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).

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VOKERA Linea ONE Installation & Servicing Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual