Vokera Synergy 25 E User guide

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Installation & Servicing Instructions

THESE INSTRUCTIONS TO BE RETAINED BY USER

Contents

Design principles and operating sequence Page

1.1 Principle components 2

1.2 Mode of operation (at reset) 2

1.3 Mode of operation 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 (concentric) 3

2.8A Flue details (twin pipes) 3

2.9 Efficiency 3

2.10 Pump duty 4

2.11 Emissions 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

3.6.1 Pipework 6

3.6.2 Automatic by-pass 6

3.6.3 Drain cocks 6

3.6.4 Air release points 6

3.6.5 Expansion vessel 6

3.6.6 Filling point 6

3.6.7 Low pressure sealed system 6

3.6.8 Frequent filling 6

3.7 Electrical supply 6

3.8 Mounting on a combustible surface 6

3.9 Timber framed building 6

3.10 Inhibitors 6

General requirements (EIRE) Page

3.A1 Related documents 7

3.A2 Location of appliance 7

3.A3 Gas supply 7

3.A4 Flue system 7

3.A5 Air supply 7

3.A6 Water circulation 7

3.A6.1 Pipework 7

3.A6.2 Automatic by-pass 7

3.A6.3 Drain cocks 7

3.A6.4 Air release points 7

3.A6.5 Expansion vessel 8

3.A6.6 Filling point 8

3.A6.7 Low pressure sealed system 8

3.A6.8 Frequent filling 8

3.A7 Electrical supply 8

3.A8 Mounting on a combustible surface 8

3.A9 Timber framed building 8

3.A10 Inhibitors 8

3.A11 Declaration of conformity 8

Installation Page

4.1 Delivery 9

4.2 Contents 9

4.3 Unpacking 9

4.4 Preparation for mounting the appliance 9

4.5 Fitting the flue 9

4.5.1 Concentric horizontal flue 9

4.5.2 Concentric vertical flue 11

4.5.3 Twin flue system 12

4.6 Connecting the gas and water 14

4.6.1 Gas 14

4.6.2 Flow and return 14

4.6.3 Safety valve 14

4.6.4 Condense pipe 15

4.7 Electrical connections 15

4.7.1 Casing removal 15

4.7.2 Appliance terminal block 15

4.7.3 Connecting the mains (230V) input 15

Commissioning Page

5.1 Gas supply installation 17

5.2 The heating system 17

5.3 Initial filling of the system 17

5.4 Initial flushing 17

5.5 Pre-operation checks 17

5.6 Initial lighting 17

5.7 Checking burner pressures 17

5.8 Final flushing of the heating system 17

5.8.1 Inhibtors 18

5.9 Setting the boiler operating temperature 18

5.10 Setting the system design pressure 18

5.11 Regulating the central heating system 18

5.12 Final checks 18

5.13 Instructing the user 18

Servicing instructions Page

6.1 General 19

6.2 Routine annual servicing 19

6.3 Replacement of components 19

6.4 Component removal procedure 19

6.5 Pump assembly 19

6.6 Safety valve 19

6.7 Automatic air release valve 20

6.8 Water pressure switch 20

6.9 Pressure gauge 20

6.10 Primary thermistors 20

6.11 High limit thermostat 20

6.12 Printed circuit board 20

6.13 Gas valve 21

6.14 Integral time switch 21

6.15 Electrode, burner thermostat, burner & injectors 21

6.16 Flue fan 22

6.17 Main heat exchanger 23

6.18 Air pressure switch 23

6.19 Automatic by-pass 23

6.20 Expansion vessel 23

6.20.1 Expansion vessel removal 23

6.20.2 Expansion vessel removal 23

6.21 Latent heat collector 24

6.21A Dismantling the latent heat collector 24

6.22 Condense trap removal 24

Checks, adjustments and fault finding page

7.1 Checking appliance operation 25

7.2 Appliance mode of operation 25

7.2.1 Selector switch in the off position 25

7.2.2 Selector switch in the hot water only position 25

7.2.3 Appliance functions 25

7.2.4 Heating/HW mode 25

7.3 Checking and adjusting burner pressure 25

7.3.1 Setting the maximum burner pressure 25

7.3.2 Setting the minimum burner pressure 26

7.4 Combustion analysis test 26

7.5 Checking the expansion vessel 26

7.6 External faults 26

7.6.1 Installation faults 26

7.7 Electrical checks 26

7.7.1 Earth continuity test 26

7.7.2 Short circuit test 27

7.7.3 Polarity check 27

7.7.4 Reversed polarity or supply fault 27

7.7.5 Resistance to earth check 27

7.8 Fault finding 27

7.9 Fault codes 27-33

Wiring diagrams Page

8.1 External wiring 34

8.2 Installation of Vokera twin channel programmer 34

8.3 Typical control applications 34

8.4 Vokera time clock 34

8.5 Vokera room thermostat 34

8.6 “S” plan wiring 34

8.7 “Y” plan wiring 34

8.8 Other controls 34

Exploded diagrams Page

Table 1 - 5 39 - 44

INTRODUCTION

The Synergy e is a high-efficiency system boiler with an output of 28kW. The appliance - by design - incorporates electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge and automatic by-pass. This appliance is not suitable for use with LPG. The Synergy e is produced as room sealed, category II2H appliances, suitable for internal wall mounting applications only. It is provided with a fan powered flue outlet with an annular co-axial combustion air intake that can be rotated - horizontally - through 360 degrees for

various horizontal or vertical applications. The Synergy e range can also be used with the Vokera twin flue system.

The Synergy e range is approved for use with C12 & C32 type flue applications.

This appliance is designed for use with a sealed system only; consequently it is not intended for use on open vented systems.

Fig.1 General Layout

1 Safety Valve 2 Pressure Switch 3Pump 4 Automatic Air Release Valve 5 Main Burner 6 Electrode 7 Main Heat Exchanger 8 Latent Heat Collector 9 Condense Sensor 10 Flue Gas Analysis Test Point 11 Flue Outlet 12 Air Intake 13 Differential Analog Pressure Switch 14 Silicone Tube 15 Fan Assembly 16 Combustion Chamber 17 Burner Temperature Control 18 Expansion Vessel 19 Transformer 20 Gas Valve 21 Modulator Coil 22 Condense Trap 23 Status LED 24 Temperature Indicator 25 Central Heating Temperature Control 26 Combustion Switch 27 Timeclock Aperture (optional) 28 Pressure Gauge 29 Mode Selector Switch

Fig. 1

25 26

SECTION 1 DESIGN PRINCIPLE AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS

● A fully integrated electronic control board

featuring electronic temperature control, anticycle control, pump over-run, self-diagnostic fault indicator, full air/gas modulation.

● Low-water-content, copper heat exchanger.

● Electronic ignition with flame supervision

● Integral high-head pump

● Fan

● Expansion vessel

● Analogue pressure switch (PAD)

● Water pressure switch

● Two-stage gas valve

● Pressure gauge

● Safety valve

1.2 MODE OF OPERATION (at rest)

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

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

protection system protects the appliance against the risk of frost damage. The first stage enables activation of the pump should the temperature of the appliance fall to 7°C. The second stage becomes active when the temperature has dropped to 3°C. Should the second stage become active, the appliance will function on minimum power until it reaches 30°C.

● anti-block function – the anti-block function

enables the pump to be energised for short periods, when the appliance has been inactive for more than 19-hours.

● a high limit thermostat that over-rides the

temperature control circuit to prevent or interrupt the operation of the burner.

● an analogue pressure switch (PAD) that

checks the operation of the fan and flue thereby allowing safe operation of the burner.

● a sensor that interrupts the operation of the

appliance if the condense pipe becomes blocked.

● a safety valve which releases excess pressure

from the primary circuit.

Air Intake

PA D

Condense

trap

Expansion

vessel

Pump

Latent Heat

Collector

AARV

Flue Outlet

Main Heat

Exchanger

Main

Burner

Gas Valve

1.3 MODE OF OPERATION

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

1.4 SAFETY DEVICES

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

● a water pressure switch that monitors system

water pressure and will de-activate the pump, fan and burner should the system water pressure drop below the rated tolerance.

Safety

valve

Automatyc

by-pass

Fig. 2

Pressure

Switch

SECTION 2 TECHNICAL DATA

2.1 Central heating Synergy 25 e

Heat input 25.0 kW Max heat output 60/80°C (return & flow temp.) 24.7 kW Max heat output 30/50°C (return & flow temp.) 26.6 kW Min heat output 60/80°C (return & flow temp.) 7.28 kW Min heat output 30/50°C (return & flow temp.) 7.90 kW Minimum working pressure 0.45 bar Maximum working pressure 3.0 bar Minimum flow rate 350 l/h

2.3 Gas pressures

Inlet pressure (G20) 20.0 mbar Burner pressure maximum 8.9 mbar Burner pressure minimum 1.0 mbar Maximum gas rate 2.64 Sm3/h Minimum gas rate 0.79 Sm3/h Injector size (quantity) 12 x 1.35 mm

2.4 Expansion vessel

Capacity 8-litres Maximum system volume 76-litres Pre-charge pressure 1.0 bar

2.5 Dimensions

Height 820mm Width 400mm Depth 350mm Dry weight (kg) 44.0

2.6 Clearances

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

2.7 Connections

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

2.8 Electrical

Voltage (V/Hz) 230/50 Power consumption 174W Internal fuse 2A External fuse 3A

2.9 Flue details (concentric)

Maximum horizontal flue length (60/100mm) 2.25m Maximum vertical flue length (60/100mm) 3.25m Maximum horizontal flue length (80/125mm) 5.50m Maximum vertical flue length (80/125mm) 7.0m

2.9A Flue Details (twin pipes)

Maximum horizontal flue length (80mm + 80mm) 10m+10m Maximum vertical flue length (80mm + 80mm) 10m+10m

2.10 Efficiency

SEDBUK (%) 90.52

SECTION 2 TECHNICAL DATA

2.10 PUMP DUTY

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

6,5

5,5

4,5

3,5

2,5

1,5

Water pressure (mbar)

0,5

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

Fig. 3

Litres Per Hour

2.11 Emissions

Synergy 25 eAppliance

NOx max/min 160/140 CO max/min 70/20 CO2 max/min 6.5/4.8 CO/CO2 ratio max/min 0.00108 to 1/0.00044 to 1

Fig. 4

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

SECTION 3 GENERAL REQUIREMENTS (UK)

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

3.1 RELATED DOCUMENTS

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

3.2 LOCATION OF APPLIANCE

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

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 BS6891. If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time.

3.4 FLUE SYSTEM

The terminal should be located where the dispersal of combustion products is not impeded and with due regard for the damage and discoloration that may occur to building products located nearby. The terminal must not be located in a place where it is likely to cause a nuisance (see fig. 4). In cold and/or humid weather, water vapour will condense on leaving the terminal; the effect of such pluming must be considered.

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 INSTALLTION 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

If installed less than 2m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material. The guard must be fitted centrally over the terminal. Refer to BS 5440 Part 1, when the terminal is

0.5 metres (or less) below plastic guttering or 1 metre (or less) below painted eaves.

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

A method for initial filling of the system and replacing water lost during servicing etc. is required (see fig. 14). This method of filling must comply with the current Water Supply (Water Fittings) Regulations 1999 and Water Bylaws 2000 (Scotland).

3.6.7 LOW PRESSURE SEALED SYSTEM

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

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.

Make-up vessel or tank

Automatic air-vent

Stopcock

5.0 metres minimum

Fig. 5

Non-return

valve

Heating return

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 3mm. 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 Timber Frame Buildings’.

3.10 INHIBITORS

Vokera recommend that a inhibitor - suitable for use with low water-content, copper 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.

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). n cold and/or humid weather, water vapour will condense on leaving the terminal; the effect of such pluming must be considered. If installed less than 2m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material. The guard must be fitted centrally over the terminal. Refer to I.S. 813, when the terminal is 0.5 metres (or less) below plastic guttering or 1 metre (or less) below painted eaves.

3A.5 AIR SUPPLY

3A.6 WATER CIRCULATION

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

3A.6.1 PIPEWORK

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

3A.6.2 AUTOMATIC BY-PASS

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

3A.6.3 DRAIN COCKS

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

3A.6.4 AIR RELEASE POINTS

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

3A.6.5 EXPANSION VESSEL

3A.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. is required (see fig. 14). You should ensure this method of filling complies with the local water authority regulations.

3A.6.7 LOW PRESSURE SEALED SYSTEM

3A.10 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.11 DECLARATION OF CONFORMITY

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

813) must be provided on completion of the installation. A copy of the declaration must be given to the responsible person and also to the gas supplier if required.

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

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 Buildings’ gives specific advice on this type of installation.

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 (see fig. 6)

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.

200

360

820

150

107.5

145

Fig. 6

4.4 PREPARATION FOR MOUNTING THE APPLIANCE (see fig. 6A)

The appliance should be mounted on a smooth, vertical, non-combustible surface, which must be capable of supporting the full weight of the appliance. Care should be exercised when determining the position of the appliance with respect to hidden obstructions such as pipes, cables, etc.

When the position of the appliance has been decided - using the template supplied – carefully mark the position of the wall- mounting bracket (see fig. 6A) and flue-hole (if applicable).

CONDENSATE

PIPE

Fig. 6A

RETURN

FLOW

GAS

453

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

NOTE

These instructions relate only to the Vokera condensing 60/100mm concentric flue system. For specific details on the installation of the 80/ 125mm concentric flue system please refer to the instructions supplied. The appliance flue outlet elbow can be rotated through 360° on its vertical axis. In addition the flue may be extended from the outlet elbow in the horizontal plane (see 2.8). A reduction must also be made to the maximum length (see table below) when additional bends are used.

Reduction for additional bends

Bend Reduction in maximum flue length for each bend

45° bend 0.5 metre 90° bend 1.0 metre

Horizontal flue terminals and accessories

Part No. Description Min-Max Length

0225720 Horizontal flue kit for use 1000mm

with add. bends &

extensions 0225755 Telescopic extension 350mm – 500mm 0225740 0.5m extension 500mm 0225745 1.0m extension 1000mm 0225750 2.0m extension 2000mm 0225730 45° bend (pair) N/A 0225735 90° bend N/A 0225760 Wall bracket (5) N/A

Using the template provided, mark and drill a 115mm hole for the passage of the flue pipe. The hole should have a 1° rise from the boiler to outside, to ensure any condense fluid that forms, is allowed to drain back to the appliance. 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.

Push-fit connection

Terminal or

extension

NOTE

Fit the internal trim to the flue assembly prior to connecting the flue pipe to the bend.

You must ensure that the entire flue system is properly supported and connected. Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The exterior trim can now be fitted.

Fig. 7A

“Y” = “X” + 45mm

4.5.1.1 EXTENDING THE FLUE

Connect the bend - supplied with the terminal kit

- to the top of the boiler using clamp (supplied) see fig. 7. The additional bends & extensions have push-fit connections, care should be taken to ensure that the correct seal is made when assembling the flue system. Connect the required number of flue extensions or bends (up to the maximum equivalent flue length) to the flue terminal (see fig. 7 & 8).

125mm

outer

clamp

Boiler

Fig. 7

FITTING THE HORIZONTAL FLUE KIT

Carefully measure the distance from the centre of the appliance flue outlet to the edge of the finished outside wall (dimension X). Add 45mm to dimension X to give you Dimension Y (see fig 7A). Measure dimension Y from the terminal end of the concentric flue pipe and cut off the excess ensuring any burrs are removed. Pass the concentric flue pipe through the previously drilled hole. Fit the flue bend to the boiler flue outlet and insert the concentric flue pipe into the flue bend ensuring the correct seal is made. Using the clamp, gasket and screws supplied, secure the flue bend to the appliance flue spigot. The 60mm M & F adaptor (supplied with the flue kit) should be discarded.

The hole should have a 1° rise from the boiler to outside, to ensure any condense fluid that forms, is allowed to drain back to the appliance.

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (see fig. 7 & 8). Remove any burrs, and check that all seals are located properly. You must ensure that the entire flue system is properly supported and connecte. 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.

Fig. 8

4.5.2 CONCENTRIC VERTICAL FLUE

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

NOTE

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

Reduction for bends

Bend Reduction in maximum flue length for each bend

45° bend 0.5 metre 90° bend 1.0 metre

Vertical flue terminal and accessories

Part No. Description Length

0225725 Vertical flue terminal 1.0 metre 0225770 Pitched roof flashing plate N/A 0225765 Flat roof flashing plate N/A 0225755 350-500 telescopic extension 350mm – 500mm 0225740 500mm extension 500mm 0225745 1000mm extension 1000mm 0225750 2000mm extension 2000mm 0225730 45° bend (pair) N/A 0225735 90° bend N/A 0225760 Wall bracket (4) N/A

Using the dimensions given in fig. 9 as a reference, mark and cut a 115mm hole in the ceiling and/or roof. Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing. The fixing holes for the wall-mounting bracket should now be drilled and plugged, an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely. Once the bracket has been secured to the wall, mount the appliance onto the bracket.

Fig. 9

IMPORTANT

The vertical flue terminal is 1.0 metre in length and cannot be cut; therefore it may be necessary to adjust the height of the appliance to suit or use a suitable extension. Connect the vertical flue assembly to the boiler flue spigot using the 60mm & 100mm clips, gaskets & screws (supplied), ensuring the correct seal is made. The flue support bracket (supplied with the vertical flue kit) can now be fitted.

If the vertical flue requires extension/s or additional bend/s, connect the required number of flue extensions or bends (up to the maximum equivalent flue length) between the boiler and vertical flue assembly (see fig. 8).

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

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (see fig. 8). Remove any burrs and check that any seals are located properly. You must ensure that the entire flue system is properly supported and connected.

4.5.3 TWIN FLUE SYSTEM

The Vokera twin flue system enables greater flue distances to be achieved (see 4.4.2) than that of a concentric flue system. It can be used for horizontal or vertical applications, however the twin flue system must be converted to the dedicated concentric flue kit for termination. It is essential that the installation of the twin flue system be carried out in strict accordance with these instructions.

GUIDANCE NOTES ON TWIN FLUE INSTALLATION

● The flue must have a fall back of 1° back to

the appliance to allow any condensate that may form in the flue system to drain via the condensate drain. Consideration must also be given to the fact that there is the possibility of a small amount of condensate dripping from the terminal.

● Ensure that the entire flue system is

adequately supported, use at least one bracket for each extension.

● The entire flue system must be adequately

insulated to maintain heat within the flue system thereby reducing the possibility of condensate production.

● As the exhaust outlet pipe can reach very high

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

● The condensate drain pipe must be connected

in accordance with building regulations.

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.

Pay attention to condense trap!

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

● Insert the exhaust connection manifold (A)

onto the appliance flue outlet.

● Remove the blanking plate (located to the right

of the appliance flue outlet) and - using the same screws - install the air inlet plate (B).

● Using the hole in the exhaust connection

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

● Using the two holes in the air inlet plate as a

guide, drill a 3mm hole in each and secure the air inlet pipe/bend using the screws provided.

● The twin flue pipes extensions and accessories

can now be installed by pushing together (the plain end of each extension or bend should be pushed approximately 50mm into the female socket of the previous piece).

Reduction for bends

Bend Reduction in maximum flue length for each bend

45° bend 1.0 metre 90° bend 1.0 metre

Twin flue accessories

Part No. Description Length

0225805 Horizontal flue terminal 1.0 metre 0225810 Vertical flue terminal 1.0 metre 359 Twin adapter kit N/A 0225770 Pitched roof flashing plate N/A 0225765 Flat roof flashing plate N/A 0225815 Condensate drain kit N/A 0225820 0.25m extension (pair) 250mm 0225825 0.5m extension (pair) 500mm 0225830 1.0m extension (pair) 1000mm 0225835 2.0m extension (pair) 2000mm 0225840 45° bend (pair) N/A 0225845 90° bend (pair) N/A 0225850 Twin bracket (5) N/A 0225855 Single bracket (5) N/A

Fig. 10

Fig. 11

Fig. 12

1-deg. = 17mm

1.0-metre

4.5.3.2 HORIZONTAL TERMINATION (see fig. 12)

The twin flue system must be converted to the

dedicated concentric flue kit for termination.

● The horizontal terminal is supplied with a built-

in converter box and cannot be shortened.

● A 130mm hole is required for the passage of

the concentric terminal through the wall.

● The air inlet pipe must always be level with or

below, that of the exhaust pipe. Depending on site conditions it may be preferable to install the terminal assembly prior to fitting the twin flue pipes.

Mark and drill a 130mm hole for the passage of the horizontal flue terminal, ensuring that there is a 1° fall back to the boiler (17mm per 1000mm). Insert the terminal assembly into the flue hole.

Push-fit the twin flue pipes onto the concentric to twin converter box ensuring that the exhaust pipe connects to the exhaust connection on the concentric to twin converter.

If necessary cut the plain ends (male) of the twin flue pipes to allow connection to the concentric to twin converter

NOTE

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

NOTE

You must ensure that the entire flue system is properly supported and connected. 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 (see fig. 13)

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

● The vertical terminal is supplied with a built-in

converter box and cannot be shortened.

● A 130mm hole is required for the passage of

the concentric terminal through the ceiling and/

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

NOTE

● Before cutting twin flue pipes ensure

allowances have been made for connection

onto the previous piece and onto the

concentric to twin converter. The last twin flue

pipes must be pushed 50mm onto the male

spigots of the concentric to twin converter.

● You must ensure that the entire flue system is

properly supported and connected.

● Ensure that any horizontal sections of pipe

have a 1° all towards the appliance (17mm per

1000mm).

Control valve

Temporary connection

Control

valve

Fig. 13

4.6 CONNECTING THE GAS AND WATER

The appliance is supplied with service valves (fig.

14). The service valves are of the compression type. The accessories pack contains sealing washers etc, for use with the service valves. When connecting pipe work to the valves, tighten the compression end first then insert the sealing washers before tightening the valve to the appliance.

NOTE

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

Flow pipe

Fig. 14

Double

check valve

Supply

4.6.1 GAS (see fig. 6A & 14)

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

NOTE

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

4.6.2 FLOW & RETURN (see fig. 6A & 14)

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

NOTE

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

4.6.3 SAFETY VALVE (see fig. 6A & 14)

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

4.6.4 CONDENSE PIPE

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

CONNECTING THE CONDENSATE OUTLET

Gently pull the condense outlet pipe down from its location inside the boiler until approximately 200mm protrudes from the underside of the boiler. Connect a suitable plastic (not copper) pipe (no less than 20mm diameter) to the outlet pipe and ensure it discharges in accordance with building regulations or other rules in force.

4.7 ELECTRICAL CONNECTIONS

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

4.7.1 CASING REMOVAL

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

● press the controls cover to release the controls

cover catch

● locate and unscrew the 2 screws that secure

the controls fascia to the appliance casing (see fig. 15)

● gently lower the control fascia until it rests

● remove the 2 screws located at the Left & Right

of the underside of the casing

● lift the casing upward to disengage it from the

top locating hooks and then remove

● store the casing and screws safely until

required. Re-fit in the reverse order.

4.7.2 APPLIANCE TERMINAL BLOCK

The appliance terminal block is located on the left side of the control fascia (see fig. 15). Locate and remove the screws securing the terminal block cover.

NOTE

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

Fig. 15

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

Remove the terminal block cover as described in 4.7.2. Pass the cable through the cable anchorage (see fig. 16). On the terminal block there are 7 terminals from Right to Left they are:

1. LIVE

2. NEUTRAL

3. 230V output

4. 230V input

5. (spare)

6. (spare)

7. (spare)

8. (spare) Connect the supply cable wires (LIVE and

NEUTRAL) to their corresponding terminals on the appliance terminal block. Connect the EARTH wire to the EARTH block (see fig. 16) ensuring that it’s left slightly longer that the others, this will prevent strain on the EARTH wire should the cable become taut. Do not remove the link wire (between 3 & 4) unless additional external controls are to be fitted (see section 8). Re-fit the appliance terminal block 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. The appliance casing and screws can now be re-fitted.

Fig. 16

Connect the supply cable wires (LIVE and NEUTRAL) to their corresponding terminals on the appliance terminal block. Connect the EARTH wire to the EARTH block (see fig. 16) ensuring that it’s left slightly longer that the others, this will prevent strain on the EARTH wire should the cable become taut.

SECTION 5 COMMISSIONING

5.1 GAS SUPPLY INSTALLATION

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

5.2 THE HEATING SYSTEM

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

5.3 INITIAL FILLING OF THE SYSTEM

Ensure both flow and return service valves are open, remove appliance casing as described in

4.7.1, identify the automatic air release valve and loosen the dust cap by turning the cap anticlockwise one full turn. IMPORTANT, THERE ARE NO MANUAL AIR RELEASE VALVES LOCATED ON THE APPLIANCE. Ensure all manual air release valves located on the heating system are closed. Using the approved method of filling (fig. 14), 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 both the inlet and service valves and begin venting all manual air release valves, starting at the lowest first. It may be necessary to go back and top-up the pressure until the entire system has been filled. Inspect the system for water soundness, rectifying any leaks.

5.4 INITIAL FLUSHING

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

5.6 INITIAL LIGHTING

Ensure the electrical supply to the appliance is switched on. Move the selector switch to the ON position, ensure any time clock or programmer is switched to an ‘ON’ position and ensure any other external controls are also calling for heat. The appliance will now operate in the heating mode as described in 1.3. Should the appliance fail to ignite, refer to 5.5 and/or section 7 (faultfinding).

5.7 CHECKING THE BURNER PRESSURE

Although the burner pressure is factory set, it is necessary to check it during commissioning. Isolate the appliance from the electrical supply and attach a suitable manometer to the gas valve outlet test-point (see fig. 17). Light the boiler as described in 5.6, allowing the appliance to stabilise. Compare the reading on the manometer with the value described in 2.3. If adjustment is required, follow the detailed instructions in section 7 (7.3).

Outlet

test-point

Protective

cap

Inlet

test-point

Fig. 17

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 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.

Once the burner pressure has been checked, isolate the appliance from the electrical supply, remove the manometer and tighten the gas valve outlet test nipple.

5.8 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.

5.8.1 INHIBITORS

See Section 3 “General requirements”.

5.9 SETTING THE BOILER OPERATING TEMPERATURE

The flow outlet temperature can be adjusted between 40°C - 80°C via the thermostat knob (see fig.1).

5.10 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 (see fig. 1).

Show the user how to operate the appliance and any associated controls correctly. Show the user the location of the filling valve and how to top-up the system pressure correctly and show the location of all manual air release points. Explain to the user how to turn off the appliance for both long and short periods and advise on the necessary precautions to prevent frost damage. Explain to the user that for continued safe and efficient operation, the appliance must be serviced annually by a competent person.

5.11 REGULATING THE CENTRAL HEATING SYSTEM

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

5.12 FINAL CHECKS

● ENSURE ALL TEST NIPPLES ON THE

APPLIANCE GAS VALVE HAVE BEN TIGHTENED AND CHECKED FOR SOUNDNESS

● ENSURE THE APPLIANCE FLUE SYSTEM

IS FITTED CORRECTLY AND IS PROPERLY SECURED

● ENSURE ALL PIPE WORK IS RE-CHECKED

FOR SOUNDNESS

● RE-FIT APPLIANCE CASING

● COMPLETE 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.

5.13 INSTRUCTING THE USER

Hand over all documentation supplied with this appliance - including these instructions - and explain the importance of keeping them in a safe place. Explain to the user how to isolate the appliance from the gas, water and electricity supplies and the locations of all drain points.

SECTION 6 SERVICING

6.1 GENERAL

To ensure the continued safe and efficient operation of the appliance, it is recommended that it is checked and serviced at regular intervals. To ensure correct and safe operation of the appliance, it is essential that any worn or failed component be replaced only with a genuine Vokera spare part. 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 and the domestic hot water systems would also require attention from time to time.

6.2 ROUTINE ANNUAL SERVICING

Check the operation of the appliance and ensure it functions as described in section 7. Compare the performance of the appliance with its design specification. The cause of any noticeable deterioration should be identified and rectified without delay. Thoroughly inspect the appliance for signs of damage or deterioration especially the flue system and the electrical apparatus. Check and adjust - if necessary - all burner pressure settings (see 7.3). Check and adjust - if necessary - the system design pressure (see 5.10). Carry out an analysis of the flue gases (see 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. Ensure both flue venturis are clean and free from any debris or obstruction. Ensure the burner, main heat exchanger, and latent heat collector are clean and free from any debris or obstruction.

Ensure some water absorbent cloths are available to catch any residual water that may drip from the appliance or removed component. Undertake a complete commissioning check as detailed in section 5, after replacing any component. ALWAYS TEST FOR GAS

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

6.5 PUMP ASSEMBLY (see fig. 18)

Carry out component removal procedure as described in 6.4. Disconnect and remove the ancillary items (3, 4, 5, 6, 7) from the pump assembly. Slacken and remove the securing screw (8) from the heating manifold. Disconnect the electrical cover & lead (1, 2). The pump assembly can now be removed from the heating manifold. Replace in the reverse order.

Fig. 18

6.6 SAFETY VALVE (see fig. 19)

Carry out component removal procedure as described in 6.4. Disconnect the outlet pipe from the safety valve, remove safety valve locking screw (1) from the heating manifold. Replace in the reverse order.

6.3 REPLACEMENT OF COMPONENTS

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

6.4 COMPONENT REMOVAL PROCEDURE

To remove a component, access to the interior of the appliance is essential. Isolate the appliance from the electrical supply and remove the fuse. And when necessary, close all service valves on the appliance, remove the appliance casing as described in section 4.7.1 and drain the water content from the appliance via the safety valve.

Fig. 19

6.7 AUTOMATIC AIR RELEASE VALVE (see fig.

18) (AAV)

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

6.8 WATER PRESSURE SWITCH (see fig. 20)

Carry out component removal procedure as described in 6.4. Remove locking screw (1) and the water pressure switch from the heating manifold, and - after taking note of the electrical connections disconnect the wiring. Replace in the reverse order.

Fig. 22

6.11 HIGH LIMIT THERMOSTAT (see fig. 23)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber cover. Pull off electrical connections from the high limit thermostat (2), slacken and remove retaining screws (3). Replace in reverse order.

Fig. 20

6.9 PRESSURE GAUGE (see fig. 21)

Carry out component removal procedure as described in 6.4. Remove pressure gauge locking screw (1), located on pump base, and withdraw the pressure gauge pipe (2), 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.

Fig. 21

6.10 PRIMARY THERMISTOR (see fig. 22)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber cover and remove the right side air baffle. Disconnect thermistor electrical plug. Using a 13mm spanner slacken and remove the thermistor and sealing washer (1, 2) from the main heat exchanger. Replace in the reverse order.

Fig. 23

6.12 PRINTED CIRCUIT BOARD (see fig. 24)

Carry out component removal procedure as described in 6.4. Locate and remove the screws (1) which secure the PCB cover & terminal cover, then remove cover, after carefully taking note of all wiring connections, disconnect all wiring from the PCB, locate and remove the PCB securing screws (2, 3,), remove the required PCB (4, 5, 6). Replace in the reverse order.

NOTE

Ensure that any replacement PCB has the correct ‘Jumper Tag’ configuration (see section 8).

Fig. 24

6.13 GAS VALVE (see fig. 25)

Carry out component removal procedure as described in 6.4. The gas valve must be changed as complete unit. Disconnect the electrical plug and leads from the gas valve. Slacken and unscrew gas valve inlet and outlet connections (3). Please note, the sealing washers (2) must be discarded and replaced with new sealing washers (2). Locate and remove gas valve retaining screws on the underside of the boiler if required, the gas valve can now be removed. Replace in the reverse order. Check and adjust burner pressure settings.

WARNING: A GAS SOUNDNESS CHECK MUST BE CARRIED OUT.

6.14 INTEGRAL TIME SWITCH (if fitted)

Carry out component removal procedure as described in 6.4. Locate and remove the terminal cover and securing screws (2), locate and remove the time clock retaining screws, remove time clock. Disconnect wiring after carefully taking note of all electrical connections. Replace in the reverse order.

6.15 ELECTRODE, BURNER THERMOSTAT, BURNER & INJECTORS

Fig. 26: carry out component removal procedure

as described in 6.4. Unclip and remove the air chamber cover (2). Locate and remove the 6 screws securing the front combustion cover (3), pull the cover towards you before lifting and disengaging. Disconnect the electrode lead and burner thermostat from their respective connectors. Ease the electrode sealing grommet from its seating (4). Remove the retaining screw (6) for the burner thermostat and remove the thermostat (7).

Fig. 27: locate and remove the four screws which secure the burner in position (1), gently ease the burner out of its location. Once the burner has been removed, the electrode retaining screw can be can be removed. Locate the burner injectors (2) and remove (if necessary). Replace in the reverse order. Please note, the injector sealing washers (3) must be replaced if the injectors have been removed, ensure all seals are in good condition, taking care to ensure they are replaced correctly. Replace in the reverse order.

Fig. 25

Fig. 26

Fig. 27

6.16 FLUE FAN (see fig. 27 & 28)

Carry out component removal procedure as described in 6.4.

Fig. 27: unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging (2). Locate and remove the six screws that secure the front combustion cover, then remove the cover (3).

Fig. 28: disconnect the electrical connections and silicone tubes (10) attached to the fan, noting their positions. Locate and remove the screws (6) that

secure the analogue pressure switch assembly (4 & 5). Locate and remove the screws that secure the flue hood and air baffle, disconnect the flue clip (1) from the fan-flue elbow, and gently ease the fan (3) & flue hood assembly (2) from its location. Locate and remove the four screws that secure the fan to the flue hood. Remove the fan to flue elbow. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

Fig. 28

6.17 MAIN HEAT EXCHANGER (see fig. 27 & 29)

Carry out component removal procedure as described in 6.4. Fig. 27: unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging (2). Locate and remove the six screws that secure the front combustion cover, then remove the cover (3). Fig. 29: remove the air chamber side panels if necessary by unscrewing the securing screws

(3). Disconnect the flow and return connections (4, 5) on the heat exchanger. The heat exchanger can now be withdrawn from the appliance. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.18 AIR PRESSURE SWITCH (see fig. 27 & 28)

Carry out component removal procedure as described in 6.4. Fig. 27: unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging (2). Fig. 28: locate and remove the two screws (6) holding the air pressure switch to the air chamber. Disconnect the electrical connections and silicone tubes (10) attached to the air pressure switch, noting their positions. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.19 AUTOMATIC BYPASS (see fig. 30)

Carry out component removal procedure as described in 6.4. Disconnect and remove the flow pipe at the heating manifold (1) and at the connection to the air chamber. Using a hooked piece of wire, carefully withdraw the bypass cartridge (2). Ensure all seals are in good condition, taking care to ensure they are replaced correctly. Replace in the reverse order ensuring the cartridge is facing the correct way.

Fig. 30

6.20 EXPANSION VESSEL fig. 1

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

6.20.1 EXPANSION VESSEL REMOVAL (with sufficient clearance above)

Carry out component removal procedure as described in 6.4. Disconnect the flue from the appliance. Disconnect the flexible expansion pipe from the vessel (fig. 31). Locate and remove the four screws that secure the vessel top holding plate, remove the plate. The expansion vessel can now be removed. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.20.2 EXPANSION VESSEL REMOVAL (with insufficient clearance above)

Carry out component removal procedure as described in 6.4. Disconnect the flue elbow or pipe from the appliance flue outlet. Unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging. Remove the RH side panel of the air chamber. Disconnect the wiring to the fan, pressure switch, primary thermistor & overheat thermostat.

Carefully unclip the wires from the air chamber

and withdraw the wiring & grommet from the air chamber. Disconnect the electrode lead and burner thermostat wires. Disconnect the outlet gas pipe, the flow & return pipes and the condense pipe from the air chamber. Locate and remove the 2-screws that secure the lower section of the air chamber. Locate and remove the 2-screws that secure the upper section of the air chamber. The complete air chamber assembly can now be lifted clear from the appliance. Disconnect the flexible expansion pipe from the vessel (fig. 31). Locate and remove the 2-screws that secure the vessel (1). The expansion vessel can now be removed. Replace in the reverse order. Take extreme care when refitting the wiring to the air chamber. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

Fig. 33

6.21A DISMANTLING THE LATENT HEAT COLLECTOR (see fig. 34)

During routine servicing or maintenance, there is no requirement to remove or dismantle the collector, however should it be deemed necessary to dismantle the collector, all seals should be discarded and replaced with new ones.

Fig. 31

6.21 LATENT HEAT COLLECTOR fig’s. 32 & 33

Carry out component removal procedure as described in 6.4. Remove the flue hood and fan assembly as detailed in 6.16. Disconnect the condense sensor wire from the sensor. Fig. 32: disconnect and remove the inlet (1), outlet (3) and condense pipes (2) from the collector. Fig. 33: unscrew and remove the 3 screws (1) that secure the collector to the air chamber and disconnect the collector (2) from the flue connection. Replace in the reverse order ensuring all seals are intact and located correctly.

Fig. 34

6.22 CONDENSE TRAP REMOVAL (see fig. 35)

Carry out component removal procedure as described in 6.4. Disconnect the flexible (outlet) condense pipe from the condense trap (1). Disconnect the rigid (inlet) condense pipe from the condense trap (2). Locate and remove the pins that secure the trap to the lower frame of the boiler (3). Carefully remove the condense trap. Replace in the reverse order. If necessary remove the upper connection of the pipe (4).

Fig. 32

Fig. 35

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 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

NOTE: there must be sufficient system water

pressure (min. 0.5 bar) to ensure the water pressure switch is activated. If there is insufficient system pressure the pump and fan will be prevented from operating.

7.2.1 SELECTOR SWITCH IN THE OFF POSITION

When the selector switch is in the OFF position, there is no LED display or LED status indicator. The appliance will not respond to any heating/ HW requests.

Active Functions:

● frost-protection system

● pump anti-block.

7.2.2 SELECTOR SWITCH IN THE ON POSITION

When the selector switch is in the ON position, the status LED is illuminated and the LED display shows the current temperature measured at the thermistor.

Active Functions:

● frost-protection system

● pump anti-block

● fan anti-block.

7.2.3 APPLIANCE FUNCTIONS

● Frost-protection: this function is only active

when there are no requests for heating or HW. Should the temperature of the primary thermistor drop below 7°C, the pump will be activated for approximately 20-minutes. Should the temperature of the primary thermistor exceed 10°C during this period, the cycle will be aborted. If the temperature drops below 4°C, the boiler will operate on minimum power until the temperature of the primary thermistor reaches 30°C. Thereafter the pump & fan will over-run for 30-seconds.

● Anti-block cycle: when there has been no

heating or HW request for 19-hours, the antiblock cycle is activated. The pump will be activated for a period of 1-minute if the selector switch is in the ON position, the fan will also be active for 1-minute.

7.2.4 HEATING/HW MODE

With the selector switch in the ON position and any additional controls (time clock, room thermostat, etc,) calling for heat, the appliance will operate in the heating/HW mode. The pump and fan will be active. The operation of the fan causes the analogue pressure switch (PAD) to deliver a signal voltage to the control PCB. If the signal voltage is sufficient a slow ignition sequence is enabled, whereby the current supplied to the gas valve modulating coil is progressively increased from minimum to

maximum over a period of 8-seconds. During this period the ignition electrode sparks continuously even if the burner has ignited.

NOTE

If the spark/sensing electrode does not sense ignition the appliance will then go to lockout. Ignition is sensed by the electronic circuitry to ensure flame stability at the burner. Once successful ignition has been achieved, the electronic circuitry allows 75% of the full gas rate through the appliance. After 15 minutes the gas rate is increased to maximum (100%). When the set-point has been reached (the position of the temperature selector) as measured at the primary thermistor, the appliance will begin the modulation phase whereby the fan and gas valve will continuously modulate to maintain the set-point. If the temperature continues to rise and exceeds the set-point by 6°C, the burner will shut down and the boiler will perform a three-minute anti-cycle (timer delay). A new ignition sequence will be enabled when the 3-minute anti-cycle has been performed and the temperature at the primary thermistor has dropped 6°C below the set-point.

NOTE

The timer delay can be de-activated by the insertion of a ‘jumper’ on the PCB or by isolating the appliance from the electrical supply for 30 seconds. When the request for heating/HW has been satisfied, the appliance pump and fan may continue to circulate to dissipate any residual heat within the appliance.

7.3 CHECKING AND ADJUSTING BURNER PRESSURE (see fig. 17)

Although the burner pressure is factory set, it is necessary to check it during servicing or if the gas valve has been removed. Isolate the appliance from the electrical supply and attach a suitable manometer to the gas valve outlet test nipple.

7.3.1 SETTING THE MAXIMUM BURNER PRESSURE (see fig. 36)

Light the boiler as described in 5.6 and compare the reading on the manometer with the value described in 2.3. If adjustment is required, remove the protective cap from the gas valve modulating coil assembly and turn the outer (10mm) nut clockwise to increase, or counter-clockwise to decrease the burner pressure.

Fig. 36

NOTE

Always check and/or adjust the minimum and maximum gas pressures whilst the appliance is heating the radiators and HW cylinder.

7.3.2 SETTING THE MIMIMUM BURNER PRESSURE (see fig. 37)

Once the maximum burner pressure has been checked and/or adjusted, remove one of the grey wires from the modulating coil. Compare the reading on the manometer with the value described in 2.2. If adjustment is required, turn the inner (red) crosshead screw clockwise to increase, or counter-clockwise to decrease the burner pressure, whilst ensuring that the outer (10mm) nut does not move. When checking and/ or adjustment has been completed, isolate the appliance from the electrical supply, replace the protective cap, refit the grey wire to the modulating coil, remove the manometer, and tighten the outlet test nipple.

IMPORTANT, A GAS SOUNDNESS CHECK MUST BE CARRIED OUT.

Fig. 37

7.4 COMBUSTION ANALYSIS TEST

A combustion analysis check can easily be carried out on the appliance via the test points located on the top of the appliance, however you must check that the burner pressures are set correctly (see 7.3).

● Insert the flue gas analyser probe into the right

hand test point (see fig 38).

● Locate and remove the protective cap that

conceals the ‘CO mode’ button (see fig. 38).

● Light the boiler as described in 5.6 and press

the ‘CO mode’ button once.

● The boiler will now enter the combustion

analysis mode (CO mode) for a period of 15 minutes. During this time it will remain on full gas and ‘CO’ will be displayed on the LED display.

● Once the flue gas analysis has been made,

press the ‘CO mode’ to resume normal operation.

Protecting

cap

Air analysis outlet Fumes analysis outlet

Fig. 38

7.5 CHECKING THE EXPANSION VESSEL

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

1.0 bar ± 0.1 bar. IIf the charge pressure is less, use a suitable pump to increase the charge.

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 (section 5).

7.6 EXTERNAL FAULTS

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

7.6.1 INSTALLATION FAULTS

Symptom Possible causes

No ignition Check wiring

Check electrical supply

No HW or heating Check wiring of time clock

and/or external thermostats

Fault code Possible causes

01 Gas supply problem

Gas line requires purging

Reversed polarity

Broken, internal flue joint

02 Flow/return valves closed

Stuck pump

03 Debris in flue system

Debris in flue venturi

04 Insufficient water pressure

Air in boiler

7.7 ELECTRICAL CHECKS

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

7.7.1 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.

7.7.2 SHORT CIRCUIT CHECK

Isolate the appliance from the electrical supply, and using a suitable multi-meter, carry out a short circuit test between the Live & Neutral connections at the appliance terminal strip (fig.16). Repeat above test on the Live & Earth connections at the appliance terminal strip (fig.16).

NOTE

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

7.7.3 POLARITY CHECK

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

● connect test leads between the Live & Neutral

connections at the appliance terminal strip (fig.16). The meter should read approximately 230V ac. If so proceed to next stage. If not, see 7.7.4.

● connect test leads between the Live & Earth

connections at the appliance terminal strip (fig.16). The meter should read approximately 230V ac. If so proceed to next stage. If not, see 7.7.4.

● connect test leads between the Neutral & Earth

connections at the appliance terminal strip (fig.16). The meter should read approximately 0 - 15Vac. If so polarity is correct. If not, see

7.7.4.

7.7.4 REVERSED POLARITY OR SUPPLY FAULT

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

7.7.5 RESISTANCE TO EARTH CHECK

Isolate the appliance from the electrical supply, and using a suitable multi-meter carry out a resistance test. Connect test leads between the Live & Earth connections at the appliance terminal strip (fig.16). If the meter reads other than infinity there is a fault that must be isolated, carry out a detailed continuity check to identify the location of the fault.

IMPORTANT

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

7.8 FAULT FINDING

Before attempting any faultfinding, the electrical checks as detailed in 7.7 must be carried out. Isolate the appliance from the electrical supply. Disconnect any external controls from terminals TA & Spare of the appliance terminal strip, and make safe. Insert a solid link-wire between terminals 3 & 4. Ensure jumper tags are fitted to the main PCB at:

● JP5

● JP7

● JP8 (Nat. Gas only)

● M7

Restore the electrical supply to the boiler and turn the selector switch to the on position. The boiler should now function as described in section

7.2. Should the boiler fail to respond, the internal fuses and connectors should be checked to ensure integrity and continuity. If the boiler still fails to respond, refer to the detailed faultfinding flowcharts overleaf.

7.9 FAULT CODES

When the boiler displays a fault code, the appropriate code is shown on the display, accompanied by a flashing red LED. To reset the boiler, slowly turn the mode selector switch to the reset position then back to the on position. If the boiler does not reset, refer to the following section and the detailed faultfinding flowcharts overleaf.

FAULT CODE 01

Fault code 01 appears when the burner has failed to ignite, or the flame supervision system has failed to detect a flame.

● Check incoming gas supply

● Check spark electrode

● Check polarity

● Check integrity of flue system

● Check gas valve

● Check ignition control PCB

FAULT CODE 02

Fault code 02 appears if the boiler has overheated.

● Check high limit thermostat

● Check thermistors

● Check pump

● Check gas pressures

FAULT CODE 03

Fault code 03 appears if the boiler or flue system has developed a fault.

● Check operation of fan

● Check flue venturi

● Check analogue pressure switch

● Check flue system

FAULT CODE 04

Fault code 04 appears if the pressure in the boiler is low.

● Check water pressure

● Check water pressure switch

● Check water pressure gauge

FAULT CODE 05

Fault code 05 appears if the appliance is connected to the optional remote control (RC05) and there is a communication problem.

● Check wiring between RC05 and appliance

FAULT CODE 06

Fault code 06 appears if a problem exists with the jumper tags configuration of the PCB.

● Check jumper tag configuration

FAULT CODE 08

Fault code 08 appears if the burner thermostat has been activated.

● Check gas pressures

● Check burner thermostat

● Check wiring continuity

FAULT CODE 09

PCB fault

FAULT CODE d1

Fault code d1 appears if the condense trap/pipe has become blocked.

● Ensure the condense trap is clear

● Ensure the condense pipe is clear

FAULT CODE 07

Fault code 07 appears if a problem exists with the primary thermistor.

● Check thermistor

● Check wiring continuity

FAULT CODE d2

Fault code d2 appears if a problem exists with the condense sensor.

● Check wiring continuity

● Check condense sensor

FAULT FINDING TEST ‘A’: turn the selector switch to the reset position

START

Status LED

is green

Go to test "C"

YES

Go to test "B"

Status LED

is red

Does the

selector knob

rotate the

switch on the

display PCB

YES

Replace

selector knob

YES

Is there

5vdc across

terminals

M9.1 & M9.2

on main PCB

YES

Does the

selector knob

rotate the

switch on the

display PCB

YES

Have the

fuses been

checked

Replace

selector knob

Status LED

is blank

Have the electrical

checks as

detailed in 7.7

been carried

out

YES

Replace

display PCB

Is there

5vdc across

terminals

M2.1 & M2.2

on main PCB

Replace main

PCB

Replace ribbon

cable between

main PCB &

display PCB

START

Display

shows 01

Display

shows 02

Display

shows 03

Display

shows 04

RESET

Check gas

supply

Display

shows 06

Display

shows 07

RESET

Ensure JP5

tag is on

Check

thermistor

values and/or

replace

Go to test "C"

Replace main

PCB

Check wiring

and continuity

Display

shows 08

Check

gas

pressure

Check continuity

and/or replace

thermostat

Display shows

Replace main

PCB

Fault code

showing d1

Check condensate

level & sensor

Fault code

showing d2

Check condensate

sensor wiring &

continuity

FAULT FINDING TEST ‘B’: turn the selector switch to the “on” position

START

Does

pump run

Is there

230V between

terminals

M15.1 &

M15.2

Replace main

PCB

YES

Replace pump

Check wiring &

connections

Does

fan run

YES

Is there

230V at L & N

of pump

Is there

a spark at the

electrode

YES

Go to test "D"

YES

Is there

230V between

terminals

M12.1 &

M12.2

YES

Is there

230V between

L & N

terminals of

fan

Check

wiring &

continuity

YES

Replace fan

Check flue gas

tube

YES

Is there

a voltage <1VDC

between terminals

M3.10 & M3.11 on

PCB

Checking wiring

&connections or

analog air sensor

YES

Replace main

PCB

YES

Check wiring &

connections,

check water

pressure switch

YES

Checking wiring

& connections

Is there

a voltage >0.5VDC

between pin M3.11 on

main PCB and the gray

wire on analog air

sensor

- check flue gas tube

- check wiring & connections

- check analog air sensor

- check fan

Is there

a voltage >0.5

VDC between pins

M3.10 & M3.11 on

main PCB

YES

Is there

24Vdc between

M5.3 & black

wire of burner

thermostat

Checking wiring

& connections

Go to test “E”

Checking burner

thermostat or

combustion

Is there

24Vdc between

terminals M5.3

& M3.5

YES

Is there

24Vdc

between

terminals

M5.3 & M5.4

FAULT FINDING TEST ‘C’: turn the selector to the “on” position

START

Does

burner light

Does burner

stay light

YES

END

YES

Is spark

electrode ok

YES

Is there

230V between

1 & 2 of

ignition PCB

Is there

230V between

gas valve

YES

Replace

ignition PCB

Check wiring &

connections

Is gas valve

YES

Replace gas

valve

Check gas

Is ionisation

voltage ok

YES

Replace

ignition PCB

Replace spark

electrode

Replace spark

electrode

FAULT FINDING TEST ‘D’: turn the selector to the “on” position

FAULT FINDING TEST ‘E’: turn the selector to the “on” position

START

Is there

230V between

terminals

M14.1 &

YES

M14.2

Replace main

PCB

Check wiring &

connections

Is there

230V between

4 & 5 on

ignition PCB

Replace

ignition PCB

YES

Is there

230V between

4 & EARTH

Replace spark

electorde

YES

Is spark

electrode and

spark gap ok

YES

Replace ignition

transformer

SECTION 8 WIRING DIAGRAMS

8.1 EXTERNAL WIRING

The appliance comes with a factory fitted link to allow basic operation of the boiler via the mode selector switch. If external controls are to be added to the system, they must be connected to the appliance as shown in the following diagrams. For advice on controls that are not featured in this book, please contact Vokera technical on 0870 333 0520.

8.2 INSTALLATION OF VOKERA TWIN CHANNEL PROGRAMMER (see fig. 39)

● Isolate the appliance from the electrical supply

and remove the casing as described in 4.7.1

● Remove the blanking plate from the clock

aperture

● Remove the appliance PCB cover

● Remove the factory fitted link between

terminals 3 & 4 on the appliance terminal strip

● Take the wires supplied with the programmer

and connect them as shown in fig. 39

● Mount the programmer to the clock aperture

plate ensuring it’s secured in place

● Connect any external controls as detailed in

8.6 or 8.7

● Replace the PCB cover and casing once the

programmer installation has been completed.

Vokera Twin Channel

Programmer

Red

Pink

Grey

Purple

Brown

Blue

H/W On H/W Off

Heating On Heating Off Live Supply Neutral

● If no room thermostat is to be fitted, ensure a

link is fitted between TA & =

● Mount the time clock to the aperture plate

ensuring it’s secured in place

● Replace the PCB cover and casing once the

installation has been completed.

Blue

Brown

White

Red & White

Fig. 40

8.5 VOKERA ROOM THERMOSTAT (see fig. 41)

Connect the Vokera room thermostat to the appliance as detailed in fig. 41.

Fig. 39

8.3 TYPICAL CONTROL APPLICATIONS

The appliance can be used with the following controls:

● Vokera mechanical clock (part no. 201)

● Vokera digital clock (part no. 202).

● Vokera room thermostat (part no. 011)

● Vokera twin-channel programmers

● Twin-channel programmers

● Single-channel time clocks

● Programmable room thermostats.

In addition, the appliance can be used in conjunction with a typical ‘S’-Plan or ‘Y’-Plan system.

8.4 VOKERA TIME CLOCK (see fig. 40)

● Isolate the appliance from the electrical supply

and remove the casing as described in 4.7.1.

● Remove the blanking plate from the clock

aperture

● Remove the appliance PCB cover

● Remove the factory fitted terminal strip and

harness from the main PCB

● Take the wires supplied with the time clock and

connect them as shown in fig. 40

Vokera room thermostat

Fig. 41

8.6 “S” PLAN WIRING

See fig. 42.

8.7 “Y” PLAN WIRING

See fig. 43.

8.8 OTHER CONTROLS

Contact the controls manufacturer and/or Vokera technical department should you require more specific information on the suitability of a particular control. Further guidance on the recommended practice for the installation of external controls, can be found in CHeSS - HC1/HC2 (www.energy-

efficiency.gov.uk).

Room thermostat

Wiring Centre

3 amp fuse

Twin Channel Programmer

Heating

Hot water

Off On

Appliance

Terminal Strip

NLE45 678910

Load

Live

Cylinder thermostat

Load

Common

Wiring Centre or Junction Box

Motorised Valve (hot water)

orange grey brown blue green/yellow

Motorised Valve (heating)

Vokera

Hot water

Heating

Twin Channel

Programmer

Off

Appliance

Terminal Strip

3 amp fuse

7456321

Common

“S” plan system: external programmer or integral Vokera programmer

Wiring Centre

78910NLE456

Motorised Valve (heating)

Cylinder

thermostat

Load

Room

thermostat

Load

green/yellow blue brown orange grey

Fig. 42

Motorised Valve (hot water)

green/yellow

blue

brown orange grey

Wiring Centre

3 amp fuse

230V supply @ 50Hz

Appliance

Terminal Strip

7654321

3-Port

mid-position valve

white grey

orange blue green/yellow

10987654321

Load

Heating

Hot water

Off On

Twin Channel Programmer

Add if programmer

has heating only position

Appliance

Terminal Strip

Live

Room thermostat

Common

Calling

Satisafied

Cylinder thermostat

Vokera

Twin Channel

Programmer

7654321

“Y” plan system: external programmer or integral Vokera programmer

Wiring Centre

3 amp fuse

230V supply @ 50Hz

Room thermostat

Fig. 43

10987654321

Load

Live

Calling

Cylinder thermostat

3-Port

mid-position valve

orange grey

white blue

green/yellow

Common

Satisafied

NOTE: L-N-E CONNECTION IS ADVISABLE

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

Fig. 44

B.C.B. (ACF02X) Burner control board

R.T. Room thermostat P. S. Water pressure switch D.A.P.S. Differential analogue pressure switch H.L.T. Hight limit thermostat H.T. Heat thermistor MOD Modulator S.S.E. Spark/Sense electrode OPE Gas valve solenoids B.E.B. Boiler control board S.B. Secondary board JP8. Natural gas selector JP9 Timer on- off selector JP5 Jumper C.H. only PT2 Central heating temperature control

PT1(S.B.) Selection of 0-reset / winter - summer F Fan P Pump DS1-DS2 Temperature / allarm display TA1 Combustion test F1 Fuse 100 mA F (on 24V circuit) F2 Fuse 2 A F (on 230 V circuit) RL1 Ignition relay RL2 Pump relay ISO1 Fan triac L1 Led OK (green) L2 Led alarm (blink red) TRF1 Transformer G.V. Gas valve C.S. Condensate sensor

Fig. 45

SECTION 9 EXPLODED DIAGRAMS

362

400

401

226

402

POS. DESCRIPTION

1 Frame R01005342 12 Quick primer pressure gauge R1857 16 2A fuse R8968 17 100 mA fuse R1947 18 Cover R10021849 19 Ignition module R10021848 20 Printed Circuit Board R10025911 26 Instrumental panel R10021951 31 Case R1880 38 Printed Circuit Board R10024558 39 Spring R1862 40 Door panel R10024508 43 Push-push cover R1864 48 Led Light Guide R1858 49 Hole cap R8654 50 Pin R1867 51 Hole cover R1861 52 Selector knob kit R01005073 53 Control knob kit R01005072 90 3A fuse R3478

226 Edge clip R5128 326 O ring R1869 362 Transformer R10022659 400 Flat cable R10021117 401 Y-S plan cable R10023066

388

500

393

201

394

200

395

200

394

277

200

396

371

400

202

285

200

287

200

370

401

200

288

290

289

398

370

289

372

288

POS. DESCRIPTION

1 Expansion vessel R2204 2 Flexible pipe R10023603 3 Circulation pump R2225 5 Automatic air vent bottle R0439 6Pipe R10025961 7Pipe R10024312 8 Heat exchanger R10024578

9Pipe R10021041 10 Pipe R10025962 25 Siphon R10023495 26 Siphon pipe R10023530 27 Pipe R10024440 40 Siphon plug R10023531 45 Retarder R10024136 47 Condensing level detector R10025212 48 Pipe R10024311 49 Pipe R10024313 50 Siphon plug R10024133

200 Washer 24 x 17 R5023 201 Washer 18,5 x 11 R5026 202 Washer R5041 285 Sensor R8484 287 Limit thermostat R2258 288 O-Ring R6898 289 Clip R2223 290 Clip R2165 370 O-Ring R10023533 371 Clip R10023532 372 Clip R2588 388 Washer Ø 60 R10021949 393 O-Ring 4300 R10024141 394 O-Ring R20 R10024142 395 O-Ring OR R22 R10024143 396 Connection R01005292 398 Clip R10024336 400 Condensing level detector cable R10024121 500 Condensing unit assembly R01005291

289

288

300

288

303

289

290

288

289

303

400

353

POS. DESCRIPTION

2 Connection R10022658 3 Pressure switch R2044

7 By-pass valve R2047 22 Safety valve R2907 23 Connection R10022499 27 Heating clock R1789 31 Venting plugs kit R01005137 63 Pipe R10023065

288 O-Ring R6898 289 Clip R2223 290 Clip R2165 300 Clip R2222 303 Connection R2217 353 Nut R1824 400 Hydraulic control cable R10024740

332

351

200

211

400

401

500

501

POS. DESCRIPTION

1 Air box bottom R10024449 2 Ambidx air box side R10024166 3 Air box clip R0442 4 NG Burner R10023168 5 Spark electrode R10025891

9 NG plate R5172 10 Gas valve solenoid R10020838 12 Gas pipe R1839 13 Gas valve R10025074 14 Gas pipe R1840 15 Gas cock R1787 16 Air box cover R10020216 17 Washer R5072 18 Glass R3139 19 Glass flange R4007 21 Washer R5905

200 Washer R5023 332 Thermostat R2600 351 Nut R1823 400 Gas valve cable R10021947 401 Gas valve coil cable R10022112

295

300

POS. DESCRIPTION

1 Combustion chamber assembly R10025935 2 Combustion chamber back panel R5270 3 Combustion chamber lateral panel R5271 4 Combustion chamber front panel R5269

7 Hood assembly R10025934 10 Fan R10025938 16 Clamp for tube R10024126 19 Fan flue connection R10024137 20 Block with combustion analysis check R8085 23 Brass cap R8086 25 Pressure differential switch R2677

295 Silicone tube R1457 300 Combustion-fan cable R10025941

Cod. 10025964 - 18/04 - Ed. 1

energizing home heating

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

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

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

A Riello Group Company

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Vokera Synergy 25 E User guide

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