Vokera Pinnacle 16 User guide

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Installation & Servicing Instructions

THESE INSTRUCTIONS TO BE RETAINED BY USER

Contents

Design principles & operating sequence Page

1.1 Principle components 2

1.2 Mode of operation (at rest) 2

1.3 Mode of operation (heating or hot water request) 2

1.4 Safety devices 2

Technical data Page

2.1 Central heating 3

2.2 Gas pressure 3

2.3 Expansion vessel 3

2.4 Dimensions 3

2.5 Clearances 3

2.6 Connections 3

2.7 Electrical 3

2.8 Flue details 3

2.9 Efficiency 3

2.10 Adjusting operating parameters 3

2.11 Emissions 3

2.12 Pump duty 4

General requirements (UK) Page

3.1 Related documents 5

3.2 Location of appliance 5

3.3 Gas supply 5

3.4 Flue system 5

3.5 Air supply 5

3.6 Water circulation 5

3.7 Electrical supply 6

3.8 Mounting on a combustible surface 6

3.9 Timber framed buildings 6

3.10 Condensate disposal 6

3.11 Inhibitors 6

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.10 Condensate disposal 9 3A.11 Inhibitors 9 3A.12 Declaration of conformity 9

Installation Page

4.1 Delivery 10

4.2 Contents 10

4.3 Unpacking 10

4.4 Preparation for mounting the appliance 10

4.5 Fitting the flue 10

4.6 Connecting the gas & water 13

4.7 Condensate outlet 13

4.8 Automatic air release valve 14

4.9 Electrical connections 14

4.10 Casing removal 15

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 head 18

6.6 Safety valve 18

6.7 Automatic air release valve 18

6.8 Pressure gauge 18

6.9 NTC thermistors (temperature sensors) 19

6.10 Printed circuit board (PCB) 19

6.11 Gas valve 19

6.12 Fan 19

6.13 Burner 19

6.14 Electrode 20

6.15 Injector 20

6.16 Automatic by-pass assembly 20

6.17 Condense trap 20

6.18 Condense pressure switch 20

6.19 Combustion cover 20

6.20 Expansion vessel 21

6.21 Input & status PCB 21

Checks, adjustments and fault finding Page

7.1 Checking appliance operation 22

7.2 Appliance mode of operation 22

7.3 Service paameters (5-42) 22

7.4 Adjusting the gas valve 22

7.5 1st digit status code 24

7.6 Temporary fault codes 24

7.7 Final fault codes 24

7.8 Diagnostic recall 24

7.9 Checking the expansion vessel 24

7.10 External faults (installation) 25

7.11 Electrical checks 25

7.12 Fault finding 25

Wiring diagrams Page

8.1 Installation of Vokera time clock 31

8.2 External controls important 31

Exploded diagrams Page

9.1 Table 1 36

9.2 Table 2 37

9.3 Table 3 38

9.4 Table 4 39

9.5 Table 5 40

L.P.G. instructions Page

10.1 Technical data 41

10.2 Related documents 41

10.3 Gas supply 41

10.4 Gas supply installation 41

10.5 Adjusting the gas valve 41

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 Final flushing of the heating system 16

5.8 Inhibitors 16

5.9 Appliance operating parameters 16

5.10 Parameters 3 & 4 16

5.11 Information mode 16

5.12 Setting the system design pressure 17

5.13 Regulating the central heating system 17

5.14 Checking dynamic gas pressure 17

5.15 Final checks 17

5.16 Instructing the user 17

INTRODUCTION

The Pinnacle range of boilers are central heating condensing boiler, which – by design – incorporates full sequence electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge and automatic bypass. Pinnacle is produced as a room sealed, category C1, C3, C6 appliance, suitable for wall mounting applications only. Pinnacle is provided with a fan powered flue outlet

4 3

with an annular co-axial combustion air intake that can be rotated – horizontally – through 360 degrees for various horizontal or vertical applications. Pinnacle can also be used with the Vokera twin flue system. This appliance is designed primarily for use with sealed systems; however it can also be used on an open vented system, provided that the necessary installation requirements are met.

10 11

General layout (fig. 1A)

1 Auto by-pass 2 Safety valve

12 13

3 Condense trap 4 Pump 5 Return sensor (NTC2) 6 Gas valve 7 Silicone pressure tube

14 15

8 Flow sensor (NTC1) 9 Auto air vent (AAV) 10 Flue outlet & air intake

11 Flue gas analysis test point 12 Burner plate

13 Expansion vessel 14 Spark/Sensing Electrode 15 Heat exchanger 16 Pressure switch

17 Fan assembly 18 Electronic Control Board (PCB) R Heating return connection F Heating flow connection G Gas connection

Fig. 1A

Fig. 1B

RF G

Control board (fig. 1B)

1 STEP button 2 PLUS button

3 MODE button 4 4 digits display

3 2

6 7

5 Status LED 6 RESET button 7 MINUS button 8 CH button/MEMO button

9 Time clock aperture 10 Pressure gauge

SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS

● A fully integrated electronic control board

featuring differential temperature control, continuous air/gas modulation, anti-cycle control, pump over-run, self-diagnostic fault indicator, electronic ignition with flame supervision & appliance frost protection

● Cast aluminium mono-block heat exchanger

● Low Nox burner with pre-mix

● Two-stage gas valve

● Pump

● Expansion vessel

● Pressure gauge

● Safety valve

1.2 MODE OF OPERATION (at rest)

When there is no demand for heating or hot water and the appliance remains inactive for a period of 24 hours, the pump will be energised for a few moments to prevent it from seizing. Should the flow temperature sensor fall below 7 ºC the pump will be energised. If the flow sensor temperature falls to below 3 ºC the burner will be lit and the appliance will operate at the minimum output until the temperature of the flow sensor reaches 10 ºC, whereupon the pump will continue to run in pump over-run mode.

differential is inverted;

● a fan speed sensor that checks the correct

operation of the fan, thereby allowing safe operation of the burner;

● a condense pressure switch that will stop the

burner from operating should the condense trap become blocked;

● a safety valve which releases excess pressure

from the primary circuit.

NTC1

(flow

sensor)

Heat

exchanger

Expansion

vessel

1.3 MODE OF OPERATON (heating or hot water request)

When there is a request for heat via the time clock and/or external controls, the pump will start and the fan will be activated via the flow temperature sensor. When the fan is sensed to be operating correctly, the ignition sequence commences. The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow & return temperature sensors, 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 and return pipes of the boiler – reduce the fan speed via the electronic circuitry. Depending on the load, either the water temperature will continue to rise until the set point is achieved or the water temperature will fall whereby fan speed will increase relative to the output required. When the boiler has reached the set point, the burner will switch off. The built-in anti-cycle device prevents the burner from relighting for an adjustable period of time (factory default is 3 minutes). When the temperature of the flow sensor falls below the set-point, the burner will re-light.

NTC2

(return

sensor)

return flowgas

Fig. 2

1.4 SAFETY DEVICES

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

● a high limit thermostat that interrupts the

operation of the burner;

● a differential temperature protection circuit which

interrupts the burner if the temperature

SECTION 2 TECHNICAL DATA

2.1 Central heating 16 26

Heat input (gross) 17.7 kW 29 kW Maximum heat output 60/80°C (return & flow temperature) 15.4 kW 25.3 kW Maximum heat output 30/50°C (return & flow temperature) 16.8 kW 26.8 kW Minimum heat output 60/80°C (return & flow temperature) 4.4 kW 7.3 kW Minimum heat output 30/50°C (return & flow temperature) 4.9 kW 8.1 kW Minimum working pressure 0.5 bar 0.5 bar Maximum working pressure 3 bar 3 bar Minimum flow rate 350 litres per hour 350 litres per hour

2.2 Gas pressure

Inlet pressure (G20) 20.0 mbar 20.0 mbar Maximum gas rate 1.69 m3/h 2.76 m3/h Minimum gas rate 0.49 m3/h 0.80 m3/h Injector size single injector with six 3.1 mm holes

2.3 Expansion vessel

Capacity 10 litres 10 litres Maximum system volume 91 litres (approx.) 91 litres (approx.) Pre-charge pressure 1.0 bar 1.0 bar

2.4 Dimensions

Height 820 mm 820 mm Width 450 mm 450 mm Depth 355 mm 355 mm Dry weight 53 kg 53 kg

2.5 Clearances

Sides 12 mm 12 mm Top Bottom 150 mm 150 mm Front 600 mm 600 mm

2.6 Connections

Flow & return 22 mm compression 22 mm compression Gas 15 mm compression 15 mm compression Safety valve 15 mm compression 15 mm compression

2.7 Electrical

Voltage 230V/~ 50hz 230V/~ 50hz Power consumption 130 W 130 W Internal fuse F2A F2A External fuse 3A 3A

2.8 Flue details

Maximum horizontal flue length (concentric) 10.0 metres 6.45metres Maximum vertical flue length (concentric) 11.0 metres 7.45 metres Maximum twin flue length (horizontal or vertical) 39 m/39 m + terminal 29 m/29 m + terminal

2.9 Efficiency

SEDBUK rating 90.3% (Band “A”) 90.3% (Band “A”)

2.10 Adjustable operating parameters PARAMETER MINIMUM MAXIMUM FACTORY SETTING

P. 4 Central heating flow temperature 20 °C 90 °C 75 °C P. 20 Pump over-run 10 seconds 99 m 10 m P. 28 Anti-cycle delay 0 seconds 306 seconds 91.8 seconds

2.11 Emissions 16 26

NOx Min. output 20 ppm 15 ppm NOx Max. output 40 ppm 30 ppm CO Min. output 50 ppm 50 ppm CO Max. output 50 ppm 50 ppm CO2 Min. output 9.8% 9.8% CO2 Max. output 9.8% 9.8% CO/CO2 ratio 0.0005 to 1 0.0005 to 1

150 mm from casing or 25 mm above flue elbow (whichever is applicable)

single injector with six 3.8 mm holes

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

2.12 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 20 ºC temperature differential.

Fig. 3

SECTION 3 GENERAL REQUIREMENTS (UK)

6,5

5,5

4,5

3,5

2,5

1,5

Water pressure (mH

0,5

0 100 200 300 400 500 600 700 800 900 1000 1100 120

Litres Per Hour

Key Location Minimum distance

A Below an opening (window, air-brik, etc.) 300 mm B Above an opening (window, air-brik, etc.) 300 mm C To the side of an opening (window, air-brik, etc.) 300 mm D Below gutter, drain-pipe, etc. 75 mm E Below eaves 200 mm F Below balcony, car-port roof, etc. 200 mm G To the side of a soil/drain-pipe, etc. 150 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 600 mm K From a terminal facing a terminal 1200 mm L From an opening in the car-port into the building 1200 mm

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

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

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

of the vertical terminal

Fig. 4

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.

3.3 GAS SUPPLY

The gas meter – as supplied by the gas supplier – must be checked to ensure that it is of adequate size to deal with the maximum rated input of all the appliances that it serves. Installation pipes must be fitted in accordance with BS 6891. Pipe work from the meter to the appliance must be of adequate size. Pipes of a smaller size than the appliance gas inlet connection must not be used. The installation must be tested for soundness in accordance with BS 6891.

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 (fig. 4).

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

ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS

When an appliance is installed in a room or internal space containing a bath or shower, the appliance or any control pertaining to it must not be within reach of a person using the bath or shower. The location chosen for the appliance must permit the provision of a safe and satisfactory flue and termination. The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the appliance. Where the installation of the appliance will be in an unusual location special procedures may be necessary, BS 6798 gives detailed guidance on this aspect.

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

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

3.5 AIR SUPPLY

3.6 WATER CIRCULATION

In a cold and/or humid water, water vapour may condense on leaving the terminal; the effect of such pluming must be considered.

If installed less than 2 metres 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.

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.

Detailed recommendations are given in BS 5449 Part 1 and BS 6798. The following notes are for general guidance only.

3.6.1 PIPEWORK

It is recommended that copper tubing to BS 2871 Part 1 is used in conjunction with soldered capillary joints.

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

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

3.6.2 AUTOMATIC BY-PASS

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

3.6.3 DRAIN COCKS

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

3.6.4 AIR RELEASE POINTS

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

3.6.5 EXPANSION VESSEL

The appliance has an integral expansion vessel to accommodate the increased volume of water when the system is heated. It can accept up to 10 litres of expansion from within the system, generally this is sufficient, however if the system has an unusually high water content, it may be necessary to provide additional expansion capacity.

3.6.6 FILLING POINT (fig. 5)

A method for initial filling of the system and replacing water lost during servicing etc. has been provided. This method of filling must comply with the current Water Supply (Water Fittings) Regulations 1999 and Water Bylaws 2000 (Scotland). Fig. 5 shows a widely accepted method.

control valve

flow/return

pipe

temporary

connection

double check

valve

control valve

supply pipe

Fig. 5

3.6.7 LOW PRESSURE SEALED SYSTEM

An alternative method of filling the system would be from an independent make-up vessel or tank mounted in a position at least 1 metre above the highest point in the system and at least 5 metres above the boiler (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.

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 mm. The switch must only supply the appliance and its corresponding controls, i.e. time clock, room thermostat, etc. Alternatively an un-switched shuttered socket with a fused 3-pin plug both complying with BS 1363 is acceptable.

3.8 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

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 aTimber Frame Buildings”.

3.10 CONDENSATE DISPOSAL

When choosing a location for the boiler, consideration should be given to the disposal of the condensate discharge into a suitable drain or soil pipe. The condensate outlet pipe must be connected to the drain in accordance with building regulations or other rules in force.

3.11 INHIBITORS

Vokera recommend that a inhibitor – suitable for use with aluminium heat exchangers – is used to protect the boiler and system from the effects of corrosion and/or electrolytic action. The inhibitor must be administered in strict accordance with the manufacturers* instructions.

*Fernox and Sentinel manufacture products that have proved suitable for use with Vokera appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our appliances.

Fig. 6

CH return valve

Gas cock CH flow valve

Fig. 6A

CONDENSATE TRAP

RETURN

FLOW

GAS

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

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 may 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

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.

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.

3A.6.2 AUTOMATIC BY-PASS

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

3A.6.3 DRAIN COCKS

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

3A.6.4 AIR RELEASE POINTS

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

3A.6.5 EXPANSION VESSEL

3A.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. must be provided. A typical arrangement is shown in figure 5. You should ensure this method of filling complies with the local water authority regulations.

3A.6.7 LOW PRESSURE SEALED SYSTEM

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.

Buildings’ gives specific advice on this type of installation.

3A.10 CONDENSATE DISPOSAL

3A.11 INHIBITORS

*Fernox and Sentinel manufacture products that have proved suitable for use with Vokera appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our appliances.

3A.12 DECLARATION OF CONFORMITY

A Declaration of Conformity (as defined in I.S.

813) must be provided on completion of the installation.

A copy of the declaration must be given to the responsible person and also to the gas supplier if required.

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.

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

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

service connections and washers;

● the instruction pack containing the installation

& servicing instructions, user instructions, Benchmark logbook, 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.

Reduction for additional bends

Bend 45° bend

90° bend

Horizontal flue terminals and accessories

Part No. 0225720

0225755 0225740 0225745 0225750 0225730 0225735 0225760

Reduction in maximum flue length for each bend

0.5 metre

1.0 metre

Description

Horizontal flue kit for use with add. bends & extensions

Telescopic extension

0.5 m extension

1.0 m extension

2.0 m extension 45° bend (pair) 90° bend Wall bracket (5)

connection

Min-Max length 1000 mm

350 mm-500 mm 500 mm 1000 mm 2000 mm N/A N/A N/A

Push-fit

Horizontal

terminal or

extension

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 (fig. 6A) and flue-hole (if applicable).

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 HORIZONTAL FLUE

(For concentric vertical flue, see section 4.5.2). (For twin flue applications, see section 4.5.3). 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 section 2.9). A reduction must also be made to the maximum length (see table below) when additional bends are used.

Boiler top

adaptor

Boiler

Fig. 7

Using the template provided (fig. 6A), mark and drill a 125 mm hole for the passage of the flue pipe. The hole should have a 1º rise from the boiler to outside.

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.

FITTING THE HORIZONTAL FLUE KIT

Using a twisting motion, connect the boiler top adaptor – supplied with the flue terminal kit – to the appliance flue outlet ensuring the male spigot of the adaptor is pushed fully into the flue outlet spigot of the boiler (fig. 7). Carefully measure the distance from the centre of the appliance flue outlet to the edge of the finished outside wall (dimension X). Add 45 mm to dimension X to give you Dimension Y (fig 7A). Measure dimension Y from the terminal end of the concentric flue pipe and cut off the excess. Pass the concentric flue pipe through the previously drilled hole. Fit the flue bend to the boiler top

adaptor and insert the concentric flue pipe into the flue bend ensuring the correct seal is made.

Fig. 7A

“Y” = “X” + 45 mm

Using the clamp, gasket and screws supplied, secure the flue bend to the appliance flue spigot.

NOTE

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

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

4.5.1.1 EXTENDING THE FLUE

Connect the bend – supplied with the terminal kit – to the top of the boiler using the boiler top adapter and clamp (supplied, fig. 7). The additional bends & extensions have push-fit connections, care should be taken to ensure that the correct seal is made when assembling the flue system. Connect the required number of flue extensions or bends (up to the maximum equivalent flue length) to the flue terminal (fig. 7 & 7B).

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (fig. 7 & 7B). Remove any burrs, and check that all seals are located properly.

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

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

4.5.2 CONCENTRIC VERTICAL FLUE

The 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 section 2.9), however if additional bends are fitted, a reduction must be made to the maximum flue length (see table below).

Reduction for bends

Bend 45° bend 90° bend

Part No. 0225725

0225770 0225765 0225755 0225740 0225745 0225750 0225730 0225735 0225760

Reduction in maximum flue length for each bend

0.5 metre

1.0 metre

Vertical flue terminal and accessories

Description

Vertical flue terminal Pitched roof flashing plate Flat roof flashing plate 350-500 telescopic extension 500 mm extension 1000 mm extension 2000 mm extension 45° bend (pair) 90° bend Wall bracket (4)

Min-Max length 1000 mm

N/A N/A 350 mm-500 mm 500 mm 1000 mm 2000 mm N/A N/A N/A

Fig. 7B

Plain end

Boiler

Push-fit connection

Extension pipe

Boiler top adaptor

Fig. 8

300 mm minimum

520 mm

170mm

Using the dimensions given in fig. 8 as a reference, mark and cut a 105 mm hole in the ceiling and/or roof.

IMPORTANT

You must ensure that the terminal is at least 300 mm from any structure or surface (fig. 8).

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. Ensure that any horizontal sections of the flue system have a 1º fall back to the boiler (17 mm per 1000 mm). 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.

Secure the vertical flue terminal or intermediate flue component, to the appliance using the boiler top adaptor and 100 mm clamp supplied.

NOTE

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

4.5.3 TWIN FLUE SYSTEM

The Vokera twin flue system enables greater flue distances to be achieved (see section 2.9) than that of the standard concentric flue system. It can be used for horizontal or vertical applications, however the twin flue system must be converted to the dedicated concentric flue kit for termination. It is essential that the installation of the twin flue system be carried out in strict accordance with these instructions.

GUIDANCE NOTES ON TWIN FLUE INST ALLATION

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

appliance to allow any condensate that forms in the flue system to 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.

● Extreme care must be taken to ensure that no

debris is allowed to enter the flue system at any time.

● As the exhaust outlet pipe can reach very high

temperatures it must be protected to prevent persons touching the hot surface.

Reduction for bends

Bend 45° bend 90° bend

Reduction in maximum flue length for each bend

1.0 metre

Twin flue accessories

Part No. Description 0225805

0225810 359 0225770 0225765 0225815 0225820 0225825 0225830 0225835 0225840 0225845 0225850 0225855

Horizontal flue terminal Vertical flue terminal Twin adapter kit Pitched roof flashing plate Flat roof flashing plate Condensate drain kit

0.25 m extension (pair)

0.5 m extension (pair)

1.0 m extension (pair)

2.0 m extension (pair) 45° bend (pair) 90° bend (pair) Twin bracket (5) Single bracket (5)

Length 1000 mm

1000 mm N/A N/A N/A N/A 250 mm 500 mm 1000 mm 2000 mm N/A N/A N/A N/A

MOUNTING THE BOILER

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

4.5.3.1 INSTALLA TION OF TWIN ADAPT OR KIT (fig. 9)

● Insert the exhaust connection manifold (B) onto

the appliance flue outlet and secure to the flue spigot using the screws provided.

● Remove the blanking plates (located to the left

of the appliance flue outlet) and – using the same screws – install the air baffle (A).

Fig. 9

4.5.3.2 HORIZONTAL TERMINATION (fig. 10)

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

● The horizontal terminal is supplied with a built-

in converter box and cannot be shortened.

● A 130 mm hole is required for the passage of

the concentric terminal through the wall.

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

Mark and drill a 130 mm hole for the passage of the horizontal flue terminal, ensuring that there is a 1° fall back to the boiler (17 mm per 1000 mm). 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 50 mm onto the male spigots of the concentric to twin converter.

convertor box

● The convertor box on the vertical terminal will

have to be temporarily removed when inserting the terminal through the flashing.

convertor box

NOTE

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

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

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. 11)

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

● The vertical terminal is supplied with a built-in

converter box and cannot be shortened.

● A 130 mm 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 50 mm onto the male spigots of the

concentric to twin converter.

● You must ensure that the entire flue system is

properly supported and connected.

● Ensure that any horizontal sections of pipe

have a 1° fall towards the appliance (17 mm

per 1000mm).

Fig. 10

Fig. 11

4.6 CONNECTING THE GAS AND WATER

Care must be taken to ensure that the appliance and/or its ancillary components are protected from the use of a blowtorch or similar soldering equipment. The appliance is supplied with accessories that include sealing washers and service valves and connections. When connecting pipe work to the valves, tighten the compression end first then insert the sealing washers before tightening the valve to the appliance.

NOTE

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

4.6.1 GAS (fig. 6 & 6A)

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

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 & 6A)

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

4.6.3 SAFETY VALVE

Connect the safety valve discharge pipe to the safety valve outlet 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.

4.7 CONDENSATE OUTLET (fig. 6A)

During normal operation the boiler produces condensate which is collected in a trap located in the lower part of the boiler. A flexible pipe

(condensate 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 condensate outlet pipe down from its location inside the boiler until approximately 250 mm protrudes from the underside of the boiler. Connect a suitable plastic (not copper) pipe (no less than 20 mm diameter) to the outlet pipe and ensure it discharges in accordance with building regulations or other rules in force.

4.8 AUTOMATIC AIR RELEASE VALVE

Mount the AAV as shown in fig. 12.

screws

Fig. 13A

Fig. 13B

Fig. 12

4.9 ELECTRICAL CONNECTIONS

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

6500. Wiring to the appliance must be rated for operation in contact with surfaces up to 90 ºC.

4.9.1 ELECTRICAL INPUT BOARD

The appliance electrical input board is located behind the control fascia. To gain access to the appliance electrical connections you must proceed as follows:

● push to release front door panel and lower to

reveal controls. Loosen the 2 captive screws securing the front control panel to the lower part of the casing and lower to reveal inside of the boiler (fig. 13A);

● remove the 4 screws securing the input board

cover (fig. 13B).

NOTE

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

4.9.2 CONNECTING THE MAINS (230V) INPUT (fig. 14)

Remove the electrical input board cover as described in section 4.9.1. Pass the cable through the cable anchorage. Connect the supply cable wires (earth, live and neutral) to their corresponding terminals on the electrical input board. Ensure that the EARTH wire is left slightly longer that the others, this will prevent strain on the EARTH wire should the cable become taut.

Do not remove the link wire (between terminals 2 & 3 on plug M7) unless additional external controls are to be fitted (see section 8). Re-fit the electrical input board cover.

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.

Fig. 14

4.10 CASING REMOVAL

Lower the front control panel as described in section 4.9.1.

● Locate and remove the 2 screws that secure

the controls fascia to the appliance casing (fig. 13A)

● locate and remove the 2 screws that secure the

casing to the back frame of the boiler (fig. 15)

● gently pull one side of the casing then the other

to disengage it from the retaining clips

● lift the casing upward to disengage it from the

top locating hooks and then remove

● store the casing and screws safely until required.

Re-fit in the reverse order.

screw

Fig. 15

SECTION 5 COMMISSIONING

5.1 GAS SUPPLY INSTALLATION

Inspect the entire installation including the gas meter, test for soundness and purge.

5.2 THE HEATING SYSTEM

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

5.3 INITIAL FILLING OF THE SYSTEM

5.3.1. Ensure both flow and return service valves are

open, identify the automatic air release valve (fig.

12) and loosen the dust cap by turning the cap anti-clockwise one full turn.

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

5.3.3. Using the method of filling as described in fig. 5, slowly proceed to fill the system. As water enters the system the pressure gauge will begin to rise. Once the gauge has reached 1 bar close the filling valve 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.

5.4 INITIAL FLUSHING OF THE SYSTEM

The whole of the heating system must be flushed both cold and hot as detailed in section 5.8. Open all radiator or heating valves and the appliance flow & return service valves. Drain the boiler and system from the lowest points. Open the drain valve full bore to remove any installation debris from the boiler prior to lighting. Refill the boiler and heating system as described in section 5.3.

5.5 PRE-OPERATION CHECKS

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

● ensure all gas service valves from the meter to

the appliance are open and the supply pipe has been properly purged;

● ensure the proper electrical checks have been

carried out, (see section 7.7) 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. Switch the time clock or programmer to an ‘on’ position and ensure all external controls are also calling for heat.

The appliance will operate in the central heating mode as described in section 1.3. Should the appliance fail to ignite, refer to section 5.6 and/or section 7 (faultfinding).

5.7 FINAL FLUSHING OF THE HEATING SYSTEM

The system shall be flushed in accordance with BS 7593. If a cleanser is to be used, it shall be from a reputable manufacturer* and shall be administered in strict accordance with the manufacturers instructions.

*Both Sentinel and Fernox manufacture products that have proved suitable for use with Vokera appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our appliances.

5.8 INHIBITORS

See Section 3 “General Requirements”.

5.9 APPLIANCE OPERATING PARAMETERS

The appliance is supplied with pre-set operating parameters. Parameters 3 & 4 can be adjusted at any time, however the remaining parameters (5 –

42) can only be accessed after entering the relevant service code, and should only be adjusted by qualified service personnel.

5.10 PARAMETERS 3 & 4

Parameters 3 & 4, are used to alter or adjust the operating mode and flow temperature. Use the following table and procedure to check or adjust the relevant parameters:

Parameter Description Range

1 2 3

● Press the

Heating outlet temperature

N/A N/A

Heating mode

mode

N/A N/A

00 = off 01 = on 03 = off

(pump on continuously)

04 = on

(pump on continuously)

20 °C - 90 °C

button until “PARA” appears

in the display.

● Press the

button until the appropriate

parameter is shown in the left side of the display.

● Use the

buttons to adjust the value

of the paramater as shown in the right side of the display.

● Press the

button to store the new setting.

reset

button to return to the

stand-by mode.

IMPORTANT

Under no circumstances should any parameters

- other than those shown above - be changed or adjusted by non competent personnel.

5.11 INFORMATION MODE

The appliance keypad can be used to display certain information on the working status of the boiler. Information such as flow & return temperature, and temperature rise can be viewed using the following table and procedure:

Step number Information displayed

1 2 3 4 5 6 7

9 A

Temperature at flow sensor Temperature at return sensor Unused Unused Unused Required temperature (as set at parameter 4) Temperature rise of flow sensor (measured in °C per

second) Temperature rise of return sensor (measured in °C

per second) Unused Unused

● Press the

mode

button until “INFO” appears

in the display.

● Press the

button until the appropriate step

number is shown in the left side of the display.

● The measured value of each step is shown on

the right side of the display.

● Press the

mode

button until “Stby” appears

in the display to return to the stand-by mode.

5.12 SETTING THE SYSTEM DESIGN PRESSURE

The design pressure should be a minimum of 1 bar and a maximum of 1,5 bar.

The actual reading should ideally be 1 bar plus the equivalent height in metres (0,1 bar = 1 metre) to the highest point in the system above the base of the appliance (up to the maximum of 1,5 bar total). N.B. The safety valve is set to lift at 3 bar/30 metres/45 psig.

To lower the system pressure to the required value, pull lever on head of safety valve to release water until the required figure registers on the pressure gauge (fig. 1).

5.13 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.

5.14 CHECKING DYNAMIC GAS PRESSURE

Isolate the appliance from the electrical supply and remove the appliance casing as described in section 4.10. Unclip and remove the front air chamber cover.

Attach a suitable manometer to the inlet test nipple of the gas valve.

Restore the electrical supply to the boiler and generate a request for central heating via the room thermostat and/or timer.

Press the

and

time to return to the normal operating mode. Isolate the appliance from the electrical supply,

remove the manometer from the inlet test nipple, tighten the test nipple screw, and check for soundness.

Refit the air chamber cover and appliance casing in the reverse order.

5.15 FINAL CHECKS

● ENSURE ALL TEST NIPPLES ON THE

APPLIANCE GAS VALVE ARE TIGHT AND HAVE BEEN 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 APPLIANCE LOGBOOK.

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

5.16 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 its 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.

buttons at the same

Press the

mode

and + buttons at the same

time, the boiler will now run at full power for 15 minutes.

The dynamic gas pressure will now be shown on the manometer, and should be 20 mbar +/- 1 mbar. If the dynamic gas pressure is out-with the tolerance range, you should contact the gas supplier for advice.

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.

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

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 or other CORGI registered personnel.

The following instructions apply to the appliance and its controls, but it should be remembered that the central heating system will also require attention from time to time.

6.2 ROUTINE ANNUAL SERVICING

● Check the operation of the appliance and ensure

it functions as described in section 7.

● Compare the performance of the appliance

with its design specification. The cause of any noticeable deterioration should be identified and rectified without delay.

● Thoroughly inspect the appliance for signs of

damage or deterioration especially the flue system and the electrical apparatus.

● Check and adjust – if necessary – the system

design pressure (see section 5.12).

● Ensure both the burner and heat exchanger are

clean and free from any debris or obstruction.

● Carry out an analysis of the flue gases (see

section 7.4), 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.

● Inspect all joints for signs of leakage and repair

if necessary.

● Refer to the commissioning section and/or

replacement of parts section for detailed instruction if required.

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. Always use genuine Vokera spare parts.

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

6.5 PUMP HEAD (fig. 1)

Carry out component removal procedure as described in section 6.4. Using a 4 mm Allen key or ‘T’ bar, unscrew and remove the four Allen screws that hold the pump in position, pull firmly on the pump head to release it from the base. Disconnect the electrical leads. Replace in the reverse order.

6.6 SAFETY VALVE (fig. 16)

Carry out component removal procedure as described in section 6.4. Disconnect the outlet pipe from the safety valve. Remove safety valve locking screw from the underside of the appliance manifold. Pull safety valve free from manifold. Replace in the reverse order.

Safety valve

Fig. 16

Locking screw

6.7 AUTOMATIC AIR RELEASE VALVE (fig. 12)

Carry out component removal procedure as described in section 6.4. Using a suitable pair of pump pliers, unscrew the AAV from its position. Replace in the reverse order.

6.8 PRESSURE GAUGE (fig. 17)

Carry out component removal procedure as described in section 6.4. Remove pressure gauge locking screw, located on manifold, and withdraw the pressure gauge pipe, locate the spring tabs on the pressure gauge body, push and hold tabs in, to enable extraction of the gauge from its location. Replace in the reverse order.

Manifold

6.4 COMPONENT REMOVAL PROCEDURE

To remove a component, access to the interior of the appliance is essential. Isolate the appliance from the electrical supply and remove the fuse. And when necessary, close all service valves on the appliance, remove the appliance casing as described in section 4.10. Drain the water content from the appliance via the safety valve. Ensure some water absorbent cloths are available to catch any residual water that may drip from the appliance or removed component. Undertake a complete commissioning check as detailed in section 5, after replacing any component.

Fig. 17

Pressure gauge

connection

Locking screw

6.9 NTC THERMISTORS (temperature sensors)

Carry out component removal procedure as described in section 6.4.

Flow & return sensors (fig. 1 & 18)

Pull back protective boot and remove the 2 spade connectors. Slacken and remove the 2 securing screws. Replace in the reverse order.

Screw

Fig. 18

Screw

6.10 PRINTED CIRCUIT BOARD (PCB) (fig. 19)

Carry out component removal procedure as described in section 6.4.

● Locate and remove the 2 screws that secure

the PCB housing bracket to the underside of the air chamber.

● Remove the 4 screws that secure the housing

cover to the housing.

● After carefully taking note of all wiring

connections, disconnect all wiring from the PCB.

● Locate and remove the 3 screws that secure

the PCB to the housing.

Replace in the reverse order.

Fig. 20

6.12 FAN (fig. 20A)

Carry out component removal procedure as described in section 6.4. Unclip and remove the air chamber cover. Disconnect the electrical plug from the fan. Locate and remove the 4 bolts that secure the fan to the pre-mix manifold. Replace in the reverse order.

Fig. 20A

Fig. 19

6.11 GAS VALVE (fig. 20)

Carry out component removal procedure as described in section 6.4. The gas valve must be changed as complete unit. Unclip and remove the air chamber cover. Disconnect the electrical plug from the gas valve. Disconnect silicone tube from gas valve regulator. Slacken and unscrew gas valve inlet and outlet connections. Please note, the sealing washers must be discarded and replaced with new sealing washers. The gas valve can now be removed. Replace in the reverse order. Refer to section seven for detailed instructions on how to set-up the gas valve. WARNING, A GAS SOUNDNESS

CHECK MUST BE CARRIED OUT.

6.13 BURNER (fig. 21 & 23)

Carry out component removal procedure as described in section 6.4. Unclip and remove the air chamber cover. Locate and remove the 8 nuts (10 mm) securing the premix manifold/burner assembly.Disconnect the gas valve outlet pipe at its connection to the premix manifold. Disconnect the silicone pipe from the pre-mix manifold. Gently pull away the fan/ pre-mix manifold assembly from the heat exchanger. Remove the earth wire from the burner earth tab and gently lift the burner from its location. Replace in the reverse order. Please note, ensure all seals are in good condition, taking care to ensure they are replaced correctly.

Securing nuts

Gas valve outlet

connection

Spark

electrode

Fig. 21

6.14 ELECTRODE (fig. 21 & 22)

Carry out component removal procedure as described in section 6.4. Unclip and remove the air chamber cover. Remove the electrode lead. Remove the 2 screws that secure the electrode to the combustion cover, and gently withdraw the electrode.

Replace in the reverse order ensuring that the electrode seal is in good condition, and that the combustion cover insulation board is undisturbed.

All dimensions in mm.

Fig. 22

Inlet connection

Pressure

switch connection

Outlet connection

Fig. 24

6.18 CONDENSE PRESSURE SWITCH (fig. 25)

Carry out component removal procedure as described in section 6.4. Unclip and remove the air chamber cover. Disconnect the electrical wiring and pressure tube from the pressure switch. Remove the retaining screws and/or clip. Replace in the reverse order.

6.15 INJECTOR (fig. 23)

Carry out component removal procedure as described in section 6.4.

Unclip and remove the air chamber cover. Remove the fan as detailed in section 6.12 using a 17 mm socket, locate and unscrew the injector. Replace in the reverse order.

Burner plate

Injector

Fan

Fig. 23

6.16 AUTOMATIC BY-PASS ASSEMBLY (fig. 27)

Carry out component removal procedure as described in 6.4. Disconnect and remove the flow pipe and expansion pipe from the manifold assembly. Using a suitably shaped screwdriver, lever out the auto

6.17 CONDENSE TRAP (see fig. 24)

Carry out component removal procedure as described in section 6.4. Disconnect the pressure switch tube from the condense trap. Disconnect both the inlet and outlet connections from the trap. Carefully withdraw the trap, keeping it upright to avoid spillage. Replace in the reverse order.

Condense pressure switch

Fig. 25

6.19 COMBUSTION COVER (fig. 26)

Carry out component removal procedure as described in section 6.4. Unclip and remove the air chamber cover. Remove the gas valve as described in section

6.11. Remove the condense pressure switch as described in section 6.20. Disconnect the electrical connection from the fan, disconnect the spark electrode lead and earth wire from the spark electrode. Locate and remove the twelve 10 mm securing nuts. Carefully remove the combustion cover from the locating studs. Remove the combustion cover from the air chamber, withdrawing it at a slight angle from the right hand

Fig. 26

1 Hydraulic manifold 2 Safety valve locking screw 3 Pressure gauge locking screw 4 Safety valve 5 Expansion pipe 6 Bleed/drain nipple 7 Automatic bypass 8 Expansion pipe locking screw

side. Replace in the reverse order, ensuring that all seals and insulation panels are undamaged and in good condition.

6.20 EXPANSION VESSEL (fig. 1)

Due to the compact design of this appliance, removal and/or replacement of the expansion vessel may require the appliance to be removed from the wall, if this is deemed impractical, an external expansion vessel may be fitted to the return pipe as close to the appliance as possible.

6.20.1 EXPANSION VESSEL (removal, fig. 28)

Carry out component removal procedure as described in section 6.4. Disconnect the flue from the appliance. Disconnect the expansion vessel from the expansion pipe. Remove the flow sensor as shown in section 6.9. Locate and remove the 4 screws. Remove the rear frame. Slacken the flow pipe nut: the expansion vessel can now be removed shifting the flow pipe on the left side. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.21 INPUT PCB & STATUS PCB (fig. 29)

Carry out component removal procedure as described in section 6.4. Refer to section 4.10 for details on how to remove casing. Remove the 5 screws securing the control board cover. Carefully note the positions of all connections relative to the PCB that is to be removed. Remove the wiring and plugs from the PCB. Locate and remove the securing screws. Remove PCB. Replace in the reverse order, ensuring correct configuration of wiring.

Fig. 27

screws

rear

frame

Fig. 28

input PCB

status PCB

Fig. 29

SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING

7.1 CHECKING APPLIANCE OPERATION

When carrying out any repairs or servicing to the appliance, the relevant commissioning and/or set-up 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 MODE OF OPERATION

7.2.1 START-UP

When power is first supplied to the appliance it will go through a self-purge procedure whereby the pump and fan will be momentarily energised. The boiler will then operate in either one of the following modes:

● Stand-by

● Heating mode

7.2.2 STAND-BY

When there is no demand for heating or hot water. And the appliance remains inactive for a period of 24 hours, the pump will be energised for a few moments to prevent it from seizing. Should the flow temperature sensor fall below 7 °C the pump will be energised. If the flow sensor temperature falls to below 3 °C the burner will be lit and the appliance will operate at the minimum output until the temperature of the flow sensor reaches 10 °C, whereupon the pump will continue to run in pump over-run mode.

7.2.3 CENTRAL HEATING MODE

When there is a request for heat via the time clock and/or external controls the motorised valve and pump will go through a self-test function this is to ensure correct operation and valve configuration. Once the self-test function is complete, the pump and fan will be activated via the flow temperature sensor. When the fan is sensed to be operating correctly, the ignition sequence commences. The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow & return temperature sensors, 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 and return pipes of the boiler – reduce the fan speed via the electronic circuitry. Depending on the load, either the water temperature will continue to rise until the set point is achieved or the water temperature will fall whereby fan speed will increase relative to the output required. When the boiler has reached the set point, the burner will switch off. The built-in anti-cycle device prevents the burner from relighting for an adjustable period of time (factory default is 92 seconds). When the temperature of the flow sensor falls below the set-point, the burner will re-light.

7.3 SERVICE PARAMETERS (5 – 42)

To check or adjust the service parameters, you must first access the service mode.

To access the service mode:

● press and hold the

mode

and S buttons

simultaneously for 2 seconds;

● when “COdE” appears in the display, press

again, “C” should now be shown on the left

side of the display, with a random number on the right side of the display;

● using the

buttons, scroll until “05”

is shown in the right side of the display;

● press

● press to exit the sevice mode.

to store the code;

7.4 ADJUSTING THE GAS VALVE The gas valve must be set-up or adjusted with

the aid of o properly calibrated flue gas analyser.

Isolate the appliance from the electrical supply and remove the appliance casing as described in section

4.10. Unclip and remove the front air chamber cover. Set the flue gas analyser to read CO2 and insert

the probe into the flue analysis test point (fig. 1). Restore the electrical supply to the boiler and

generate a request for central heating via the room thermostat and/or timer.

Press the

mode

and

buttons at the same

time, the boiler will now run at minimum power for 15 minutes.

Consequently, by pressing the buttons at the same time, the boiler will run on

maximum power for 15 minutes.

7.4.1 MINIMUM SETTING

With the boiler operating at minimum output the CO2 reading should be 9.8% (+/- 0.2%). If the CO reading is correct, proceed to section 7.4.2. 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 (fig. 30) – clockwise to increase, counter clockwise to decrease – until the correct value is displayed on the CO2 analyser (allow time for the analyser to stabilise).

● Using the procedure detailed in section 7.4,

change the fan speed momentarily from minimum to maximum, then back to minimum.

● Check that the correct value is still being

obtained. If not, repeat the above procedure.

7.4.2 MAXIMUM SETTING

The maximum setting must only be checked and/ or adjusted after the correct minimum setting has been verified. Using the procedure detailed in section 7.4, change the power from minimum to maximum.

With the boiler operating at maximum output the CO2 reading should be 9.8% (+/- 0.2%). If the

CO2 reading is correct, press the + and buttons at the same time to return to the normal

mode

and

Service parameters must only be changed or adjusted by qualified service personnel

Parameter

5 6 7 8

9 10 11 12 13

14 15 16 17 18 19 20 21 22

23 24

25 26 27 28 29 30 31

32 33 34 35 36

37 38 39 40 41 42

Description

Minimum setting for flow sensor

Unused Unused Unused Unused Unused Unused Unused

Maximum fan speed for heating

(hundreds)

Maximum fan speed (units)

Unused Unused

Minimum fan speed (hundreds)

Minimum fan speed (units)

Ignition fan speed

Pump over-run

Unused

Set point drop before re-lighting

(heating)

Set point overshoot before burner

off (heating)

Unused Unused Unused Unused

Heating anti-cycle

Unused Unused

Temperature differential required

for modulation

Unused Unused Unused Unused

Temporary manual fan speed

setting (20 minutes)

Unused Unused Unused Unused Unused

Normal output/off/minimum output/

off cycle

Range

5 °C - 60° C

10 - 55 (RPM x 100)

00 - 99 (RPM)

05 - 55 (RPM x 100)

00 - 99

05 - 55 (RPM x 100)

01 - 99 minutes

0 °C - 20 °C 0 °C - 10 °C

0 - 30 (1=10.2 secs.)

5 °C - 40 °C

0% - 100%

00 = OFF, 01 = ON

Factory setting

Pinnacle 16

20 °C

-15 20

-1 0

25 00 20

40* (4000 RPM)

13* (1300 RPM)

55* (5500 RPM)

10 minutes

5 °C 2 °C

-3 5

-2

9 (91.8 secs.)

0 3

25 °C

-1

15 00 00

-1 (= OFF) 24

00 35 10 20 00

Factory setting

Pinnacle 26

20° C

-15 20

-1 0

25 00 20

55 (5500 RPM)

17 (1700 RPM)

44* (4400 RPM)

10 minutes

5 °C 2 °C

-3 5

-2

9 (91.8 secs.)

0 3

25 °C

-1

15 00 00

-1 (= OFF) 24

00 35 10 20 00

New setting

*This is the setting for Natural Gas. On LPG versions, the factory setting is:

Parameter

13 17

Maximum fan speed for heating

Minimum fan speed (hundreds)

Description

(hundreds)

Ignition fan speed

Range

10 - 55 (RPM x 100) 05 - 55 (RPM x 100)

05 - 55 (RPM x 100)

operating mode . If the CO2 reading is incorrect, the maximum gas pressure must be adjusted as follows:

● Using a suitable screwdriver, very slowly turn

the maximum adjustment screw (fig. 30) – clockwise to increase, counter clockwise to decrease – until the correct value is displayed on the CO2 analyser (allow time for the analyser to stabilise).

● Using the procedure detailed in section 7.4,

change the power momentarily from maximum to minimum, then back to maximum.

● Check that the correct value is still being

obtained. If not, repeat the above procedure.

Factory setting

Pinnacle 16

41* (4100 RPM) 14* (1400 RPM)

39* (3900 RPM)

● Press the

Factory setting

55 (5500 RPM) 17 (1700 RPM)

30* (4400 RPM)

and

Pinnacle 26

buttons at the same

New setting

time to return to the normal operating mode.

Isolate the appliance from the electrical supply and remove the analyser test probe from the analysis test point and refit cap. Refit the air chamber cover. Refit appliance casing.

NOTE

You should ensure that all radiators or heat emitters are fully open during the above procedures. This will ensure that the fan speed (output) of the boiler is not compromised due to a high flow temperature.

Fig. 30

7.5 1ST DIGIT STATUS CODE

When the boiler is operating normally (without fault), the first digit of the display shows the current status of the boiler whilst the right side will show the relevant temperature.

Status

Standby

Purge

Ignition

Burner on

Waiting for fan

Built-in delay

Pump over-run

Temporary fault

condition

Combustion test at

maximum output

Combustion test at

minimum output

Anti seizing cycle

Manual operation of

fan

1st digit

0 1 2 3 5 6 7

9/b

Flow temp./temporary fault

Maximum screw

Minimum screw

Right

Flow temperature Flow temperature Flow temperature Flow temperature Flow temperature Flow temperature Flow temperature

code

Flow temperature

Flow temperature Flow temperature

Code

E 00 E 02 E 03 E 04 E 05 E 06 E 07 E 11 E 13 E 14 E 15 E 16 E 17 E 18 E 19 E 25 E 28 E 29 E 30 E 31 E 32 E 36 E 37 E 44 E 60 E 65

Appliance lockout and power failure

Flow sensor temperature exceeded

Return sensor temperature exceeded

Temperature differential exceeded

Open circuit on return sensor

False flame

No flame detected

Internal fault (PCB)

Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB)

Excessive temperature rise

No signal from fan

Incorrect signal from fan

Short circuit on flow sensor

Short circuit on return sensor

Open circuit on flow sensor

Internal fault (PCB) Parameter anomaly

Not enough fan driving force

7.8 DIAGNOSTIC RECALL

In addition to displaying a fault code, the appliance memorises the operating conditions at the time of lockout, this information can be recalled and displayed using the following procedure:

1st digit

shows

1 2 3 4 5 6

Appliance status at time of fault

Flow sensor temperature at time of fault

Return sensor temperature at time of fault

Right display

Most recent fault code

Reason

shows

N/A N/A

7.6 TEMPORARY FAULT CODES

The built-in fault diagnostic system automatically displays a unique fault code that can be used to determine why the boiler has temporarily locked out.

Code

b 18 b 19 b 24 b 25 b 26 b 28 b 29 b 30 b 65

Flow sensor above 95 °C

Return sensor above 95 °C

Temperature differential inverted

Excessive temperature rise

Condensate trap blocked

Temperature differential exceeded

Insufficient fan speed for ignition

Reason

No signal from fan

Incorrect signal from fan

7.7 FINAL FAULT CODES

When a volatile lockout condition occurs, or a temporary fault condition has not been corrected, the appliance will be permanently locked out and a manual reset will be required.

● access the appliance service mode as detailed

in section 5.10

● press the

mode

button until “ERRO” appears

in the display

● press the

button to recall the information

as detailed below

● press the

reset

button to exit the appliance

service mode.

7.9 CHECKING THE EXPANSION VESSEL

Carry out the component removal procedure as described in section 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.

Please note, you must ensure the safety valve is in the open position whilst re-charging takes place. Replace the dust cap and carry out the relevant commissioning procedure.

7.10 EXTERNAL FAULTS

Before carrying out any fault-finding or component replacement, ensure the fault is not attributable to any aspect of the installation. For example, external wiring fault, service valves closed, gas supply turned off, etc. The table below may assist in identifying some common installation faults.

Fault code

displayed

E 02

b/E 18

E 36

Possible cause

Gas turned off Air in gas pipe

Insufficient gas

Pump seized

Flow/return service valve closed Flow sensor cable disconnected

7.11 ELECTRICAL CHECKS

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

7.11.1 EARTH CONTINUITY TEST

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

7.11.2 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 input board (fig.14). Repeat above test on the Live & Earth connections at the appliance input board (fig.14).

NOTE

Should it be found that a 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.

7.11.3 POLARITY CHECK

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

● connect test leads between the Live & Neutral

connections at the appliance input board (fig.14). The meter should read approximately 230V ac. If so proceed to next stage. If not, see section

7.11.4.

● connect test leads between the Live & Earth

connections at the appliance input board (fig.14) the meter should read approximately 230V ac. If so proceed to next stage. If not, see section

7.11.4.

● connect test leads between the Neutral & Earth

connections at the appliance input board (fig.14) the meter should read approximately 0 – 15Vac. If so polarity is correct. If not, see section

7.11.4.

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.

7.11.5 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 input board (fig.14). If the meter reads other than infinity there is a fault that must be isolated, carry out a detailed continuity check to identify the location of the fault.

IMPORTANT

These series of checks must be carried out before attempting any fault-finding 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.

7.11.6 FUSES

The appliance is equipped with spare fuses. These fuses are located on the covers of the input board and main PCB respectively. If a fuse has blown it is usually indicative of an external wiring fault or a faulty component such as the pump, fan, valve actuator, etc. Under no circumstances should a blown fuse be replaced with one of a higher rating.

7.12 FAULT FINDING BEFORE ATTEMPTING ANY FAULT

DIAGNOSIS OR REPAIR THE FOLLOWING PROCEDURE SHOULD BE CARRIED OUT:

● carry out the relevant electrical checks as

detailed in section 7.11;

● disconnect any external wiring from plug M7

(terminals 2 & 3) and replace with a solid link wire;

● ensure the appliance is protected – externally –

by a 3-amp fuse.

7.12.1 FAULT FINDING TESTS

If a lockout code is displayed on digits 3 & 4, please refer to section 7.6 for the cause of the lockout.

FAULT

No display, boiler inactive No display, pump running

No display, pump running, fan speed alternating

No display, boiler working OK

Pump failure

Fan fault

Ignition fault

7.12.2 WIRING DIAGRAMS

Figures 33 & 34 indicate the positions of all plugs, fuses and internal wiring configuration.

GO TO

Test 1 Test 1A Test 1A Test 1A

Test 2

Test 3

Test 4

7.11.4 REVERSED POLARITY OR SUPPLY FAULT

Repeat the above tests at the appliance isolator, if testing reveals correct polarity and/or supply at

7.12.3 FAULT FINDING TEST ‘1’

7.12.4 FAULT FINDING TEST ‘1A’

7.12.5 FAULT FINDING TEST ‘2’

7.12.6 FAULT FINDING TEST ‘3’

7.12.7 FAULT FINDING TEST ‘4’

SECTION 8 WIRING DIAGRAMS

8.1 INSTALLATION OF VOKERA TIMECLOCK

(part n° 201 or 202)

The Vokera time clock (part no. 201 & 202) can be installed using the following procedure:

• Isolate the appliance from the electrical supply and remove the casing as described in 4.9.1.

• Gain access to the electrical input board as detailed in 4.9.2.

• Remove the square blanking plate from the clock aperture of the control panel.

• Connect the wires to the clock as shown in fig.

31.

• Mount the clock to the clock aperture using the screws provided.

• Remove the factory fitted link between terminals 2 & 3 on plug M7.

• Connect the clock wires to the electrical input board as shown in fig. 31.

• Replace the input board cover and appliance

casing once the clock installation has been completed.

8.2 EXTERNAL CONTROLS WIRING

If additional or alternative controls are required, they must be connected to the boiler as shown in the following diagrams.

NOTE

Guidance on the recommended practice for the installation of external controls, can be found in CHeSS – HC1/HC2 (www.energyefficiency.gov.uk).

Room thermostat contact rated at 230V

Fig. 31

Room

thermostat

contact rated at

230V

“S” plan system

Fig. 32

Room

thermostat

contact rated at

230V

“Y” plan system

Fig. 32A

FUNCTIONAL DIAGRAM

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

Fig. 33

Key

R.T. Room thermostat F Fan P Pump S1 Flow thermistor (NTC) S2 Return thermistor (NTC) BE05 Connection board MCBA Control board L1 N/A L2 (V) Led OK

L2 (R) Led alarm L3 N/A F1 Fuse 2 AF F3 Fuse 4 AT S/S.E. Spark/sense electrode OPE Gas valve solenoids P.S. Pressure switch (NC)

FUNCTIONAL DIAGRAM

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

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

Fig. 34

PCB

Input PCB Input PCB Input PCB Input PCB Input PCB Input PCB

PLUG or CONNECTION

M2 M3 M4 M5 M7

DESIGNATION

Incoming 230V supply

230V supply to main PCB

230V clock supply Low voltage connector (to main PCB) Low voltage connector (heat request)

2AF fuse

PCB

Main PCB Main PCB

Main PCB Main PCB Main PCB Main PCB Main PCB Main PCB Main PCB

PCB

Display PCB Display PCB Display PCB

PLUG or CONNECTION

X1 X2

X3 X7 X8

X10

F1 F2 F3

PLUG or CONNECTION

X7A

3-pins connector

DESIGNATION

Incoming 230V supply & pump connection

Fan connection, condense pressure switch

connection, gas valve connection

Sensor connections

Display board connection

Unused

External transformer connection

2AF fuse 2AF fuse 4AT fuse

DESIGNATION

Connection from main PCB

Unused

Status LED connection

PCB

Gas valve

Fan

Condense pressure switch

Flow sensor

Return sensor

Pump

External transformer

24V connection for time clock or

room thermostat

Relay for actuator

Status LED

PLUG or CONNECTION

OPE

P.S.

S1 S2

R.T.

RL3V

DESIGNATION

Plug X2 on main PCB Plug X2 on main PCB Plug X2 on main PCB Plug X3 on main PCB Plug X3 on main PCB Plug X1 on main PCB

Plug X10 on main PCB

Plug M4 on input PCB (terminals 2 & 3)

Input PCB

3-pins connector on display PCB

SECTION 9 EXPLODED DIAGRAMS

100

16 17 20

260

261

300

101

226

POS. DESCRIPTION 16 26

1 Frame 001005243 001005243 12 Quick primer pressure gauge 1857 1857 13 Pin 10023044 10023044 15 Cover 10023681 10023681 16 2 A 5X20 inline fuse 8968 8968 17 3,15 A 5X20 inline fuse 8969 8969 18 Printed Circuit Board cover 10021849 10021849 20 Printed Circuit Board 10023549 10023549 21 Led Light Guide 10023892 10023892 26 Instrumental panel 10023346 10023346 31 Case 10023589 10023589 39 Spring 1862 1862 40 Door panel 10023772 10023772 43 Push-push cover 1864 1864 48 Green-red led 1858 1858 49 Plastic bezel 8654 8654

301

50 Pin 1867 1867 67 Printed circuit holding 10023476 10023476 74 Bracket 10023571 10023571 75 Display Printed Circuit Board 10023297 10023297 80 Printed Circuit Board 10023763 10023763 90 Fuse 3478 3478 99 Membrane keypad 10023891 10023891 100 Cover 10023477 10023477 101 Wired transformer 10023478 10023478 226 Edge clip 5128 5128 260 Nut 5230 5230 261 O-ring 1869 1869 300 Flat cable 10023586 10023586 301 Cable 10024393 10024393

353

277

POS. DESCRIPTION 16 26

3 Pressure switch 10022556 10022556 7 Heating by-pass valve 1552 1552 9 Heating distributor manifold 10021821 10021821 22 Safety valve 1806 1806 23 Pipe 10023065 10023065 27 Heating cock 1789 1789 31 Venting plugs kit 01005137 01005137 52 Bracket 10022671 10022671 277 Screw 6903 6903 353 Ogive 1824 1824

310

201 2

200

338

316

253

369

200

338 200

POS. DESCRIPTION 16 26

1 Expansion vessel 2573 2573 2 Flexible pipe 2164 2164 3 Pump 8876 8876 4 Pump cable 10023573 10023573 5 Brass nut 10022444 10022444 6 Pipe 10023574 10023574 8 Heat exchanger 8884 8884 9 Pipe 10023575 10023575 10 Pipe 10023697 10023697 12 Washer 9287 9287 16 Air vent bottle + cock assembly 9806 9806 25 Siphon 10024112 10024112 26 Pipe 10023530 10023530 27 Pipe 10023579 10023579

310

371

398

370

291

288

34 Connection for air vent bottle 8911 8911 36 Connection pipe 10023580 10023580 200 Washer 5023 5023 201 Washer 5026 5026 253 Headless screw 5216 5216 288 O-ring 6898 6898 291 Washer 6897 6897 310 NTC sensor 1194 1194 316 Washer 1022 1022 338 Connection for dom. exp. vessel 8873 8873 369 Connection 10023493 10023493 370 O-ring 10023533 10023533 371 Clip 10023532 10023532 398 Clip 10024336 10024336

200 39

256

295

24 23

351

200

POS. DESCRIPTION 16 26

1 Roomsealed chamber 10023486 10023486 2 Upper panel for air box 8881 8881 3 Main burner jet support 1195 1195 4 Main burner 1196 1196 5 Spark electrode kit 01005242 01005242 12 Gas pipe 10022442 10022442 13 Gas valve 10022441 10022441 14 Pipe 10023578 10023578 15 Gas cock connection 1787 1787 16 Front panel for air box 1035 1035 17 Glass kit 01005234 01005234 21 Washer 5905 5905

23 Main burner jet NG 8897 8970 23 Main burner jet LPG 10022453 9295 24 Washer 9299 9299 27 Air box hole cap 8084 8084 35 Air conveyor 10022450 8886 39 Gas pipe 10022443 10022443 40 Washer 9285 9285 41 Spring 9296 9296 200 Washer 5023 5023 256 Screw 5221 5221 295 Silicone tube 1457 1457 351 Brass nut 1823 1823

11 341 321

POS. DESCRIPTION 16 26

2 Exchanger lower insulation panel 1 193 1193 4 Exchanger upper insulation panel 1016 1016 5 Clip 10021115 10021115 6 Cover for heat exchanger 1033 1033 10 Fan 10024230 10024230 11 Gas diaphragm 10022451 13 Pressure connection 8915 8915 14 Pressure connection 8916 8916 20 Connection 8908 8908 22 Washer 8912 8912 23 Plug 8909 8909 40 Screw 1006 1006 41 Screw 9292 9292 321 Fan gasket 8893 8893 341 Screw 10021080 -

SECTION 10 L.P.G. INSTRUCTIONS

For details of converting boilers to LPG please refer to the instructions supplied with the relevant conversion kit.

10.1 TECHNICAL DATA 16

Inlet pressure

Gas rate (max.)

Gas rate (min.)

Injector size

CO2 level (cover off)

Maximum fan speed for heating

Minimum fan speed

Soft-light

NOx (max)

NOx (min) CO (max)

CO (min)

Single injector with six 1.6 mm holes

37 mbar

2.49 l/per hr.

0.72 l/per hr. Single injector with six 2.3 mm holes

9,80%

4.100RPM*

1.400RPM*

3.900RPM* 40 ppm 20 ppm 50 ppm 50 ppm

* set parameters: P. 13 (maximum), P. 17 (minimum), P. 19 (ignition) as shown in section 7.3.

10.2 RELATED DOCUMENTS BS 6798 BS 5449

BS 5440 BS 5482

PART 1 PART 1 PART 1

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

37 mbar

4.08 l/per hr.

1.19 l/per hr. 9,80%

5.500RPM*

1.700RPM*

3.000RPM* 30 ppm 20 ppm 50 ppm 50 ppm

10.3 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.

10.4 GAS SUPPLY INSTALLATION

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

10.5 ADJUSTING THE GAS VALVE The gas valve must be set-up or adjusted with the aid of a properly calibrated flue gas analyser.

Remove the appliance casing as detailed in section 4.10. Unclip and remove the air chamber cover. Set the flue gas analyser to read CO2 and insert the probe into the flue analysis test point (see fig.1). Using the procedure as detailed in section 7, enter the appliance service mode and set the power to minimum.

10.5.1 MINIMUM SETTING

With the boiler operating at minimum output the CO2 reading should be 9.8% (+/- 0.2%). If the CO reading is correct, proceed to 10.5.2. If the CO reading is incorrect, the minimum gas pressure must be adjusted as follows:

● using a suitable screwdriver, very slowly turn the

minimum adjustment screw (fig. 30) – clockwise to increase, counter clockwise to decrease – until the correct value is displayed on the CO2 analyser (allow time for the analyser to stabilise).

● using the procedure as detailed in section 7,

change the power momentarily from minimum to maximum, then back to minimum.

● check that the correct value is still being

obtained. If not, repeat the above procedure.

10.5.2 MAXIMUM SETTING

The maximum setting must only be checked and/ or adjusted after the correct minimum setting has been verified. Using the procedure as detailed in section 7, change the power from minimum to maximum.

With the boiler operating at maximum output the CO2 reading should be 9.8% (+/- 0.2%). If the CO

reading is correct, press the exit the appliance engineer mode. If the CO

reading is incorrect, the maximum gas pressure must be adjusted as follows:

● using a suitable screwdriver, very slowly turn

the maximum adjustment screw (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).

● using the procedure as detailed in section 7,

change the power momentarily from maximum to minimum, then back to maximum.

● check that the correct value is still being

obtained. If not, repeat the above procedure.

2 2

● press the

service mode.

Remove the analyser test probe from the analysis test point and refit cap. Refit the air chamber cover. Refit appliance casing.

NOTE

You should ensure that all radiators or heat emitters are fully open during the above procedures. This will ensure that the power (output) of the boiler is not compromised due to a high flow temperature.

reset

button to exit the appliance

button to

energizing home heating

Cod. 10023766 - 39/03 - Ed. 2

Vokèra Ltd.

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

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

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

After Sales Service - Tel: 0870 333 0220

Vokèra Ireland

West Court, Callan, Co Kilkenny

Tel: 05677 55057 Fax: 05677 55060

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

A Riello Group Company

COLLECTIVE MARK

“Vokèra”

supports Benchmark

Vokera Pinnacle 16 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual