VOKERA Mynute 12HE, Mynute 15HE, Mynute 35HE, Mynute 20HE, Mynute 25HE Installation And Servicing Instructions

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Installation & Servicing Instructions

0694

0694BR1207

THESE INSTRUCTIONS TO BE RETAINED BY USER

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Contents

Design principles & operating sequence Page

1.1 Principle components 3

1.2 Mode of operation (at rest) 3

1.3 Mode of operation 3

1.4 Safety devices 3

Technical data Page

2.1 Central heating 4

2.2 Gas pressures 4

2.3 Expansion vessel 4

2.4 Dimensions 4

2.5 Clearances 4

2.6 Connections 4

2.7 Electrical 4

2.8 Flue details (concentric) 4

2.8A Flue details (twin pipes) 4

2.8B Flue details (80/125) 4

2.9 Efficiency 4

2.10 Emissions 4

2.11 Pump duty 5

General requirements (UK) Page

3.1 Related documents 6

3.2 Location of appliance 6

3.3 Gas supply 6

3.4 Flue system 6

3.5 Air supply 6

3.6 Water circulation 6

3.7 Electrical supply 7

3.8 Mounting on a combustible surface 7

3.9 Timber framed buildings 7

3.10 Inhibitors 7

General requirements (EIRE) Page

3A.1 Related documents 8 3A.2 Location of appliance 8 3A.3 Gas supply 8 3A.4 Flue system 8 3A.5 Air supply 8 3A.6 Water circulation 8 3A.7 Electrical supply 9 3A.8 Mounting on a combustible surface 9 3A.9 Timber framed buildings 9 3A.10Inhibitors 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 14

4.7 Electrical connections 14

6.8 Water pressure switch 19

6.9 Primary thermistor 19

6.10 Return thermistor 19

6.11 Printed circuit board 19

6.12 Gas valve 19

6.13 Electrodes and condense sensor 20

6.14 Flue fan & mixer 20

6.15 Burner 20

6.16 Main heat exchanger 20

6.17 Automatic by-pass 21

6.18 Expansion vessel 21

6.19 Condense trap removal 21

6.20 Flue collector removal 22

Checks, adjustments and fault finding Page

7.1 Checking appliance operation 22

7.2 Appliance modes of operation 22

7.3 Appliance fan speed 23

7.4 Checking the CO2 & adjusting the valve 24

7.5 Combustion analysis test 24

7.6 Checking the expansion vessel 24

7.7 External faults 24

7.8 Electrical checks 24

7.9 Fault finding 25

7.10 Component values & characteristics 25

7.11 Boiler configuration 27

7.12 Final fault codes 26

Wiring diagrams Page

8.1 External wiring 27

8.2 Typical control applications 27

8.3 Other devices 27

8.4 Vokera twin-channel programmer 27

Exploded diagrams Page

9.1 Table 1 31

9.2 Table 2 32

9.3 Table 3 33

9.4 Table 4 34

9.5 Table 5 35

L.P.G. instructions Page

10.1 Related documents 36

10.2 Technical data 36

10.3 Converting the appliance gas type 36

10.4 Gas supply 36

10.5 Gas supply installation 36

10.6 Adjusting the gas valve 36

10.7 Appliance fan speed 3 7

Benchmark 38-39

Commissioning Page

5.1 Gas supply installation 16

5.2 The heating system 16

5.3 Initial filling of the system 16

5.4 Initial flushing of the system 16

5.5 Pre-operation checks 16

5.6 Initial lighting 16

5.7 Checking gas pressure & combustion analysis 16

5.8 Final flushing of the heating system 17

5.9 Setting the boiler operating temperature 17

5.10 Setting the system design pressure 17

5.11 Regulating the central heating system 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

6.5 Pump assembly 18

6.6 Safety valve 18

6.7 Lower automatic air release valves 19

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INTRODUCTION

The Mynute HE comprises a range of high-efficiency system boilers with outputs ranging from 12 to 35kW. These appliances – by design – incorporate electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge, and automatic by-pass.

The Mynute HE range are produced as room sealed, category II2H3P appliances, suitable for internal wall mounting applications only. Each appliance 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

Mynute

12-15-20-25 HE

Fig. 1

Mynute

30-35 HE

applications. The Mynute HE can also be used with the V okera twin flue system. The Myn ute HE is approv ed f or use with C13 & C33 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.

This booklet is an integral part of the appliance. It is therefore necessary to ensure that the booklet is handed to the person responsible for the property in which the appliance is located/installed. A replacement copy can be obtained from Voker a customer services.

General layout (fig. 1)

1 Safety valve 2 Pressure switch 3 Pump 4 Bottom auto air vent (AAV) 5 Injector 6 Condense trap 7 Return sensor 8 Flue gas analysis test point 9 Flue outlet & air intake 10 Ignition transformer 11 Top AAV 12 Flow sensor 13 High limit thermostat 14 Limit thermostat 15 Sensing Electrode 16 Spark Electrode 17 Cylindric Burner 18 Condensate level sensor 19 Main heat exchanger 20 Top AAV pipe 21 Fan assembly 22 Mixer 23 Expansion vessel 24 Hydraulic manifold 25 Gas valve 26 Condensing drain

R Heating return connection F Heating flow connection G Gas connection

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HYDROMETRE

GREEN LED

2-digit LED

display

MODE SELECTOR

RED LED

SWITCH

TEMPERATURE SELECTOR

Fig. 1A

Boiler at reset/standby Select this position if/when the boiler requires to be reset Boiler switched OFF Select this position if you w ant the boiler to remain OFF (this will over-ride any

heating/hot water request from the time-clock/programmer)

Boiler switched ON Select this position when you want the boiler to respond to a heating/hot water

request from the time-clock/programmer

°C

T emperature selector Move the temperature selector clockwise to increase the boiler outlet temperature, or

counter-clockwise to reduce the outlet flow temperature

2-digit LED display Displays the current outlet temperature of the boiler . During a fault condition, the

appropriate fault code will be display ed (refer to the users handbook for instructions

regarding fault codes) Green LED lit Boiler is working/responding to a heating/hot water request Red LED lit Boiler has identified a fault and has failed-saf e. Ref er to users handbook for

instructions on how to reset Pressure gauge Ensure the system pressure is set correctly (minimum 0.5-bar)

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SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS

A fully integrated electronic control board featuring electronic temperature control, anti-cycle control, pump over-run, self-diagnostic fault indicator, full air/gas modulation.

●●

● Radial aluminium heat exchanger.

●●

● Electronic ignition with flame supervision

●●

● Integral high-head pump

●●

● Fan

●●

● Expansion vessel

●●

● Water pressure switch

●●

● Condensate level sensor

●●

● Pressure gauge

●●

● Safety valve

●●

1.2 MODE OF OPERATION (at rest)

When the appliance is at rest and there are no requests for heating or hot water, the following functions are active:

●●

● 2-stage frost-protection system – the frost-

●●

protection system protects the appliance against the risk of frost damage. The first stage enables activation of the pump should the temperature of the appliance fall to 6oC. Should the first stage become active, the appliance will function on minimum +25% power until it reaches 35oC.

●●

● Anti-block function – the anti-block function

●●

enables the pump to be energised for short periods, when the appliance has been inactive for more than 24-hours.

●●

● fan speed sensor to ensure safe operation of the

●●

burner;

●●

● a high limit thermostat that over-rides the tem-

●●

perature control circuit to prevent or interrupt the operation of the burner;

●●

● flame sensor that will shut down the burner when

●●

no flame signal is detected;

●●

● 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.

1.3 MODE OF OPERATION

When there is a request for heat and/or hot water, 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% of the MAX Heating (set by the corresponding HTG trimmer) for a period of 15 minutes. Thereafter, the boiler’s output will either be 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 three-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 SAFETY DEVICES

When the appliance is in use, safe operation is

ensured by:

●●

● a water pressure switch that monitors system

●●

water pressure and will de-activate the pump (when lockout condition is reached), fan and burner should the system water pressure drop below the rated tolerance;

Fig. 2

expansion

vessel

safety valve

pump

return

temperature

sensor

bottom

return

AAV

automatic

by-pass

flow

pressure

switch

drain valve

main heat

exchanger

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SECTION 2 TECHNICAL DATA

2.1 Central Heating 12HE 15HE 20HE 25HE 30HE 35HE

Heat input (kW) 12 15 20 25 30 34.6 Maximum heat output (kW) 60/80°C 11.84 14.81 19.68 24.53 29.31 33.67 Minimum heat output (kW) 60/80°C 3.5 3.5 5 6 7 7 Maximum heat output (kW) 30/50°C 12.74 15.90 21.16 26.30 6.84 36.54 Minimum heat output (kW) 30/50°C 3.7 3.71 5.30 6.37 7.41 7.41 Minimum working pressure 0.5 bar Maximum working pressure 2.7 bar Minimum flow rate 350 l/h

2.2 Gas Pressures 12HE 15HE 20HE 25HE 30HE 35HE

Inlet pressure (G20) 20.0 mbar Maximum gas rate (m3/hr) 1.27 1.59 2.12 2.64 3.17 3.66 Minimum gas rate (m3/hr) 0.37 0.37 0.53 0.63 0.74 0.74 Injector size 4.6mm 4.6mm 4.6mm 6.7mm 7.0mm 7.0mm

2.3 Expansion Vessel 12HE 15HE 20HE 25HE 30HE 35HE

Capacity 6-litres 8-litres 10-litres Maximum system volume 63-litres 76-litres 91-litres Pre-charge pressure 1.0 bar

2.4 Dimensions 12HE 15HE 20HE 25HE 30HE 35HE

Height 740mm 780mm 780mm Width 400mm 400mm 450mm Depth 340mm 358mm 358mm Dry weight (kg)

2.5 Clearances Mynute HE Range

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

2.6 Connections Mynute HE Range

Flow & return 22mm Gas 15mm Safety valve 15mm Condense 21mm

2.7 Electrical 12HE 15HE 20HE 25HE 30HE 35HE

Power consumption (Watts) 150 150 150 150 165 165 Supply (V/Hz) 230/50 Internal fuse 3.15A T (for PCB) - 3.15A F (for connections block) External fuse 3A

2.8 Flue Details (concentric - 60/100) 12HE 15HE 20HE 25HE 30HE 35HE

Maximum horizontal flue length (60/100mm) 7.8m 7.8m 7.8m 7.8m 7.8m 7.8m Maximum vertical flue length (60/100mm) 8.8m 8.8m 8.8m 8.8m 8.8m 8.8m

2.8A Flue Details (concentric 80/125mm) 12HE 15HE 20HE 25HE 30HE 35HE

Maximum horizontal flue length (80/125mm) 20m 20m 20m 20m 20m 20m Maximum vertical flue length (80/125mm) 25m 25m 25m 25m 25m 25m

2.8A Flue Details (twin pipes) 12HE 15HE 20HE 25HE 30HE 35HE

Maximum horizontal flue length (80mm/80mm) 40m/40m 40m/40m 40m/40m 40m/40m 40m/40m 40m/40m Maximum vertical flue length (80mm/80mm) 40m/40m 40m/40m 40m/40m 40m/40m 40m/40m 40m/40m

2.9 Efficiency 12HE 15HE 20HE 25HE 30HE 35HE

SEDBUK (%) 90.7 90.7 90.5 90.4 90.2 90.0

2.10 Emissions 12HE 15HE 20HE 25HE 30HE 35HE

CO2 @ maximum output (%) 9.0 9.0 9.0 9.0 9.0 9.0 CO2 @ minimum output (%) 9.0 9.0 9.0 9.0 9.0 9.0 CO/CO2 ratio @ maximum output 0.001 to 1 0.001 to 1 0.001 to 1 0.0002 to 1 0.0002 to 1 0.0002 to 1 CO/CO2 ratio @ minimum output 0.0002 to 1 0.0002 to 1 0.0004 to 1 0.0003 to 1 0.0003 to 1 0.0003 to 1 CO @ maximum output (mg/kWh) 107.5 129.0 161.3 204.3 215 268.8 CO @ minimum output (mg/kWh) 21.5 21.5 43.0 32.3 32.3 32.3 NOx @ maximum output mg/kWh) 88.3 88.3 79.4 88.3 88.3 88.3 NOx @ minimum output (mg/kWh) 35.3 35.5 53.0 61.8 70.6 70.6 NOx rating class 5 class 5 class 5 class 5 class 5 class 5

Band ‘A’ Band ‘A’ Band ‘A’ Band ‘A’ Band ‘A’ Band ‘A’

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

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2.11 PUMP DUTY

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

Mynute

12-15-20-25 HE

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

Residual head (x 100 mbar)

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

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

1st speed

2nd speed

Flow rate (l/h)

Fig. 3

Fig. 4

3rd speed

Mynute

30-35 HE

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

Residual head (x 100 mbar)

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

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

1st speed

2nd speed

Flow rate (l/h)

3rd speed

Key Location Minimum distance

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

F Below balcony, car-port roof, etc. 25 mm G To the side of a soil/drain-pipe, etc. 25 mm H From internal/external corner or boundary 300 mm

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

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

P From a structure to the side of the vertical terminal 500 mm

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

of the vertical terminal

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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 appliance gas inlet connection must not be used. The installation must be tested for soundness in accordance with BS6891. If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time.

3.4 FLUE SYSTEM

The terminal should be located where the 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. 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.

BS 5440 BS 5449 BS 6798 BS 6891 BS 7074

PART 2 PART 1

PART 1

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

FLUES & VENTILATION FORCED CIRCULATION HOT WATER SYSTEMS INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW LOW PRESSURE INSTALLATION PIPES APPLICATION, SELECTION, AND INSTALLTION OF EXPANSION VESSELS AND ANCIL-

LARY EQUIPMENT FOR SEALED WATER SYSTEMS

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

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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 6 litres (12-15-20HE), 8 (25HE) and 10 litres (3035HE) 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

6.19).

3.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. is required (see fig. 5). This method of filling must comply with the current Water Supply (Water Fittings) Regulations 1999 and W ater Bylaws 2000 (Scotland).

control

valve

temporary

connection

control

valve

Make-up vessel or tank

Automatic air-vent

Non-return

valve

Fig. 5A

Stopcock

5.0 metres minimum

Heating return

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 unswitched shuttered socket with a fused 3-pin plug both complying with BS 1363 is acceptable.

3.8 MOUNTING ON A COMBUSTIBLE SURFACE If the appliance is to be fitted on a wall of combustible material, a sheet of fireproof material must protect the wall.

3.9 TIMBER FRAMED BUILDINGS

flow/return

pipe

Fig. 5

3.6.7 LOW PRESSURE SEALED SYSTEM

double

check valve

supply

pipe

3.10 INHIBITORS

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. 5A). 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.

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’.

V okera recommend that an inhibitor - suitab le for use with copper and aluminium heat exchangers

- is used to protect the boiler and system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers instructions*.

*Water treatment of the complete heating system

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

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SECTION 3A GENERAL REQUIREMENTS (EIRE)

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

3A.1 RELATED DOCUMENTS

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

3A.2 LOCATION OF APPLIANCE

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

This appliance is not suitable for external installation.

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 soundness in accordance with I.S. 813. If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time.

3A.4 FLUE SYSTEM

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.

3A.6.2AUTOMATIC 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

6.19).

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3A.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. is required. You should ensure this method of filling complies with the local water authority regulations.

3A.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.

3A.6.8 FREQUENT FILLING

3A.7 ELECTRICAL SUPPLY

3A.8 MOUNTING ON A COMBUSTIBLE SURFACE

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

Mynute

12-15-20 HE

Mynute

25-30-35 HE

3A.9 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.10 INHIBITORS

V okera recommend that an inhibitor - suitab le 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.11 DECLARA TION 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.

Fig. 6

Page 12

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SECTION 4 INSTALLATION

4.1 DELIVERY

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

4.2 CONTENTS

Contained within the carton is:

• the boiler

• the wall bracket

• template

• an accessories pack containing appliance serv-

ice connections and washers

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

4.3 UNPACKING

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

4.4 PREPARATION FOR MOUNTING THE APPLIANCE

The appliance should be mounted on a smooth, vertical, non-combustible surface, which must be capable of supporting the full weight of the appliance. Care should be exercised when determining the position of the appliance with respect to hidden obstructions such as pipes, cables, etc. When the position of the appliance has been decided – using the template supplied – carefully mark the position of the wall- mounting bracket (see fig. 6) and flue-hole (if applicable).

Reduction for additional bends

Bend Reduction in maximum flue length for each bend 45° bend

90° bend

Horizontal flue terminals and accessories

Part No. 520

521 522 523 524 525 526 527 528 529

0.5 metre

1.0 metre

Description Horizontal flue kit

Telescopic flue kit Plume management kit 90-degree bend 45-degree bends (pair) 500mm extension 1000mm extension 2000m extension Telescopic extension Wall bracket pack (5)

Length 900 mm

350 /530 mm 1370 mm N/A N/A 500mm 1000 mm 2000 mm 350 /730 mm 208mm

Using the template provided, mark and drill a 115mm hole for the passage of the flue pipe. The hole should be drilled to ensure any condense fluid that forms, is allowed to drain back to the appliance (see fig. 7A). The fixing holes for the wall-mounting bracket should now be drilled and plugged, an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely. Once the bracket has been secured to the wall, mount the appliance onto the bracket.

4.5 FITTING THE FLUE

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

4.5.1 CONCENTRIC HORIZONT AL FLUE

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

NOTE

The appliance flue outlet elbow can be rotated through 360º on its vertical axis. In addition the flue may be extended from the outlet elbow in the horizontal plane (see 2.8). A reduction must also be made to the maximum length (see table below) when additional bends are used.

Fig. 7

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FITTING THE HORIZONT AL 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 7A). 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.

4.5.1.1 EXTENDING THE FLUE

Connect the bend – supplied with the terminal kit – to the top of the boiler using clamp (supplied) see fig. 7. The additional bends & extensions hav e 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 3° 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.

“X”

30mm

“X” + 65mm = “Y”

Fig. 7A

“Y”

1-3 degree

4.5.2 CONCENTRIC VERTICAL FLUE

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

NOTE

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

Fig. 8

Page 14

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Reduction for bends

Bend 45° bend

90° bend

Ve rtical flue terminal and accessories

Part No.

530 531 532 523 524 525 526 527 528 529

Reduction in maximum flue length for each bend

0.5 metre

1.0 metre

Description

V ertical flue terminal Pitched roof flashing plate Flat roof flashing plate 90-degree bend 45-degree bends (pair) 500mm extension 1000mm extension 2000mm extension T elescopic e xtension Wall brac ket pack (5)

Using the dimensions given in fig. 9 as a reference, mark and cut a 115mm hole in the ceiling and/or roof.

“X”

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

“X”

Fig. 9

Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing. The fixing holes for the wall-mounting bracket 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.

Min-Max length 1000 mm

N/A N/A N/A N/A 500mm 1000 mm 2000 mm 350/730mm 208mm

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

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (see fig. 8). 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 Voker a twin flue system enables greater flue distances to be achieved (see 4.4.2) than that of a concentric flue system. It can be used for horizontal or vertical applications, howev er 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 INSTALLA TION

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

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

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

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

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

Reduction for bends

Bend 45° bend 90° bend

Reduction in maximum flue length for each bend

1.0 metre

Page 15

Supplied By www.heating spares.co Tel. 0161 620 6677

T win flue accessories

Part No. Description

0225805 Horizontal flue terminal 1.0 metre 0225810 Vertical flue terminal 1.0 metre 430 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

Length

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.

4.5.3.1 INSTALLA TION OF TWIN AD APTOR KIT (fig. 10 & 11)

• Insert the exhaust connection manifold (A) onto

the appliance flue outlet.

• Remove the blanking plate (located to the right

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

4.5.3.2 HORIZONTAL TERMINA TION (fig. 12)

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

• The horizontal terminal is supplied with a builtin 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 e xhaust 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.

4.5.3.3 VERTICAL TERMINATION (fig. 13)

The twin flue system must be conver ted 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.

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●●

● 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. 12

Fig. 13

NOTE

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

4.6.1 GAS (fig. 6)

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. 6)

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 SAFETY V AL VE (fig. 6)

Connect the safety valve connection pipe to the safety valve outlet. Connect a discharge pipe to the other end of the safety valve connection pipe 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 CONNECTING THE GAS AND W A TER

The appliance is supplied with service valves. 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.

4.6.4 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 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 FR OM THE SAME ISOLATOR AS THA T OF THE APPLIANCE. The supply cable from the

Page 17

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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 90ºC.

4.7.1 CASING REMOV AL (fig. 14)

To gain internal access to the appliance you must first remove the casing, proceed as outlined below:

●●

● remove the 4 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 (B) safely until

●●

required. Re-fit in the reverse order .

4.7.3 CONNECTING THE MAINS (230V) INPUT (see fig. 16).

Unhook and remove the terminal block cover (230V). Pass the cable through the cable anchorage point. Connect the supply cable wires (LIVE, NEUTRAL & EARTH) to their corresponding terminals (L, N & E) on the appliance - 230V - terminal block. When connecting the EARTH wire, ensure that it’s left slightly longer (about 2cm) 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. 14

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. Gently pull the control panel forwards and down. Locate the terminal block cover (see fig. 15).

NOTE

The appliance comes with a factory fitted link (‘T A’) 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.

Optional devices

(24V) terminal block

Fig. 16

Mains (230V)

terminal block

Fig. 15

Page 18

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SECTION 5 COMMISSIONING

5.1 GAS SUPPL Y INST ALLATION

Inspect the entire installation including the gas meter, test f or soundness and purge. Refer to BS 6891 (I.S. 813 in ROI) for specific instruction.

5.2 THE HEA TING 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. Ensure all manual air release valves located on the heating system are closed. Connect the filling loop as shown in fig. 5, slowly proceed to fill the system by firstly opening the inlet valve connected to the flow pipe, and then turning the lever on the fill valve, to the open position. 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 soundness, rectifying any leaks.

5.3.1 MANUAL AIR RELEASE (fig. 17)

When the boiler has been filled for the first time or the system has been drained and refilled, it will be necessary to release any air that may have become trapped within the appliance heat exchanger . Slac ken the bleed scre w until water is released and then close. IMPORTANT , THERE ARE NO OTHER MANU AL AIR RELEASE VALVES LOCATED ON THE APPLIANCE.

Fig. 17

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 PRE-OPERA TION 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.

●●

5.6 INITIAL LIGHTING

Ensure the electrical supply to the appliance is switched on. Ensure any external controls are switched to an ‘ON’ position and are calling for heat. Move the selector switch to the ON position, the appliance will now operate as described in 1.2. Should the appliance fail to ignite, refer to 5.6 and/ or section 7.

5.7 CHECKING GAS PRESSURE AND COMBUSTION ANAL YSIS

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 to gas 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 no means by which to calculate the gas rate, then a combustion analysis test must be carried out in accordance with BS 7967 (UK) to ensure the appliance is left working safely and correctly. Additionally, if the gas valve has been adjusted, replaced, or the appliance has been converted for use with another gas type, then it becomes necessary to carry out a combustion 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 analysis check, 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.

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IMPORTANT

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

5.8 FINAL FLUSHING OF THE HEATING SYSTEM

The system shall be flushed in accordance with BS 7593 (I.S. 813 ROI). A cleanser - suitable for aluminium heat exchangers - should be used. It shall be from a reputable manufacturer and shall be administered in strict accordance with the manufacturers’ instructions and the DWTA code of practice.

5.8.1 INHIBITORS

See Section 3 “General Requirements”.

5.9 SETTING THE BOILER OPERATING TEMPERA TURE

The flow outlet temperature can be adjusted between 40 °C - 80 °C for standard CH systems and between 20 °C - 45°C for under-floor CH systems (see par .

7.11) via the Heating thermostat knob (see fig.1).

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 valv e 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).

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

T o v alidate 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: 0870 607 0281

●●

● for ROI residents by calling: 1850 221121.

●●

5.11 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 SOUNDNESS.

●●

● ENSURE THE APPLIANCE FLUE SYSTEM IS

●●

FITTED CORRECTLY AND IS PROPERLY SECURED .

●●

● ENSURE ALL PIPE WORK IS RE-CHECKED

●●

FOR SOUNDNESS.

●●

● RE-FIT APPLIANCE CASING.

●●

● COMPLETE BENCHMARK CHECKLIST .

●●

FOR UK ONL Y

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.

Page 20

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SECTION 6 SERVICING INSTRUCTIONS

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 V okera 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, CORGI 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.

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. Under take a complete commissioning check as detailed in section 5, after replacing any component.

AL WAYS TEST FOR GAS SOUNDNESS IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED OR DISTURBED .

6.4.1 AIR BO X FRONT CO VER REMO V AL (fig. 18)

Locate the two clips and remove air box front cover . If it’ s necessary to remove the air bo x side cover , locate and remov e the 4 securing screws.

6.2 ROUTINE ANNUAL SER VICING

●●

● 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 REMOV AL PROCEDURE

T o remo ve a component, access to the interior of the appliance is essential. Isolate the appliance from the electrical supply and remove the fuse.

clips

Fig. 18

6.5 PUMP ASSEMBLY (fig. 19)

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, only for 30-35HE) 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). Locate and remove the pressure gauge securing pin (D) and disconnect the pressure gauge from the pump assembly.

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 .

6.6 SAFETY V AL VE (fig. 19)

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

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6.7 LOWER AUTO M ATIC AIR RELEASE VALVE (fig. 19)

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 AA V locking pin (G) from the pump assembly and remove the AAV assembly (H). Replace in the reverse order .

6.8 WATER PRESSURE SWITCH (fig. 19)

Carry out component removal procedure as described in 6.4. Locate and remove the locking pin (I) from the water pressure switch. Remove the wiring. Carefully withdraw the switch. Replace in the rev erse order.

6.9 PRIMARY THERMIST OR (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 re verse 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 re verse order .

6.11 PRINTED CIRCUIT BO ARD (fig. 21)

Carry out component removal procedure as described in 6.4. Pull the control fascia forward and lower it. Push the clips (A) and remo ve cove r, after carefully taking note of all wiring connections and jumper tag configuration; unhook and remove connection block (B). Disconnect all wiring from the PCB, locate and remove the PCB securing screws, remove the required PCB. Replace in the reverse order ensuring that the position of the 3 control knobs are correctly aligned with the respective potentiometers on the PCB. Ensure that the correct jumper tag configuration has been respected. It will be necessary to check the functioning of the PCB is set for the correct boiler type/application.

Fig. 19

6.7.1 TOP AUTOMATIC AIR RELEASE V AL VE (fig. 20)

Carry out component removal procedure as

Fig. 21

described in 6.4. Remove the drain pipe (A). Unscrew the top AA V

6.12 GAS V ALVE (fig. 22)

(B). Replace in the reverse order . Loctite or similar should be used as a thread sealant for the AA V.

Fig. 20

Carry out component removal procedure as described in 6.4. The gas valv e must be changed as complete unit. Disconnect the electrical plug and leads from the gas valve, slacken and unscrew gas valve inlet and outlet 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 remov ed. Replace in the rev erse order. Check and adjust burner pressure settings.

WARNING, A GAS SOUNDNESS CHECK MUST BE CARRIED OUT .

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6.12.1 INJECTOR (fig. 22)

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. Chec k and adjust burner pressure settings.

WARNING, A GAS SOUNDNESS CHECK MUST BE CARRIED OUT .

Fig. 24

Fig. 22

6.13 ELECTRODES & CONDENSE SENSOR (fig. 23)

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

6.15 BURNER (fig. 25)

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. Locate and remove the 3 internal nuts (B) which secure the fan assembly in position (C) to the heat exchanger (D). Disconnect the electrode leads and ancillary wiring from their respective connectors. Remove the retaining screws (A, fig. 24) for sensing electrode and remove. Remove the retaining nut (C, fig. 24) for condense sensor (D, fig. 24) and remove. 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 .

Fig. 23

6.14 FLUE F AN & MIXER (fig. 24)

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 away from 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 .

Fig. 25

6.16 MAIN HEA T EXCHANGER (fig. 26 & 27)

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. 26: Slacken the gas pipe (A) at the air box connection and swing/rotate of the fan assembly.

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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 no w be lifted up and withdrawn from the appliance.

Fig. 26

6.18 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.

6.18.1 EXPANSION VESSEL REMOVAL (with sufficient clearance above, fig. 29)

Carry out component removal procedure as described in 6.4. Disconnect the flue from the appliance.

Disconnect the flexible expansion pipe from the vessel. Unscrew the nut that secures the vessel to the lower frame. Locate and remove the screws (A) that secure the vessel top holding plate (B), remov e 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 .

Fig. 27: 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

6.17 A UTOMATIC BY-PASS (fig. 28)

Carry out component removal procedure as described in 6.4. Disconnect and remove the flow pipe at the heating manifold (1) and at the connection to the air chamber. Using a hook ed piece of wire, carefully withdraw the bypass cartridge (2). 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.

Fig. 29

6.19 CONDENSE TRAP REMOV AL (fig. 30)

Carry out component removal procedure as

described in 6.4. Disconnect the 2 upper rubbers condense pipe (A). Remove the pin (B) that secures the trap to the air box plate. Disconnect the lower rubber condense pipe (C) from the condense trap. Carefully remove the condense trap. Replace in the reverse order .

Fig. 28

Fig. 30

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6.20 FLUE COLLECT OR REMOV AL (fig. 31)

Fig. 31

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). Gently pull down and to the left and ease the flue collector from its location. Replace in the re verse order .

SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING

7.1 CHECKING APPLIANCE OPERA TION

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 soundness, water soundness, and the electrical integrity of the appliance.

7.2 APPLIANCE MODES OF OPERA TION 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 code will be displayed.

The 2-digit display can show several different modes of operation:

OFF mode

Frost protection mode activ e

Combustion analysis mode active

Autostop function active

Normal heating request (example 60oC).

7.2.1 SELECTOR SWITCH IN THE OFF/STANDBY POSITION

When the selector switch is in the OFF/STANDBY position, the following functions are active. Active functions:

●●

● Frost-protection system

●●

● Pump anti-block

●●

7.2.1 ON-BOARD FUNCTIONS

●●

● THERMOREGULATION: when an external

●●

sensor is connected to the appliance, the electronic circuitry will automatically adjust the flow outlet temperature to suit local weather conditions in order to maintain comfort and efficiency . A specific operating curve that is most suited to the system type and geographical area can also be selected.

●●

● OPENTHERM +: OT+ is a communication

●●

protocol that enables the boiler to be linked or connected to other OT+ controls. These controls have been designed to further increase fuel economy by ensuring the boiler remains in the modulation phase during any heating requests. This reduces the amount of ON/OFF periods and therefore increases fuel efficiency.

●●

● AUTOSTOP: further information on the AUT O-

●●

STOP function, can be obtained from your local V okera Sales Representative .

●●

● CO FUNCTION: the CO function when

●●

activated, will allow the appliance to run at maximum and minimum output whilst a combustion analysis check is being carried out. Whilst the CO function is active, all other functions are disabled (minimum power operating period, anti-cycle, set-point, etc). Once enabled, the CO function will remain active for a 15-minute period, or until the function is manually deactivated

●●

● FROST-PROTECTION: this function is only active

●●

when there are no requests for heating or HW . If the temperature drops below 6°C, the boiler will operate on minimum power until the temperature of the primary thermistor reaches 35°C. Thereafter the pump & fan will over-run for 30-seconds.

●●

● ANTI-CYCLE FUNCTION: the anti-cycle

●●

function ensures the burner remains switched off for at least 3-minutes after the set-point hysterisis (set-point + 5-deg).

●●

● PUMP ANTI-BLOCK FUNCTION: when there

●●

has been no heating or HW request for 24-hours, the anti-block cycle is activated. The pump will be activated for a period of 30-seconds.

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7.2.5 HEA TING MODE

With the selector switch in the ON position and any additional controls (time clock, programmer , room thermostat, etc,) calling for heat, the appliance will operate in the heating mode. The pump and f an will be activated via the flow temperature sensor . When the fan is sensed to be operating correctly (tacho signal), 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 increases the gas rate to 75% of the MAX Heating (set by the corresponding HTG trimmer) for a period of 15 minutes. 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 (+ hysterisis), the burner will switch off . The b uiltin anti-cycle device prevents the burner from relighting for approximately 3-minutes. When the temperature of the flow sensor falls below the set point (- hysterisis), 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 setpoint 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 5°C (hysterisis), the burner will shut down. A new ignition sequence will be enabled when the 3- minute anti-cycle has been performed and the temperature at the primary thermistor has dropped 5°C (hysterisis) below the set-point.

NOTES

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

7.3 APPLIANCE F AN SPEEDS

The appliance fan speeds require to be checked and/or adjusted prior to making any adjustments to the gas valve or if the main PCB has been replaced.

ATTENTION Gas type and appliance fan speed (output) must be set according to the specific appliance

specification. V okera accepts no responsibility if the gas type and/or fan speed is not correctly adjusted according to the respective appliance specification as detailed on the appliance data badge.

7.3.1 CHECKING/ADJUSTING THE APPLIANCE F AN SPEEDS

Move the selector switch to the OFF position and remove the 3-selector knobs.

7.3.2 ABSOLUTE MAX FAN SPEED

Locate the MAX trimmer (fig. 32) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table 7.3.6).

NOTE

The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

7.3.3 ABSOLUTE MIN F AN SPEED

Locate the MIN trimmer (fig. 32) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table 7.3.6).

NOTE

The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

7.3.4 IGNITION FAN SPEED ATTENTION Do this operation only after the adjusting of absolute max and min fan speed.

Locate the IGN trimmer (fig. 32) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table 7.3.6).

NOTE

The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

7.3.5 HEA TING FAN SPEED

Locate the HTG trimmer (fig. 32) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table 7.3.6). speed (see table 7.3.6).

NOTE

The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

Fig. 32

7.3.6 FAN SPEED T ABLE

Use the following table to set the corresponding fan speeds that are relative to the appliance you are working on.

F AN SPEED (rpm) TABLE MODEL MAX MIN HTG IGN 12HE 3.700 1.300 3.500 3.700 15HE 4.200 1.300 4.200 3.700 20HE 5.400 1.700 5.400 3.700 25HE 5.500 1.700 5.500 3.700 30HE 5.200 1.400 5.200 3.700 35HE 6.000 1.400 6.000 3.700

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7.4 CHECKING THE CO2 AND ADJUSTING THE GAS V AL VE

THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRA TED 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 CO2 and insert the probe into the flue analysis test point (A, B fig. 31). Restore the electrical supply to the boiler and switch the boiler to the OFF mode. To adjust the gas valve you must first ensure that the fan speed potentiometers (trimmers) have been set correctly (see 7.3). Remove the 3-selector knobs, locate and press the CO button (see fig. 32). The appliance will now operate in CO mode for approximately 15-minutes (see 7.10).

7.4.1 GAS VALVE MAXIMUM SETTING

Locate and gently turn the HTG trimmer till the maximum value (fan speed) is obtained and check that it corresponds with the appropriate CO2 value (Maximum) for the respective appliance. If the CO2 reading is correct, proceed to gas valve minimum setting (7.4.2). However, if the CO2 reading is incorrect, the maximum gas pressure must be adjusted as follows:

●●

● Using a suitable screwdriver, very slowly tur n

●●

the maximum adjustment screw (see fig. 33) – clockwise to decrease, counter clockwise to increase – until the correct value is displayed on the CO2 analyser (allow time for the analyser to stabilise).

7.4.2 GAS VAL VE MINIMUM SETTING

Locate and gently turn the HTG trimmer till the minimum value (fan speed) is obtained and check that it corresponds with the appropriate CO2 value (Minimum) for the respective appliance. If the CO2 reading is correct, rotate the HTG trimmer until the correct value is obtained for the respective appliance (see fan speed table) and proceed to 7.4.3. However, if the CO2 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. 33) – clockwise to increase, counter clockwise to decrease - until the correct value is displayed on the CO2 analyser (allow time for the analyser to stabilise).

Maximum

screw

Compensation

pipe connection

Minimum

screw

Fig. 33

7.4.3 COMPLETION

On completion of the combustion analysis check and/or any gas valve adjustment, set the HTG trimmer to the corresponding value as detailed in the fan speed table. Refit the 3-selector knobs and move the mode selector to the OFF position. Remove the test probe from the test point and refit the sealing screw/s and/or cap.

IMPORTANT

A GAS SOUNDNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED, REPLACED , OR DISTURBED .

7.5 COMBUSTION ANAL YSIS TEST

A combustion analysis check can easily be carried out on the appliance via the test points located on the top of the appliance (see 7.4).

●●

● Insert the flue gas analyser probe into the flue

●●

gas test point (see fig. 31).

●●

● Operate the boiler in CO mode and compare

●●

the values with those shown in section 2 (Nat. Gas) or section 10 (LPG). If different adjust the gas valve according to 7.4.1, 7.4.2, & 7.4.3.

7.6 CHECKING THE EXP ANSION 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 re-charging takes place. Replace the dust cap and carry out the relevant commissioning procedure (section 5).

7.7 EXTERNAL FA UL TS

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

7.7.1 INST ALLA TION F A UL TS

Symptom Possible cause

No display/ignition Check wiring/check No hot water Check external controls

No heating Check external controls

Fault code Possible cause 10 Check gas supply, check

electrical supply

flue system, check polarity

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 ear th 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.

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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 (fig.16). Repeat above test on the Live & Earth connections at the appliance terminal strip (fig.16).

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 (fig.16). 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 (fig.16). 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 (fig.16). The meter should read appro ximately 0 – 15V ac. If so polarity is correct. If not, see 7.8.4.

7.8.4 REVERSED POLARITY OR SUPPL Y F A UL T

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 test. Connect test leads between the Live & Earth connections at the appliance terminal strip (fig. 16). 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. 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 F AUL T 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 M5 (fig. 16), and insert a link-wire between the two wires at the ‘TA’ connections (fig. 16).

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 flo wcharts located at the end of this section.

7.10 COMPONENT V ALUES & CHARACTERISTICS

COMPONENT VALUE

Fan 230Vac Pump 230Vac Valve actuator (Combi only) 230Vac Ignition transformer 230Vac Gas valve 230Vac Room thermostat connection 230Vac NTC thermistor (dry contact) 10Kohm NTC thermistor (wet contact) 10Kohm

FUNCTION VALUE

Standard Heating Range (°C) 40 – 80 Floor Heating Range (°C) 20 – 45 CH limited power at 75% 15 Min Heating OFF hysterisis ( Heating ON hysterisis (

C) SP + 5

C) SP – 5 Anti-cycle delay 3-min Pump over-run 30-sec Low output (min. output + %) Min+25 CO function max temp. (0C) 95

CO re-light temp. (

C) 75 CO function time 15-min Flow NTC max temp. (0C) 95

High limit thermostat ( Burner thermostat ( Maximum differential (

C) 105

C) 170

C) 35

IGNITION CONTROL VALUE

Ignition attempts before L/O (lockout). 5 Re-ignition attempts after loss of flame signal 5

7.11 BOILER CONFIGURATION

The boiler can be configured by means of the JUMPER Tag which configuration is shown in the below:

JP4 CONFIGURA TION

●●

● JUMPER ON POSITION 1: FLOOR HEA TING

●●

(IF SET) / ST AND ARD HEA TING (IF NOT USED)

●●

● JUMPER ON POSITION 2: (UNUSED)

●●

● JUMPER ON POSITION 3: (UNUSED)

●●

● JUMPER ON POSITION 4: (UNUSED)

●●

● JUMPER ON POSITION 5: (UNUSED)

●●

● JUMPER ON POSITION 6: CH HEA TING ONL Y.

●●

FOR CONFIGURATION SEE REFERENCE NUMBER (PIN1 ON PCB) AS SHOWN IN BELOW.

JP4

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7.12 FAULT CODES

When the boiler detects a temporary fault condition, the appropriate code is shown flashing on the display. If/when the fault code is final, the pump will perform a 60-second post circulation and the red LED will be illuminated.

CODE CAUSE ALARM TYPE ACTION

AL10 Ignition failure/not flame sensed, Final Reset, check appliance operation

condense sensor activated

AL20 Limit thermostat fault Final Reset, check appliance operation AL21 External device fault (UHT/CPA) Final Reset, check appliance AL26 Return temperature too high Final Reset, check pump, ensure there is sufficient

flow sensor temperature). circulation around heating circuit/s

AL28 Temperature differential inverted Final Reset, check pump, ensure there is sufficient

(return sensor temperature higher than circulation around heating circuit/s thermistors

flowsensor temperature) AL34 Fan tacho signal fault Final Reset check appliance operation, check fan AL40 Insufficient system water pressure Final Check/refill system pressure, reset, check

appliance operation

AL41 Insufficient system water pressure Temporary Check/refill system pressure, check appliance

operation

AL52 Internal fault Final Reset, check appliance operation

AL5 5 Jumper tag fault Final Check jumper tag configuration

AL60 Jumper tag fault Temporary Check jumper tag configuration AL71 Primary (flow) thermistor fault Temporary Check primary ther mistor, check wiring AL73 Return thermistor fault Temporary Check return thermistor, check /wiring AL74 Variation on temperature of primary Final Reset, check appliance operation, check

and/or return too high pump, ensure there is sufficient circulation

around heating circuit/s

AL79 Flow temperature too high, or Final Reset, check appliance operation, check

temperature differential between thermistors

primary and return too high

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SECTION 8 WIRING DIAGRAMS

8.1 EXTERNAL WIRING

The appliance comes with a factory fitted (TA) 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 0870 333 0520.

8.1.1 EXTERNAL WIRING LIMITATIONS

Any external wiring must remain within the limits as detailed in the table below

CONNECTION MAX. LENGTH

External sensor 30-metres Room thermostat 30-metres OT+ connection 30-metres

8.2 TYPICAL CONTROL APPLICA TIONS

The appliance can be used with the following controls:

●●

● single-channel, voltage-free time clocks (fig. 34a)

●●

● programmable room thermostats (fig. 34b)

●●

● twin-channel programmers (figs 39 & 40). The

●●

appliance can be used in conjunction with typical ‘S’-Plan/’Y’-Plan systems (see 8.4.1 & 8.4.2), please contact Vokera technical should you require further detailed instruction.

8.3 OTHER DEVICES

Although it’s permissible to use/connect certain OT+ (Opentherm Plus) controls or the Vokera external sensor, you should ensure that these controls do not inhibit or limit the response to any heat request from a DHW cylinder. Contact the controls manufacturer and/or V okera 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.energyefficiency.gov.uk).

Fig. 34b

OPTIONAL DEVICE (24V) TERMINAL BLOCK

U.H.T. = underfloor heating thermostat C.P.A.= condensate pump alarm E.S.= external sensor OT+= opentherm + connection

Fig. 35

8.4 VOKERA TWIN-CHANNEL PROGRAMMER

Fig. 34a

(code 514)

The Vokera 2-channel programmer kit (product code 514) has been developed specifically for the Mynute HE range and eliminates the need for an external programmer . The kit is comprised of the following:

●●

● 2-channel programmer

●●

● 24V wiring harness

●●

● 230V wiring harness & terminal strip

●●

● instructions.

●●

Isolate the appliance from the electrical supply; unhook and remove the control PCB cover. Remove the clock blanking disc from the clock aperture on the boiler. Secure the programmer to the clock aperture using the screws previously removed.

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Fig. 36

CONNECTIONS

Fig. 37

PROGRAMMER

TERMINAL STRIPS

Unhook and lift the connection casing; connect the end of the 24V harness to the 24V connection on the main PCB (A1, see fig. 38).

Unhook and remove the cover of connection casing. Passing under connection casing insert the four terminal strip (M4) and the 230V wiring harness in the opening. Position the four terminal strip in the own seat (see photos 36 & 37) and connect the 230 wiring harness as indicated in the figs 39 & 40. The programmer can be used with a typical ‘S’ – Plan or ‘Y’ – Plan controls arr angement as detailed in figures 39 & 40.

IMPORTANT

●●

● The boiler must always be supplied with a

●●

permanent 230V electrical supply.

●●

● Always remove the link between T A & TA on the

●●

appliance 230V terminal strip whenever additional controls are connected to the appliance.

●●

● Do not connect any controls or auxiliary

●●

equipment to the 24V terminal strip, other than that approved/supplied b y V ok era Ltd.

CASING

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FUNCTIONAL DIAGRAM

Fig. 38

CONTROL SWITCHING OF TIME CLOCK AND ROOM THERMOSTAT RATED IS 230 V.a.c.

NOTE. L-N-E CONNECTION MUST NOT BE INTERCHANGED

Key

F Hv Fan power supply 230 V F Lv Fan signal control P Pump F Fuse 3.15A F (fast) F1-F2 Fuse 3.15A T (delay) OPE Gas valve solenoids S.E. (1) Spark electrode S.E. (2) Sense electrode C.S. Condensate sensor G.V. Gas valve TSC1 Ignition transformer TR2 PCB transformer E.S. External sensor WPS Water pressure switch FS Flow thermistor (NTC) RS Return thermistor (NTC) AD01A Main PCB CN1÷CN5 Connection to PCB 230V X2÷X16 Connection to PCB 24V F.O.H.T. Flow over heat thermostat

H.E.T. Heat exchanger thermostat M3-M5 Terminal strip for supply in/clock/room thermostat M3a-M4 Terminal strip for esternal sensor/condense pump / low

OT+ Open therm + connection JP6 For system open vent boilers X1 Connector minitank (unused) CN12 Service connector SW1 Co button A1 24V output to 2CH - programmer P1 DHW potentiometer (unused) P2 Heating potentiometer P3 Selector switch R9 Trimmer for maximum output R10 Trimmer for minimum output R14 Trimmer for ignition fan speed R19 Trimmer for heating fan speed R35 Trimmer thermoregulation UHT Underfloor heating thermostat CPA Condensate pump alarm

temperature thermostat

Page 32

Supplied By www.heating spares.co Tel. 0161 620 6677

FUNCTIONAL DIAGRAM

Fig. 39

Wiring Centre

or Junction Box

green-yellow

8.4.1. “S” - Plan with Vokera 2-channel programmer

REMOVE LINK WIRE

Room Thermostat

Load

Live

Common

Calling

Cylinder Thermostat

blue

grey

brown

orange

blue

brown

green-yellow

orange

grey

Boiler & programmer

connections

E N

Fig. 40

Load

Live

Room Thermostat

8.4.2. “Y” - Plan with Vokera 2-channel programmer

REMOVE LINK WIRE

Wiring Centre

Wiring Centre or Junction Box

or Junction Box

OFF

Satisfied

Common

Cylinder Thermostat

Boiler & programmer

connections

3-Port

3-Port Motorised Valve

Motorised Valve

Grey

Orange

White

White Blue

Blue

Green/Yellow

Green-Yellow

Calling

E N

Page 33

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SECTION 9 EXPLODED DIAGRAMS

T able 1

300

Mynute 12-15-20 HE

301

226

302

226

301

302

226

300

Mynute

25 HE

226

Mynute 30-35 HE

300

301

302

226

POS. DESCRIPTION 12 HE 15 HE 20 HE 25 HE 30 HE 35 HE

1 Frame assembly 01005441 01005441 01005441 01005444 01005445 01005445 12 Pressure gauge 2564 2564 2564 2564 2564 2564 18 Cover assembly 10028554 10028554 10028554 10028554 10028554 10028554 20 Printed Circuit Board 10028558 10028558 10028558 10028558 10028558 10028558 21 Led light guide 10028557 10028557 10028557 10028557 10028557 10028557 26 Front panel 10028551 10028551 10028551 10028551 10028551 10028551 27 Knob assembly 10028559 10028559 10028559 10028559 10028559 10028559 31 Case assembly 10028432 10028432 10028432 10028448 10028451 10028451 40 Door panel 10028553 10028553 10028553 10028553 10028553 10028553 78 Cover assembly 01005442 01005442 01005442 01005442 01005442 01005442 90 Fuse 3478 3478 3478 3478 3478 3478 226 Edge clip 5128 5128 5128 5128 5128 5128 300 Wiring harness 10028598 10028598 10028598 10028598 10028596 10028596 301 Wiring harness 10028593 10028593 10028593 10028593 10028598 10028598 302 Wiring harness 10028596 10028596 10028596 10028596 10028593 10028593

Page 34

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T able 2

Mynute 12-15-20 HE

Mynute

25 HE

353

266

353

432

288

266

265

Mynute 30-35 HE

200

290

353

288

266

353

432

290

266

265

200

290

200

265

432

288

266

353

266

353

POS. DESCRIPTION 12 HE 15 HE 20 HE 25 HE 30 HE 35 HE

3 Pressure switch 2044 2044 2044 2044 2044 2044 7 Heating by-pass valve 2047 2047 2047 2047 1552 1552 9 Heating manifold 10028415 10028415 10028415 10028415 10028415 10028415 22 Safety valve 2907 2907 2907 2907 2907 2907 27 Heating cock 1789 1789 1789 1789 1789 1789 31 Drain tap 01005137 01005137 01005137 01005137 01005137 01005137 63 Pipe 10020898 10020898 10020898 10020898 10020898 10020898 200 Washer 5023 5023 5023 5023 5023 5023 265 Washer 5236 5236 5236 5236 5236 5236 266 Washer 5237 5237 5237 5237 5237 5237

288 Ring 6898 6898 6898 6898 6898 6898 290 Clip 2165 2165 2165 2165 2165 2165 353 Nut 1824 1824 1824 1824 1824 1824 432 Clip 10024958 10024958 10024958 10024958 10024958 10024958

Page 35

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T able 3

Mynute 12-15-20 HE

Mynute

476

477

302

476

477

290

478

200

247

478

287

200

25 HE

290

476

477

476

477

478

201

200

247

478

287

200 200

Mynute 30-35 HE

290

372

201

290

512

72 324

476

477

478

200

247

200

290

477

478

287

512

372

290

372

512

POS. DESCRIPTION 12 HE 15 HE 20 HE 25 HE 30 HE 35 HE

1 Expansion vessel 10028535 10028535 10028535 2204 2573 2573 2 Pipe 10028603 10028603 10028603 10023603 10023603 10023603 3 Pump 10027571 10027571 10027571 10027571 10027258 10027258 4 Wiring harness (pump) 10028594 10028594 10028594 10028594 10028594 10028594 6 Pipe 10028428 10028428 10028428 10028617 10028624 10028624 7 Pipe 10027317 10027317 10027317 10027317 10027317 10027317 9 Pipe 10028429 10028429 10028429 10028429 10028264 10028264 10 Pipe 10028904 10028904 10028904 10028906 10028905 10028905 17 Air venting plug 10026275 10026275 10026275 10026275 10026275 10026275 25 Siphon 10028405 10028405 10028405 10028405 10028405 10028405 26 Condensing pipe 10028540 10028540 10028540 10028540 10027191 10027191 27 Condensing pipe 10027192 10027192 10027192 10027192 10027192 10027192 66 Condensing pipe 10028539 10028539 10028539 10028539 10026272 10026272 71 Pipe 10028430 10028430 10028430 10028430 10028515 10028515 72 Venting-plug 01005137 01005137 01005137 01005137 01005137 01005137 73 Cock 10028431 10028431 10028431 10028431 10028431 10028431 200 Washer 5023 5023 5023 5023 5023 5023 201 Washer - - - 5026 5026 5026 247 Washer 5203 5203 5203 5203 5203 5203 287 High limit thermostat 2258 2258 2258 2258 2258 2258 290 Clip 2165 2165 2165 2165 2165 2165 302 Washer 5025 5025 5025 - - 372 Clip 2588 2588 2588 2588 2588 2588 476 O ring 10026324 10026324 10026324 10026324 10026324 10026324 477 Split pin 10026269 10026269 10026269 10026269 10026269 10026269 478 Ntc sensor 10026273 10026273 10026273 10026273 10026273 10026273 512 Washer 10027193 10027193 10027193 10027193 10027193 10027193

Page 36

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T able 4

200

479

486

497

500

501

502

600

Mynute

12-15-20 HE

479

Mynute 25 HE

486

497

200

501

502

600

200

500

Mynute 30-35 HE

479

486

600

POS. DESCRIPTION 12 HE 15 HE 20 HE 25 HE 30 HE 35 HE

1 Roomsealed chamber 10028341 10028341 10028341 10028341 10028447 10028447

2 Side 10026231 10026231 10026231 10026231 10026231 10026231

3 Fan 10028456 10028456 10028456 10028456 10028456 10028456

4 Burner 10028537 10028537 10028537 10028537 10028537 10028537

5 Spark/ignition electrode 10027864 10027864 10027864 10027864 10027864 10027864

6 Condense electrode 10026316 10026316 10026316 10026316 10026316 10026316

12 Gas pipe 10028423 10028423 10028423 10028628 10028629 10028629

13 Gas valve 10028538 10028538 10028538 10028538 10028538 10028538

15 3/4" gas cock 10020897 10020897 10020897 10020897 10020897 10020897

16 Air box cover 10028345 10028345 10028345 10028345 10026230 10026230

19 Glass stopper assembly 10026328 10026328 10026328 10026328 10026328 10026328

27 Plug 10023805 10023805 10023805 10023805 10023805 10023805

35 Air gas conveyor 10028420 10028420 10028420 10028420 10028420 10028420

39 Gas pipe 10028424 10028424 10028424 10028424 10028206 10028206

46 Gas diaphragm 10020265 10020265 10020265 10027161 10027162 10027162

67 Washer 10026322 10026322 10026322 10026322 10026322 10026322

69 Tryton 10028425 10028425 10028425 10028425 10028425 10028425

72 Mixer 10027408 10027408 10027408 10024295 10024295 10024295

79 Flame detection electrode 10028422 10028422 10028422 10028422 10028422 10028422

200 Washer 5023 5023 5023 5023 5023 5023

479 Transformer 10026237 10026237 10026237 10026237 10026237 10026237

486 O ring 10026325 10026325 10026325 10026325 10026325 10026325

497 Washer 10026796 10026796 10026796 10026796 10026796 10026796

500 Wiring harness 10028599 10028599 10028599 10028599 10028599 10028599

501 Wiring harness (gas valve) 10028600 10028600 10028600 10028600 10028626 10028626

502 Spark electrode cable 10026558 10026558 10026558 10026558 10026558 10026558

600 Lpg conversion kit 01005446 01005446 01005446 01005447 01005448 01005448

200

500

200

501

502

35 497

Page 37

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T able 5

475

487

552

600

601

509

482

487

552

600

Mynute 12-15-20 HE

487

475

600

601

509

482

Mynute 25 HE

475

552

509

482

Mynute 30-35 HE

POS. DESCRIPTION 12 HE 15 HE 20 HE 25 HE 30 HE 35 HE

1 Condensing exchanger assembly 01005443 01005443 01005443 01005443 01005369 01005369 7 Conveyor 10028536 10028536 10028536 10028536 10028623 10028623 12 Flue drain connection 10028421 10028421 10028421 10028421 10028421 10028421 475 Washer 10026323 10026323 10026323 10026323 10026323 10026323 482 Washer 10026366 10026366 10026366 10026366 10026366 10026366 487 Washer 10026345 10026345 10026345 10026345 10026345 10026345 509 High limit thermostat 10026982 10026982 10026982 10026982 10026982 10026982 552 Washer 10028426 10028426 10028426 10028426 10028426 10028426 600 Wiring harness (gas valve) 10028595 10028595 10028595 10028595 10028601 10028601 601 Wiring harness 10027360 10027360 10027360 10027360 10027360 10027360

Page 38

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SECTION 10 LPG INSTRUCTIONS

10.1 RELATED DOCUMENTS

BS 6798

BS 5449

BS 5446

BS 5440

BS 5482

PART 1

PART 1 PART 1

10.2 TECHNICAL DATA

Gas Pressures 12HE 15HE 20HE 25HE 30HE 35HE

Inlet pressure 37.00 37.00 37.00 37.00 37.00 37.00 mbar Maximum gas rate 0.93 1.16 1.55 1.94 2.33 2.69 kg/hr Minimum gas rate 0.27 0.27 0.39 0.47 0.54 0.54 kg/hr Injector size 3.6 3.6 3. 6 4.7 5.0 5.0 m m

Efficiency

SEDBUK (%) 93.3 92.9 92.6 92.4 92.8 92.9

Emissions

CO max (mg/kWh) 129.0 172.0 215.0 215.0 236.5 268.8 mg/kWh CO min (mg/kWh) 10.8 10.8 10.8 16.1 32.3 32.3 mg/kWh NOx max (mg/kWh) 123.6 141.2 97.1 70.6 88.3 88.3 mg/kWh NOx min (mg/kWh) 35.3 35.3 53.0 53.0 70.6 70.6 mg/kWh CO2 max 10.0 10.0 10.0 10.0 10.0 10.0 % CO2 min 10.0 10.0 10.0 10.0 10.0 10.0 % CO/CO2 ratio (max) 0.001 to 1 0.001 to 1 0.002 to 1 0.002 to 1 0.002 to 1 0.002 to 1 CO/CO

ratio (min) 0.0001 to 1 0.0001 to 1 0.0001 to 1 0.0001 to 1 0.0003 to 1 0.0003 to 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

Band “A” Band “A” Band “A” Band “A” Band “A” Band “A”

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.

●●

● To change the injector see 6.12.1

●●

● To adjust CO2 value see 7.4.1-2-3

●●

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 soundness.

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.

10.6a CHECKING THE CO2 AND ADJUSTING THE GAS V AL VE

THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANAL YSER. 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 CO2 and insert the probe into the flue analysis test point (A,

B fig. 31). Restore the electrical supply to the boiler and switch the boiler to the OFF mode. To adjust the gas valve you must first ensure that the fan speed potentiometers (trimmers) have been set correctly (see 10.7). Remove the 3-selector knobs, locate and press the CO button (see fig. 32). The appliance will now operate in CO mode for approximately 15-minutes (see 7.10).

10.6.1 GAS VALVE MAXIMUM SETTING

Locate and gently turn the HTG trimmer till the maximum value (fan speed) is obtained and check that it corresponds with the appropriate CO2 value (Maximum) for the respective appliance. If the CO2 reading is correct, proceed to gas valve minimum setting (10.6.2). However, If the CO2 reading is incorrect, the maximum gas pressure must be adjusted as follows:

●●

● Using a suitable screwdriver, very slowly turn

●●

10.6.2 GAS VALVE MINIMUM SETTING

Page 39

Supplied By www.heating spares.co Tel. 0161 620 6677

the correct value is obtained for the respective appliance (see fan speed table) and proceed to

10.6.3. However, If the CO2 reading is incorrect, the

minimum gas pressure must be adjusted as follows:

●●

● Using a suitable screwdriver, very slowly turn

●●

10.6.3 COMPLETION

IMPORTANT A GAS SOUNDNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED, REPLACED, OR DISTURBED.

10.7.3 ABSOLUTE MIN FAN SPEED

Locate the MIN trimmer (fig. 32) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table above).

NOTE

The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

10.7.4 IGNITION FAN SPEED ATTENTION Do this operation only after the adjusting of absolute max and min fan speed.

Locate the IGN trimmer (fig. 32) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table above).

NOTE

The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

10.7.5 HEATING FAN SPEED

Locate the HTG trimmer (fig. 32) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table above).

NOTE

The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

F AN SPEED (rpm) TABLE MODEL MAX MIN HTG IGN 12HE 3.700 1.300 3.500 3.700 15HE 4.100 1.300 4.100 3.700 20HE 5.400 1.700 5.400 3.700 25HE 5.400 1.700 5.400 3.700 30HE 5.200 1.400 5.200 3.700 35HE 6.000 1.400 6.000 3.700

10.7 APPLIANCE FAN SPEEDS

The appliance fan speeds require to be checked and/or adjusted prior to making any adjustments to the gas valve or if the main PCB has been replaced.

ATTENTION Gas type and appliance fan speed (output) must be set according to the specific appliance speci-

fication. Vokera accepts no responsibility if the gas type and/or fan speed is not correctly adjusted according to the respective appliance specification as detailed on the appliance data badge.

10.7.1 CHECKING/ADJUSTING THE APPLIANCE FAN SPEEDS

Move the selector switch to the OFF position and remove the 3-selector knobs.

10.7.2 ABSOLUTE MAX FAN SPEED

Locate the MAX trimmer (fig. 32) and gently adjust clockwise or counter clockwise to achieve the correct fan speed (see table above).

NOTE

The display shows the fan RPM in multiples of 1000, i.e. 2.5 = 2500RPM.

Page 40

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BENCHMARK No.

COLLECTIVE MARK

GAS BOILER COMMISSIONING CHECKLIST

BOILER SERIAL No. NOTIFICATION No.

CONTROLS

TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT

TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER

HEATING ZONE VALVES FITTED NOT REQUIRED

HOT WATER ZONE VALVES FITTED NOT REQUIRED

THERMOSTATIC RADIATOR VALVES FITTED

AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED

To comply with the Building Regulations, each section must have a tick in one or other of the boxes

COMBI BOILER

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURERS INSTRUCTIONS?

THE SYSTEM CLEANER USED

THE INHIBITOR USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

N/A

/hr

GAS RATE

BURNER OPERATING PRESSURE (IF APPLICABLE)

CENTRAL HEATING FLOW TEMPERATURE °C

CENTRAL HEATING RETURN TEMPERATURE °C

/hr

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED? YES NO

WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

N/A

/hr

GAS RATE

MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

COLD WATER INLET TEMPERATURE °C

HOT WATER OUTLET TEMPERATURE °C

WATER FLOW RATE

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS? YES

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS

THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS

IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2RATIO READING? N/A YES CO/CO2RATIO

THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER

THE MANUFACTURERS LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

/hr

lts/min

COMMISSIONING ENGS NAME

PRINT CORGI ID No.

SIGN DATE

Page 41

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SERVICE INTERVAL RECORD

It is recommended that your heating system is serviced regularly

and that you complete the appropriate Service Interval Record Below.

Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service

as described in the boiler manufacturers instructions. Always use the manufacturers specified spare part when replacing all controls

SERVICE 1

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 3

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 5

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

DATE

SERVICE 2

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 4

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 6

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

DATE

SIGNATURE

SERVICE 7

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 9

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

DATE

SIGNATURE

SERVICE 8

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 10

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

DATE

Page 42

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Page 43

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Page 44

Supplied By www.heating spares.co Tel. 0161 620 6677

energizing home heating

Vokèra Ltd.

4th Floor, Catherine House, Boundary Way, Hemel Hempstead, Herts, HP2 7RP

Cod. 10028541 - 21/06 - Ed. 1

Email: enquiries@vokera.co.uk Web: www.vokera.co.uk

Sales, Technical Advice, General Enquiries - Tel: 0870 333 0520 Fax: 01442 281403

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

After Sales Service - Tel: 0870 333 0220

Vokèra Ireland

West Court, Callan, Co Kilkenny

Tel: 05677 55057 F ax: 05677 55060

A Riello Group Company

COLLECTIVE MARK

“Vok èra”

supports Benchmark

VOKERA Mynute 12HE, Mynute 15HE, Mynute 35HE, Mynute 20HE, Mynute 25HE Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual