How it Works
VOKERA
Loading...
Synergy 29

VOKERA Synergy 29 Installation & Servising Instruction

Installation & Servicing Instructions
THESE INSTRUCTIONS TO BE RETAINED BY USER
Contents
Design principles and operating sequence Page
1.2 Mode of operation (at reset) 2
1.3 Mode of operation 2
Technical data Page
2.1 Central heating 3
2.4 Dimensions 3
2.6 Connections 3
2.7 Electrical 3
2.9 Efficiency 3
2.10 Pump duty 4
2.11 Emissions 4
General requirements (UK) Page
3.2 Location of appliance 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
3.8 Mounting on a combustible surface 6
3.10 Inhibitors 6
General requirements (EIRE) Page
3.A2 Location of appliance 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.A8 Mounting on a combustible surface 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
4.5 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
5.10 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
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
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
Table 1 - 5 39 - 44
10.1 Related documents 45
10.2 Technical data 45
10.3 Converting the appliance gas type 45
10.4 Gas supply 45
10.5 Gas supply installation 45
10.6 Checking and adjusting burner pressure 45
10.6.1 Setting the maximum burner pressure 45
10.6.2 Setting the minimum burner pressure 45
INTRODUCTION
The Synergy is a high-efficiency system boiler with an output of 28kW . The appliance - b y design - incorporates electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge and automatic by-pass.
The Synergy is produced as room sealed, category II2H3+ 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
13
14
10
9
8
7
6
5
11
4
3 2
1
12
various horizontal or vertical applications. The Synergy range can also be used with the Vok era twin flue system.
The Synergy 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
15
1 Safety V alv e
16
2 Pressure Switch 3 Hydraulic manifold
17
4 Pump 5 Automatic Air Release Valve
18
6 Transformer 7 Main Burner 8 Electrode 9 Main Heat Exchanger
19
10 Latent Heat Collector 11 Condense Sensor 12 Flue Gas Analysis Test Point 13 Flue Outlet 14 Air Intake
20
15 Differential Analog Pressure Switch 16 Silicone Pressure Tube
21
17 Silicone Negative Pressure Tube 18 Fan Assembly 19 Combustion Chamber
22
20 Burner T emperature Control 21 Expansion V essel
23
24
22 Gas V alve 23 Modulator Coil 24 Condense Trap
25 Status LED 26 Temperature Indicator 27 Central Heating Temperature Control 28 Combustion Switch 29 Timeclock Aperture (optional) 30 Pressure Gauge 31 Mode Selector Switch
31
30
Fig. 1
25 26
27 28
29
1
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 thereb y 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 e xcess pressure
from the primary circuit.
Air Intake
PAD
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 oper ate to dissipate any residual heat within the appliance.
1.4 SAFETY DEVICES
When the appliance is in use, safe operation is ensured by:
● a w ater 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
Pressure
Switch
AB
Fig. 2
2
SECTION 2 TECHNICAL DATA
2.1 Central heating Synergy 29
Heat input 29.0 kW Max heat output 60/80°C (return & flow temp.) 28.1 kW Max heat output 30/50°C (return & flow temp.) 29.7 kW Min heat output 60/80°C (return & flow temp.) 9.5 kW Min heat output 30/50°C (return & flow temp.) 10.2 kW Minimum working pressure 0.5 bar Maximum working pressure 3.0 bar Minimum flow rate 350 l/h
2.2 Gas pressures
Inlet pressure (G20) 20.0 mbar Burner pressure maximum 9.3 mbar Burner pressure minimum 1.25 mbar Maximum gas rate 3.07 Sm3/h Minimum gas rate 1.05 Sm3/h Injector size (quantity) 14 x 1.35 mm
2.3 Expansion vessel
Capacity 10-litres Maximum system volume 91-litres Pre-charge pressure 1.0 bar
2.4 Dimensions
Height 820mm Width 450mm Depth 350mm Dry weight (kg) 47.0
2.5 Clearances
Sides 12mm Top 150mm from casing or 25mm above flue elbow (whichever is applicable) Bottom 150mm Front 600mm
2.6 Connections
Flow & return 22mm Hot & cold water 15mm Gas 15mm Safety valve 15mm Condense 21mm
2.7 Electrical
Voltage (V/Hz) 230/50 Power consumption 150W Internal fuse 2A External fuse 3A
2.8 Flue details (concentric)
Maximum horizontal flue length (60/100mm) 4.90m Maximum vertical flue length (60/100mm) 5.70m Maximum horizontal flue length (80/125mm) 11.80m Maximum vertical flue length (80/125mm) 13.30m
2.8A Flue Details (twin pipes)
Maximum horizontal flue length (80mm + 80mm) 20m+20m Maximum vertical flue length (80mm + 80mm) 20m+20m
2.9 Efficiency
SEDBUK (%) 87.6
3
SECTION 2 TECHNICAL DATA
7
0
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.
2.11 EMISSIONS
Appliance Synergy 29
NOx max/min 180/120 CO max/min 100/60 CO2 max/min 6.60/4.15 CO/CO2 ratio max/min 0.00152 to 1/0.00145 to 1
6,5
6
5,5
5
4,5
4
3,5
3
2,5
2
1,5
1
Water pressure (mbar)
0,5
0
0 100 20 0 300 400 5 00 600 700 800 900 1000 1100 1200 130
Fig. 3
Litres Per Hour
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
4
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 relev ant requirements of the local authority and the relevant recommendations of the f ollowing 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 b uilding 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 ter minal 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 comb ustion air supply . When installed in a cupboard or compartment, ventilation for cooling purposes is also not required.
Detailed recommendations are given in BS 5449 Part 1 and BS 6798. The following notes are for general guidance only.
5
3.6.1 PIPEWORK
It is recommended that copper tubing to BS 2871 Part 1 is used in conjunction with soldered capillary joints. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and that water flows naturally to drain cocks. Except where providing useful heat, pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing. Particular attention should be paid to pipes passing through ventilated areas such as under floors, loft space and void areas.
3.6.2 AUTOMATIC BY-PASS
The appliance has a built-in automatic by-pass, consequently there is no requirement for an external by-pass, however the design of the system should be such that it prevents boiler ‘cycling’.
3.6.3 DRAIN COCKS
These must be located in accessible positions to facilitate draining of the appliance and all water pipes connected to the appliance. The drain coc ks 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 EXP ANSION 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, howev er 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 manuf acture 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.
6
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 relev ant 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 , ref er to I.S. 813 f or 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 b uilding 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
The following notes are intended for general guidance only. This appliance is a room-sealed, fan-flued boiler , consequently it does not require a permanent air vent for combustion air supply. When installed in a cupboard or compartment, ventilation for cooling purposes is also not required.
3A.6 WATER CIRCULATION
Specific recommendations are given in I.S. 813. The following notes are f or 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.
7
3A.6.5 EXP ANSION 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, howev er if the system has an unusually high water content, it may be necessary to provide additional expansion capacity.
3A.6.6 FILLING POINT
A method for initial filling of the system and replacing water lost during servicing etc. 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
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 valv e and stopcock for isolation purposes. The feed pipe should be connected to the return pipe as close to the boiler as possible.
3A.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 manuf acture 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 tak en during the installation of the appliance to ensure all aspects of the system are capable of withstanding pressures up to at least 3 bar.
3A.7 ELECTRICAL SUPPLY
The appliance is supplied for operation on 230V @ 50Hz electrical supply; it must be protected with a 3-amp fuse. The method of connection to the mains electricity supply must allow for complete isolation from the supply . The preferred method is by using a double-pole switch with a contact separation of at least 3mm. The switch must only supply the appliance and its corresponding controls, i.e. time clock, room thermostat, etc.
3A.8 MOUNTING ON A COMBUSTIBLE SURFACE
If the appliance is to be fitted on a wall of combustible material, a sheet of fireproof material must protect the wall.
3A.9 TIMBER FRAMED BUILDINGS
If the appliance is to be fitted in a timber framed building, it should be fitted in accordance with I.S. 813 and local Building Regulations. The Institute of Gas Engineers publication (IGE/ UP/7) ‘Guide for Gas Installations in Timber Frame Buildings’ gives specific advice on this type of installation.
8
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 la y the accessories etc. to one side. Protective glo ves should be used to lift the appliance, the appliance back-frame should be used for lifting points.
820
200
150
107.5
523
115
145
35
85
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 V ok era condensing 60/100mm concentric flue system or the optional 80/125mm concentric flue system.
NOTE
These instructions relate only to the Vokera condensing 60/100mm concentric flue system. For specific details on the installation of the 80/ 125mm concentric flue system please refer to the instructions supplied. The 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.
9
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 ha ve 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 f orms, 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.
10
Fig. 8
4.5.2 CONCENTRIC VERTICAL FLUE
The appliance can be used with either the V ok era condensing 60/100mm concentric flue system or the optional 80/125mm concentric flue system.
NOTE
These instructions relate only to the Vokera condensing 60/100mm concentric flue system. For specific details on the installation of the 80/ 125mm concentric flue system please refer to the instructions supplied. The vertical flue terminal can be connected directly to the appliance flue outlet. Alternatively, an extension or bend can be connected to the appliance flue outlet if desired, 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 brac ket 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; theref ore 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).
11
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 V ok era 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 brac ket 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).
C
A
B
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
12
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 prefer able 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 f or 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 pref erable 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 to wards the appliance (17mm per
1000mm).
13
Loading...
+ 33 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use