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
9
8
7
6
5
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
16
11 Flue gas analysis test point
12 Burner plate
17
13 Expansion vessel
14 Spark/Sensing Electrode
15 Heat exchanger
16 Pressure switch
18
17 Fan assembly
18 Electronic Control Board (PCB)
R Heating return connection
F Heating flow connection
G Gas connection
2
Fig. 1A
Fig. 1B
1
RF G
5
Control board (fig. 1B)
1 STEP button
2 PLUS button
4
3 MODE button
4 4 digits display
3
2
1
6
7
8
5 Status LED
6 RESET button
7 MINUS button
8 CH button/MEMO button
9
10
9 Time clock aperture
10 Pressure gauge
1
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.
1
NTC1
4
(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
2
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
3
2.12 PUMP DUTY
0
()
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)
7
6,5
0)
6
2
5,5
5
4,5
4
3,5
3
2,5
2
1,5
1
Water pressure (mH
0,5
0
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
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.
5
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.
6
*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
7
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
The terminal should be located where the dispersal
of combustion products is not impeded and with
due regard for the damage and discoloration that
may occur to building products located nearby.
The terminal must not be located in a place where
it is likely to cause a nuisance (see I.S. 813).
In cold and/or humid weather, water vapour 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.
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.6.2 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.
8
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
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.
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
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. 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.
Buildings’ gives specific advice on this type of
installation.
3A.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.
3A.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.
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
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.
3A.7 ELECTRICAL SUPPLY
The appliance is supplied for operation on 230V
@ 50Hz electrical supply; it must be protected
with a 3-amp fuse. The method of connection to
the mains electricity supply must allow for
complete isolation from the supply. The preferred
method is by using a double-pole switch with a
contact separation of at least 3 mm. The switch
must only supply the appliance and its
corresponding controls, i.e. time clock, room
thermostat, etc.
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
9
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
10
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
11
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.
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.
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
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).
B
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
12
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