VOKERA Syntesi, syntesi e series Installation & Servicing Instructions Manual

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

Installation & Servicing Instructions

THESE INSTRUCTIONS TO BE RETAINED BY USER

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

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 (Heating) 2

1.4 Mode of operation (DHW) 2

1.5 Safety devices 2

1.6 Optional accessories 2

Technical data Page

2.1 Central heating 3

2.2 Domestic hot water 3

2.3 Gas pressure 3

2.4 Expansion vessel 3

2.5 Dimensions 3

2.6 Clearances 3

2.7 Connections 3

2.8 Electrical 3

2.9 Flue details (concentric) 3

2.9A Flue details (twin pipes) 3

2.10 Efficiency 3

2.11 Pump duty 4

2.12 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 6

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 Showers 6

3.9 Mounting on a combustible surface 6

3.10 Timber framed building 7

3.11 Inhibitors 7

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 8

3.A6.1 Pipework 8

3.A6.2 Automatic by-pass 8

3.A6.3 Drain cocks 8

3.A6.4 Air release points 8

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 Showers 8

3.A9 Mounting on a combustible surface 8

3.A10 Timber framed building 8

3.A11 Inhibitors 8

3.A12 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 Cold water inlet 14

4.6.4 Hot water outlet 14

4.6.5 Safety valve 14

4.6.6 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

4.7.4 Connecting the Vokera time clock 16

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 Filling the hot water system 17

5.6 Pre-operation checks 17

5.7 Initial lighting 17

5.7.1 Checking burner pressures 17

5.8 Final flushing of the heating system 18

5.8.1 Inhibtors 18

5.9 Setting the boiler operating temperature 18

5.9.1 Setting the domestic hot water temperature 18

5.10 Setting the system design pressure 18

5.11 Regulating the hot water 18

5.11.1 Changing the flow restrictor 18

5.11.2 Regulating the central heating system 18

5.12 Final checks 18

5.13 Instructing the user 19

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 20

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 21

6.12 Printed circuit board 21

6.13 Gas valve 21

6.14 Integral time switch 22

6.15 Electrode, burner thermostat, burner & injectors 22

6.16 Flue fan 23

6.17 Main heat exchanger 23

6.18 Air pressure switch 24

6.19 Flow restrictor 24

6.20 DHW flow switch 24

6.21 DHW heat exchanger 24

6.22 Valve actuator 24

6.23 Divertor valve assembly 24

6.24 Secondary thermistor 25

6.25 Automatic by-pass 25

6.26 DHW non-return valve 25

6.27 Expansion vessel 25

6.27.1 Expansion vessel removal 25

6.27.2 Expansion vessel removal 25

6.28 Latent heat collector 26

6.28A Dismantling the latent heat collector 26

6.29 Condense trap removal 26

Checks, adjustments and fault finding page

7.1 Checking appliance operation 27

7.2 Appliance mode of operation 27

7.2.1 Selector switch in the off position 27

7.2.2 Selector switch in the hot water only position 27

7.2.3 Selector switch in the heating & hot water position 27

7.2.4 Appliance functions 27

7.2.5 Heating mode 27

7.2.6 DHW mode 28

7.3 Checking and adjusting burner pressure 28

7.3.1 Setting the maximum burner pressure 28

7.3.2 Setting the minimum burner pressure 28

7.4 Combustion analysis test 28

7.5 Checking the expansion vessel 29

7.6 External faults 29

7.6.1 Installation faults 29

7.7 Electrical checks 29

7.7.1 Earth continuity test 29

7.7.2 Short circuit test 29

7.7.3 Polarity check 29

7.7.4 Reversed polarity or supply fault 29

7.7.5 Resistance to earth check 30

7.8 Fault finding 30

7.9 Fault codes 31-38

Wiring diagrams Page

8.1 External wiring 39

8.2 Typical control applications 39

8.3 Vokera time clock 39

8.4 Vokera remote control 39

8.5 Vokera room thermostat 39

8.6 Other controls 39

Exploded diagrams Page

Table 1 - 5 43 - 48

L.P .G. instructions Page

10.1 Related documents 49

10.2 Technical data 49

10.3 Converting the appliance gas type 49

10.4 Gas supply 49

10.5 Gas supply installation 49

10.6 Checking and adjusting burner pressure 49

10.6.1 Setting the maximum burner pressure 49

10.6.2 Setting the minimum burner pressure 49

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INTRODUCTION

The Syntesi range of appliances is comprised of 3 models of high-efficiency combination boiler with outputs to heating & DHW of 24, 28, & 34kW respectively. Each appliance – by design – incorporates electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge, and automatic by-pass.

The Syntesi range is produced as room sealed, category II2H3+ appliances, suitable for internal wall mounting applications only . They are provided with a fan powered flue outlet with an annular co-axial combustion air intake

2 1

27 28 30 3129 32

that can be rotated – horizontally – through 360 degrees for various horizontal or vertical applications. The Syntesi range can also be used with the Vokera twin flue system.

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

These appliances are designed for use with a sealed system only; consequently they are not intended for use on open vented systems.

Fig.1 General Layout

1 Safety V alve 2 Pressure Switch

3 Diverter V alve Motor 4 Domestic Heat Exchanger

5 Pump 6 Automatic Air Release Valve 7 Main Burner 8 Electrode 9 Main Heat Exchanger

10 Latent Heat Collector 11 Condense Sensor 12 Flue Gas Analysis Test Point 13 Flue Outlet 14 Air Intake 15 Differential Analog Pressure Switch

16 Silicone Pressure T ube 17 Silicone Negative Pressure T ube

18 Fan Assembly 19 Combustion Chamber

20 Burner Temperature Control 21 Expansion Vessel 22 Transformer

23 Gas V alve 24 Modulator Coil

25 Condense Trap 26 Domestic Hot Water Flow Switch

27 Hot Water Temperature Control 28 Mode Selector Switch 29 Status LED 30 Temperature Indicator 31 DHW Request LED 32 Central Heating Temperature Control 33 Combustion Switch 34 Timeclock Aperture (optional) 35 Pressure Gauge

35 34 33

Fig. 1

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SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS

● A fully integrated electronic control board

featuring electronic temperature control, 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 (P AD)

● 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 DHW, the following functions are active:

● pre-heat function – the pre-heat function ena-

bles the appliance to periodically light and maintain the temperature of the DHW heat exchanger. This “keep-hot” facility enables the appliance to provide an instantaneous response to DHW requests.

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

tection 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 ena-

bles the pump and divertor valve actuator, to be energised for short periods, when the appliance has been inactive for more than 19hours.

1.3 MODE OF OPERA TION (Heating)

When there is a request for heat 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 MODE OF OPERATION (DHW)

When there is a request for DHW via a hot water outlet or tap, 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.

During DHW request LED (31, fig. 1) is ON. 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 maximum or will modulate output to stabilise the temperature. In the event of the appliance exceeding the desired temperature the burner will shut down until the temperature drops. When the request for DHW has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance.

1.5 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.

● 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.

1.6 OPTIONAL ACCESSORIES

The Syntesi is suitable for use with a range of optional accessories that enable enhanced operation and/or applications. These include:

● RC05 remote control – the RC05 remote

control enables the appliance to be controlled, adjusted, and monitored from another location or room. The RC05 can also be used as a room thermostat or programmable room thermostat.

● external sensor – used in conjunction with the

RC05 the external sensor enables the appliance to automatically adjust its outlet flow temperature in response to the outside

Expansion

vessel

AARV

Pump

Fig. 2

temperature.

Flue Outlet

Latent Heat

Collector

Diverter

Valve Motor

Pressure

Switch

AB CD

Air Intake

PAD

Main Heat

Exchanger

Main

Burner

Gas Valve

Domestic

Heat

Exchanger

DHW Flow

Switch

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SECTION 2 TECHNICAL DATA

2.1 Central heating Syntesi 25 Syntesi 29 Syntesi 35

Heat input 25.0 kW 29.0 kW 35.0 kW Max heat output 60/80°C (return & flow temp.) 24.1 kW 28.0 kW 33.9 kW Max heat output 30/50°C (return & flow temp.) 25.9 kW 29.7 kW 36.2 kW Min heat output 60/80°C (return & flow temp.) 9.5 kW 9.5 kW 9.4 kW Min heat output 30/50°C (return & flow temp.) 10.1 kW 10.2 kW 10.2 kW Minimum working pressure 0.45 bar Maximum working pressure 3.0 bar Minimum flow rate 350 l/h

2.2 Domestic hot water

Maximum input 25.0 kW 29.0 kW 35.0 kW Maximum output 24.1 kW 28.0 kW 33.9 kW Minimum output 9.5 kW 9.5 kW 9.4 kW Flow rate (35oC rise) 9.9 kW 11.5 kW 13.9 kW Maximum inlet pressure 6.0 bar Minimum inlet pressure 0.15 bar Minimum flow rate 2.0 l/min

2.3 Gas pressures

Inlet pressure (G20) 20.0 mbar Burner pressure maximum 8.8 mbar 9.3 mbar 10.1 mbar Burner pressure minimum 1.5 mbar 1.25 mbar 1.00 mbar Maximum gas rate 2.65 Sm3/h 3.07 Sm3/h 3.75 Sm3/h Minimum gas rate 1.05 Sm3/h 1.05 Sm3/h 1.05 Sm3/h Injector size (quantity) 12 x 1.35 mm 14 x 1.35 mm 16 x 1.35 mm

2.4 Expansion vessel

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

2.5 Dimensions

Height 820mm Width 400mm 450mm 500mm Depth 350mm Dry weight (kg) 44.0 45.0 48.0

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 174W 194W Internal fuse 2A External fuse 3A

2.9 Flue details (concentric)

Maximum horizontal flue length (60/100mm) 5.75m 4.90m 0.75m Maximum vertical flue length (60/100mm) 6.55m 5.70m 1.55m Maximum horizontal flue length (80/125mm) 13.80m 11.80m 6.75m Maximum vertical flue length (80/125mm) 15.30m 13.30m 8.25m

2.9A Flue Details (twin pipes)

Maximum horizontal flue length (80mm + 80mm) 25m+25m 20m+20m 10m+10m Maximum vertical flue length (80mm + 80mm) 25m+25m 20m+20m 10m+10m

2.10 Efficiency

SEDBUK (%) 87.4 87.5 88.1

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SECTION 2 TECHNICAL DATA

2.1 1 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.

Fig. 3

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

Syntesi 25 & 29

Syntesi 35

Litres Per Hour

2.12 Emissions

Appliance

Syntesi 25 Syntesi 29

Syntesi 35

NOx max/min 160/140 180/120 160/110 CO max/min 70/20 100/60 90/80 CO2 max/min 6.5/4.8 6.60/4.15 6.5/3.7 CO/CO2 ratio max/min 0.00108 to 1/0.00044 to 1 0.00152 to 1/0.00145 to 1 0.00138 to 1/0.00216 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

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SECTION 3 GENERAL REQUIREMENTS (UK)

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

3.1 RELATED DOCUMENTS

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

3.2 LOCATION OF APPLIANCE

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

3.3 GAS SUPPL Y

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

BS 5440 P ART 1 FLUES BS 5440 P ART 2 FLUES & VENTILA TION BS 5449 P ART 1 FORCED CIRCULA TION HOT W ATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

(2nd FAMILY GASES)

BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW BS 6891 LOW PRESSURE INSTALLATION PIPES BS 7074 P AR T 1 APPLICA TION, 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.

3.4 FLUE SYSTEM (Cont’d.)

In cold and/or humid weather, water vapour will condense on leaving the terminal; the effect of such pluming must be considered. If installed less than 2m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material. The guard must be fitted centrally over the terminal. Refer to BS 5440 Part 1, when the terminal is

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

3.5 AIR SUPPL Y

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.

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3.6 WATER CIRCULATION

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

3.6.1 PIPEWORK

It is recommended that copper tubing to BS 2871 Part 1 is used in conjunction with soldered capillary joints. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and that water flows naturally to drain cocks. Except where providing useful heat, pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing. Particular attention should be paid to pipes passing through ventilated areas such as under floors, loft space, and void areas.

3.6.2 AUTOMA TIC 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’.

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.

Automatic air-vent

Non-return

valve

Stopcock

Make-up vessel or tank

5.0 metres minimum

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 8 litres (25/29) or 10 litres (35) of expansion from within the system, generally this is sufficient, however if the system has an unusually high water content, it may be necessary to provide additional expansion capacity (see 6.19).

3.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. has been provided. This method of filling complies with the current Water Supply (Water Fittings) Regulations 1999 and Water Bylaws 2000 (Scotland).

3.6.7 LOW PRESSURE SEALED SYSTEM

Fig. 5

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 SHOWERS

If the appliance is intended for use with a shower, the shower must be thermostatically controlled and be suitable for use with a combination boiler.

3.9 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.

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3.10 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’.

3.11 INHIBITORS

Vokera recommend that a inhibitor – suitable for use with low water-content, copper heat exchangers – is used to protect the boiler and system

SECTION 3A GENERAL REQUIREMENTS (EIRE)

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.

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

3A.1 RELATED DOCUMENTS

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

3A.2 LOCATION OF APPLIANCE

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

This appliance is not suitable for external installation.

3A.3 GAS SUPPLY

The gas meter – as supplied by the gas supplier – must be checked to ensure that it is of adequate size to deal with the maximum rated input of all

the appliances that it serves. Installation pipes must be fitted in accordance with I.S. 813. Pipe work from the meter to the appliance must be of adequate size. Pipes of a smaller size than the appliance gas inlet connection must not be used. The installation must be tested for soundness in accordance with I.S. 813. If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time.

3A.4 FLUE SYSTEM

The terminal should be located where the dispersal of combustion products is not impeded and with due regard for the damage and discoloration that may occur to building products located nearby . The terminal must not be located in a place where it is likely to cause a nuisance (see I.S. 813). In cold and/or humid weather, water vapour 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 W ATER CIRCULATION

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

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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 AUTOMA TIC BY -P ASS

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 EXP ANSION VESSEL

3A.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. has been provided. Y ou should ensure this method of filling complies with the local water authority regulations.

3A.6.7 LOW PRESSURE SEALED SYSTEM

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

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 SHOWERS

If the appliance is intended for use with a shower, the shower must be thermostatically controlled and be suitable for use with a combination boiler.

3A.9 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.10 TIMBER FRAMED BUILDINGS

If the appliance is to be fitted in a timber framed building, it should be fitted in accordance with I.S. 813 and local Building Regulations. The Institute of Gas Engineers publication (IGE/ UP/7) ‘Guide for Gas Installations in Timber Frame Buildings’ gives specific advice on this type of installation.

3A.11 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.

3A.12 DECLARATION OF CONFORMITY

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

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

3A.6.8 FREQUENT FILLING

Frequent filling or venting of the system may be indicative of a leak. Care should be taken during

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SECTION 4 INSTALLATION

4.1 DELIVERY

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

4.2 CONTENTS

Contained within the carton is:

● the boiler

● the fixing jig and 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.

Fig. 6A

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, carefully mark the position of the combined fixing jig and wall- mounting bracket (see fig. 6A), and – using the template supplied – mark the position of the flue-hole (if applicable).

4.5 FITTING THE FLUE

The top flue outlet permits both horizontal and vertical flue applications to be considered, alternatively , the V okera 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 2.9). A reduction must also be made to the maximum length (see table below) when additional bends are used.

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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 45º bend (pair) N/A 0225735 90º bend N/A 0225760 Wall bracket (5) N/A

Using the template provided, mark and drill a 1 15mm 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/ fixing jig should now be drilled and plugged, an appropriate type and quantity of fixing should be used to ensure that the bracket/jig is mounted securely . Once the bracket/jig 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 HORIZONT AL FLUE KIT

Carefully measure the distance from the centre of the appliance flue outlet to the edge of the finished outside wall (dimension X). Add 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 connected. Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The interior and exterior trim can now be fitted.

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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 (see 4.4.2), 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).

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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 INST ALLATION 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

Fig. 10

Twin flue accessories

Part No. Description Length

0225805 Horizontal flue terminal 1.0 metre 0225810 Vertical flue terminal 1.0 metre 359 Twin adapter kitt 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 45º bend (pair) N/A 0225845 90º bend (pair) N/A 0225850 Twin bracket (5) N/A 0225855 Single bracket (5) N/A

Fig. 11

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Fig. 12

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.

1-deg. = 17mm

1.0-metre

4.5.3.3 VERTICAL TERMINA TION (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.

● Y ou must ensure that the entire flue system is

properly supported and connected.

● Ensure that any horizontal sections of pipe

have a 1° fall towards the appliance (17mm

per 1000mm).

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C/H flow

valve

Fig. 14

C/H return

valve

Safety valve

outlet

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.

Hot water

Outlet

Cold water Inlet

Stopcock/filling

valve

Filling Loop

Gas

Cock

Fig. 13

4.6 CONNECTING THE GAS AND W ATER

The appliance is supplied with a fixing jig that includes 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.

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 COLD WATER INLET (see fig. 6A & 14)

The appliance is supplied with a 15mm combined stopcock and double check-valve, connect a 15mm pipe to the inlet of the stopcock and tighten both nuts.

4.6.4 HOT WATER OUTLET (see fig. 6A & 14)

The appliance is supplied with a 15mm outlet connection, connect a 15mm pipe to the outlet connection and tighten both nuts.

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

Connect the safety valve connection pipe between the safety valve outlet and the fixing jig.

+ 36 hidden pages

VOKERA Syntesi, syntesi e series Installation & Servicing Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual