limit R2258 288 Ring R6898 290 Clip R2165 343 Pump plug R2216 372 Clip R2588 432 Clip R10024958 477 Split pin R10026269 512 Washer R10027193 594 O ring 20024869 595 Spring pipe 20024086 633 Water detector 20003819 700 Degasser kit 20019888 701 Pipe 20019764 702 Pipe 20019763 703 Pipe 20020192 704 Clip 20019767

Tab l e 3

613

200

497

700

701

702

486

703

704

POS. DESCRIPTION Linea ONE

2 Air chamber side R10026231 3 Fan R10028456 4 Burner assembly 20016328 5 Spark / ignition electrode R10027620 6 Condense electrode R10026316 12 Gas pipe R10026318 13 Gas valve 20026586 15 3/4" gas cock R10020897 16 Air chamber access panel R10026230 19 Burner observation port kit R10026328 27 Hole cover 20005586 33 Washer R8896 35 Air/gas manifold R10028420 39 Pipe R10028206 46 Gas diaphragm 6,7 R10027162 67 Washer Ø 62 R10026322 69 Protection 20001003 72 Mixer red 20015932 79 Flame sensor R10028422 88 Blower heat shield 20006411 200 Washer R5023 486 O ring R10026325 497 Washer R10026796 613 Ignition transformer 20001563 700 Pump cable 20024202 701 Ignition flame wiring harness 20016280 702 Pump cable 20025884 703 Spark electrode cable R10026558 704 Gas valve cable R10026336

Tabl e 4

487

552

482

475

700

637

POS. DESCRIPTION Linea ONE

1 Condensing exchanger assembly 20024591 7 Conveyor 20007053 12 Flue drain connection R10028421 27 Nut screw R10020625 475 Outlet heat exch.seal gasket R10026323 482 Inlet heat exch.seal gasket R10026366 487 Washer Ø 60 R10026345 552 Washer Ø 60 R10028426 637 Flue sensor 20007050 700 Combustion cable 20016282

Tabl e 5

10.3 CONVERTING THE APPLIANCE GAS TYPE

To convert the appliance to another gas type it is necessary to change the burner injector and adjust the gas valve. It is also necessary to enter the appliance engineer mode and change the fan speed at the maximum output.

- To change the injector see 6.12.1

- To change parameters see 7.3.1

- To adjust CO

value see 7.4.1-2

10.4 GAS SUPPLY

The gas supply must be connected to the appliance by a competent LPG installer and must be of sufficient size to supply the appliance at its maximum output. An existing supply must be checked to ensure that it is of adequate size to deal with the maximum rated input of this and any other appliances that it serves.

10.5 GAS SUPPLY INSTALLATION

The entire installation including the meter must be purged and checked for gas tightness.

10.6 ADJUSTING THE GAS VALVE

THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYSER.

Isolate the appliance from the electrical supply and remove the appliance casing as described in 4.7.1. Set the flue gas analyser to read CO

and insert the probe into the flue analysis test point (see fig. 1). Restore the electrical supply to the boiler and switch off the boiler. Push

and buttons at the same time for 3 seconds to enter the adjusting menu. The display shows “CodE”. Select the adjusting password by turning the encoder and confirm it by pushing ENTER button.

10.6.1 MAXIMUM SETTING

Select the HH parameter by turning the encoder and confirm it by pushing ENTER button. The boiler starts at the maximum power, the CO

reading should be as shown in the table above.

If the CO

reading is correct, press the ENTER button to exit the

maximum setting. If the CO

reading is incorrect, the maximum gas

pressure must be adjusted as follows:

- using a suitable screwdriver, very slowly turn the maximum adjustment screw (see fig. 42) – clockwise to decrease, counter clockwise to increase – until the correct value is displayed on the CO

analyser (allow time for the analyser to stabilise).

IMPORTANT A GAS TIGHTNESS CHECK MUST BE CARRIED OUT.

10.6.2 MINIMUM SETTING

Select the LL parameter by turning the encoder and confirm it by pushing ENTER button. The boiler starts at the minimum power, the CO

reading should be as shown in the table above. If the CO2 reading is correct, press the ENTER button to exit the minimum setting. If the CO

reading is incorrect, the minimum gas

pressure must be adjusted as follows:

- using a suitable screwdriver, very slowly turn the minimum

adjustment screw (see fig. 42) – clockwise to increase, counter clockwise to decrease – until the correct value is displayed on the CO

analyser (allow time for the analyser to stabilise).

- using the procedure detailed in 9.6.1, check that the maximum

setting correct value is still being obtained. If not, repeat the above procedure.

10.1 RELATED DOCUMENTS

BS 6798 BS 5449 BS 5446 BS 5440 BS 5482

PART 1

PART 1 PART 1

INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60 kW FORCED CIRCULATION HOT WATER SYSTEMS INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES FLUES DOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS

10.2 TECHNICAL DATA

Gas Pressures Linea ONE

Inlet pressure 37.0 mbar Maximum gas rate 2.33 kg/h Minimum gas rate 0.54 kg/h Injector size (quantity) 1 x Ø 5.0 mm Fan speed @ max output (rpm) DHW 6.300 Fan speed @ max output (rpm) HTG 5.000 Fan speed @ min output (rpm) 1.400

Flue details (coaxial)

Maximum horizontal flue length (60/100mm) 3.85 Maximum vertical flue length (60/100mm) 4.85

Flue details (twin pipes)

Maximum horizontal flue length (80mm + 80mm) 30 + 30 Maximum vertical flue length (80mm + 80mm) 30+30

Efficiency

SEDBUK (%) A

Emissions

NOx (max-min) 80 - 53 mg/kWh CO (max-min) 215 - 32 mg/kWh CO2 (max-min) 10,5 - 10,5 % CO/CO2 ratio (max) 0,002 to 1 CO/CO

ratio (min) 0,0003 to 1

SECTION 10 - LPG INSTRUCTIONS

Cod. 20023652 - 07/10 - Ed. 0

Registered address:

Vokèra Ltd

Borderlake House

Unit 7 Riverside Industrial Estate

London Colney

Herts AL2 1HG

enquiries@vokera.co.uk

www.vokera.co.uk

www.vokera.ie

Sales, General Enquires

T 0844 391 0999 F 0844 391 0998

Vokèra Ireland

West Court, Callan

Co Kilkenny

T 056 7755057 F 056 7755060

Vokèra Limited reserve the right to change

specification without prior notice

Consumers statutory rights are not affected.

A Riello Group Company.

Company Reg No: 1047779

RANGE RATED - EN 483

The max CH input of this boiler has been adjusted to_____ kW, equivalent to _____ rpm max CH fan speed.

Date___/____/____

Signature _____________________

Boiler serial number

_____________________

VOKERA Linea ONE Installation & Servicing Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual