vokera Syntesi 25 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 (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

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

Fig. 1

35 34 33

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

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

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 35

i 2

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

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.

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.

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 .

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

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.

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.

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).

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

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. 10

Fig. 11

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).

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.

Connect a discharge pipe to the fixing jig connection 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.

4.6.6 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 CONDENSA TE 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.

Fig. 15

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

T o 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.

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 point. At plug M16 on the appliance control PCB there are 7 terminals from Front to Back they are:

1. NEUTRAL

2. NEUTRAL (supply for clock)

3. LIVE

4. LIVE (supply to clock)

5. TA

6. TA

7. (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 T A & Spare) unless additional external controls are to be fitted (see section 8).

● remove the clock aperture plate from the

appliance

● remove the push-out blanking disc from the

clock aperture plate (fig. 17)

● secure the clock to the aperture plate using

the screws provided with the clock (fig. 17)

● refit the clock aperture plate ensuring the clock

is positioned the correct way up

● remove the Red link-wire plug from the

appliance clock connector plug

● connect the clock wiring harness to the clock

connector plug

● re-fit the appliance PCB cover and terminal

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

4.7.4 CONNECTING THE VOKERA TIME CLOCK (part no. 201 & 202)

The appliance is supplied with a clock connector plug that is connected to plug M16 on the appliance terminal block. The clock connector plug is for use with the clock harness that is included in the accessory pack and facilitates an easy connection to the optional Vokera time clock.

Fig. 17

To fit the Vokera time clock:

● remove the appliance PCB cover

● remove and discard the wiring harness

supplied with the clock

● using the clock wiring harness supplied in the

accessory pack, connect the 4-wires to the clock as shown in fig 16.

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 HEA TING 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.

Closed Position

Normal Operating Position

Filling Position

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.

5.5 FILLING THE HOT WATER SYSTEM

Close all hot water outlets, turn appliance stopcock to the normal operating position (fig. 18), slowly open each outlet until air has been expelled and clear water is discharged. Check pipe-work etc. for water soundness.

5.6 PRE-OPERA TION 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.

Fig. 18

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. Connect the filling loop as shown in fig. 6, slowly proceed to fill the system by firstly opening the inlet valve connected to the flow valve, and then turning the lever on the combined stopcock and check valve, to the filling position (see fig. 18). As water enters the system the pressure gauge will begin to rise. Once the gauge has reached 1 bar close both 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

5.7 INITIAL LIGHTING

Ensure the electrical supply to the appliance is switched on. Move the selector switch to the Heating & Hot Water position, ensure the time clock is switched to an ‘ON’ position and ensure any other external controls are also calling for heat. The appliance will now operate in the pre-heat mode as described in 1.2. Once the pre-heat function has been completed, the appliance will operate in the central heating mode as described in 1.3. Should the appliance fail to ignite, refer to

5.6 and/or section 7 (faultfinding).

5.7.1 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. 19). Light the boiler as described in 5.7, turn the Hot Water temperature selector to maximum, and open fully a DHW outlet (preferably the bath), 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).

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

Outlet

test-point

Protective

cap

Inlet

test-point

Fig. 19

5.8 FINAL FLUSHING OF THE HEA TING 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”.

5.11 REGULATING THE HOT W A TER

The appliance is fitted with a flow rate restrictor that limits the maximum flow rate that can be drawn through the appliance.

Syntesi 25

8-litre 9-litre

(Orange) (Blue)

Fitted Spare

Syntesi 29

9-litre 10-litre 11-litre

(Orange) (Blue) (Beige)

Spare Fitted Spare

Syntesi 35

11-litre 12-litre 13-litre

(Beige) (Red) (Olive)

Spare Fitted Spare

The restrictor eliminates the need to manually adjust the DHW flow rate. However if it is felt necessary to further increase or decrease the available flow rate, spare restrictors are included in the accessory pack. The spare flow rate restrictors can be fitted to either increase or decrease the maximum flow rate. The tables above denote the size of restrictor fitted and the spare restrictors supplied in the accessory pack. Each restrictor is colour-coded to enable identification.

5.9 SETTING THE BOILER OPERATING TEMPERA TURE

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

5.9.1 SETTING THE DOMESTIC HOT WATER TEMPERA TURE

The DHW outlet temperature can be adjusted between 40°C - 65°C via the Hot Water 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).

5.11.1 CHANGING THE FLOW RESTRICTOR

Refer to 6.19 for detailed instruction on changing the flow restrictor.

5.11.2 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 CORRECTL Y AND IS PROPERL Y 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

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.

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.

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 REMOV AL PROCEDURE

TTo 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. 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. 20)

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. 20

6.6 SAFETY V ALVE (see fig. 21)

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.

Fig. 22

6.9 PRESSURE GAUGE (see fig. 23)

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

6.7 AUTOMATIC AIR RELEASE VALVE (see fig.

20) (AAV)

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

6.8 WATER PRESSURE SWITCH (see fig. 22)

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. 23

6.10 PRIMARY THERMISTOR (see fig. 24)

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. 24

Fig. 26

6.11 HIGH LIMIT THERMOSTAT (see fig. 25)

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.

NOTE

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

6.13 GAS VALVE (see fig. 27)

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.

Fig. 25

6.12 PRINTED CIRCUIT BOARD (see fig. 26)

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.

Fig. 27

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 (see fig. 28)

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. 29

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. 29

Fig. 28

6.16 FLUE FAN (see fig. 28 & 30)

Carry out component removal procedure as described in 6.4. Fig. 28: 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. 30: 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. 30

6.17 MAIN HEAT EXCHANGER (see fig. 28 & 31)

Carry out component removal procedure as described in 6.4. Fig. 28: 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. 31: 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.

Fig. 31

6.18 AIR PRESSURE SWITCH (see fig. 30)

Carry out component removal procedure as described in 6.4. Fig. 28: unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging (2). Fig. 30: 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 FLOW RESTRICTOR (see fig. 32)

Carry out the component removal procedure as described in 6.4. Slacken the cold water inlet pipe (1) at the DHW flow switch. Disconnect the cold-water inlet pipe (2) from the DHW heat exchanger and move it to the side. Using a small screwdriver, gently ease the flow restrictor (6) from its seating. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly .

inserted into the DHW manifolds. Ensure all seals are in good condition, taking care to ensure they are replaced correctly. If necessary remove the condense trap as described in 6.29.

Fig. 33

6.22 VALVE ACTUA TOR (see fig. 34)

Carry out component removal procedure as described in 6.4. Remove the locking pin (1) that secures the actuator to the heating manifold. Disconnect the electrical plug (2) from the actuator. Replace in the reverse order.

6.20 DHW FLOW SWITCH (see fig. 32)

Carry out component removal procedure as described in 6.4. Disconnect and remove the cold water inlet pipe (1, 2) from the DHW flow switch & DHW heat exchanger. Disconnect the wiring to the DHW flow switch. Remove the locking pin (3) from the DHW flow switch and lift the DHW flow switch housing from its seating, taking care not to lose the float contained within the housing. Replace in the reverse order ensuring that the housing is firmly inserted onto its seating. Ensure all seals are in good condition, taking care to ensure they are replaced correctly .

Fig. 34

6.23 DIVERTOR VALVE ASSEMBLY (see fig. 35)

Carry out component removal procedure as described in 6.4. Remove the valve actuator as described in 6.22. Locate and remove the 5-screws (2) that secure the valve housing cover to the heating manifold. Gently prise the valve seating assembly and cover (3) from the manifold. Replace in the reverse order ensuring that the seating assembly is inserted properly . Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

Fig. 32

6.21 DHW HEAT EXCHANGER

Carry out component removal procedure as described in 6.4. Locate and remove the screws (1) that secure the heat exchanger to the DHW manifolds. Carefully remove the heat exchanger from its location taking care not to spill any residual water. Replace in the reverse order ensuring that the heat exchanger ‘O’ ring seals are correctly

Fig. 35

6.24 SECONDARY THERMISTOR (see fig. 36)

Carry out component removal procedure as described i 6.4. Pull back the protective cover from the thermistor and disconnect the electrical plug. Using a 13mm spanner slacken and remove the thermistor and sealing washer from the DHW heat exchanger manifold. Replace in the reverse order.

Fig. 36

6.25 AUTOMATIC BYPASS (see fig. 37)

Carry out component removal procedure as described in 6.4. Disconnect and remove the flow pipe at the heating manifold & DHW 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. 37

6.26 DHW NON-RETURN VALVE (see fig. 38)

Carry out component removal procedure as described in 6.4. Disconnect and remove the flow pipe at the heating and DHW manifold (1), and at the connection to the air chamber. Using a hooked piece of wire, carefully withdraw the non-return 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. 38

6.27 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.

6.27.1 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. 39). 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 .

6.27.2 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. 39). 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 .

6.28 LATENT HEAT COLLECTOR fig’s. 40 & 41

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. 40: disconnect and remove the inlet (1), outlet (3) and condense pipes (2) from the collector. Fig. 41: 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. 39

Fig. 40

6.28A DISMANTLING THE LATENT HEAT COLLECTOR (see fig. 42)

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.

6.29 CONDENSE TRAP REMOVAL (see fig. 43)

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. 41

Fig. 42

Fig. 43

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 divertor valve is in the DHW position. The appliance will not respond to any DHW or heating requests.

Active Functions:

● frost-protection system

● pump anti-block

● valve actuator anti-block.

7.2.2 SELECTOR SWITCH IN THE HOT WATER ONLY POSITION

When the selector switch is in the HW only position, the status LED is illuminated and the LED display shows the current temperature measured at the secondary (DHW) thermistor. The divertor valve is in the DHW position. The appliance will respond to any DHW requests.

Active Functions:

● DHW pre-heat

● frost-protection system

● pump anti-block

● valve actuator anti-block.

7.2.3 SELECTOR SWITCH IN THE HEATING & HOT WATER POSITION

When the selector switch is in the Heating & HW position, the status LED is illuminated and the LED display shows the current temperature measured at the secondary (DHW) thermistor. The divertor valve is in the DHW position. The appliance will respond to any Heating or DHW requests.

Active Functions:

● DHW pre-heat

● frost-protection system

● pump anti-block

● fan anti-block

● valve actuator anti-block.

7.2.4 APPLIANCE FUNCTIONS

● DHW pre-heat: this function is only active

when there are no requests for heating or hot water. When the secondary thermistor drops to 35°C, the pre-heat function is enabled, the appliance operates on minimum power until the secondary thermistor reaches 55°C.

Thereafter the pump and fan will over-run for 10-seconds.

● 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 valve actuator will motor to the heating position, and the pump will be activated for approximately 20-minutes. Should the temperature of the primary thermistor excee 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 valve actuator will motor from the DHW position to the heating position for a period of 10-seconds and then motor back to the DHW position. Thereafter the pump will be activated for a period of 1minute. If the selector switch is in the Heating & HW position, the fan will also be active for 1minute.

7.2.5 HEATING MODE

With the selector switch in the Heating & HW position and any additional controls (time clock, room thermostat, etc.) calling for heat, the appliance will operate in the heating mode. The valve actuator will motor to the heating position and 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 heating 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.

NOTES

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. Any DHW request will always have priority over the heating request. When the request for heating has been satisfied, the appliance pump and fan may continue to circulate to dissipate any residual heat within the appliance.

7.2.6 DHW MODE

With the selector switch in the Heating & HW position, or HW only position, and a DHW outlet is opened, the appliance will operate in the HW mode. The valve actuator will motor to the HW position (if a heating request was active) and the pump and fan will be active. The operation of the fan causes the analogue pressure switch (P AD) 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 modulates the appliance output in order to achieve the DHW set-point (the position of the DHW temperature selector) as measured at the secondary thermistor. When the set-point has been reached, 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 5°C, the burner will shut down until the temperature drops to set-point + 4°C, whereby a new ignition sequence will be enabled. When the request for heating has been satisfied, the appliance fan may continue to operate to dissipate any residual heat from within the appliance.

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. 44

NOTE

Always check and/or adjust the minimum and maximum gas pressures whilst the appliance is in the HW only mode. Ensure a DHW outlet (preferably the bath) is fully open, and that the HW temperature selector is at maximum.

7.3.2 SETTING THE MIMIMUM BURNER PRESSURE (see fig. 45)

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 2.3. 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.

7.3 CHECKING AND ADJUSTING BURNER PRESSURE (see fig. 19)

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. 44)

Light the boiler as described in 5.7 and compare the reading on the manometer with the value

Fig. 45

7.4 COMBUSTION ANAL YSIS 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 46).

● Locate and remove the protective cap that

conceals the ‘CO mode’ butto (see fig. 46).

● Light the boiler as described in 5.7 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.

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

Protecting cap

Air analysis outlet Fumes analysis outlet

Fig. 46

7.5 CHECKING THE EXP ANSION VESSEL

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

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

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 F AUL TS

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

7.6.1 INST ALLA TION F AUL TS Symptom Possible causes

No ignition Check wiring

Check electrical supply

No hot water Check hot/cold pipe

work is not reversed

No central heating Check wiring of time clock

and/or room thermostat

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. Iff 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 SUPPL Y 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 T O 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 FAUL T 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 T A & TA. Ensure jumper tags are fitted to the main PCB at:

● JP6

● JP7

● JP8 (Nat. Gas only).

● M7

NOTE

If the Vokera remote-control (RC05) is connected to the appliance, it should be disconnected during any faultfinding checks. 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 FAUL T CODES

When the boiler displays a fault code, the appropriate code is shown on the display, accompanied by a flashing red LED. T o 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 secondary (DHW) thermistor.

● Check thermistor

● Check wiring continuity

FAUL T CODE 07

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

● Check thermistor

● Check wiring continuity

FAUL T 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

FAUL T 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

FAUL T CODE d2

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

● Check wiring continuity

● Check condense sensor

VOKERA

LINEA PLUS AG

Rev. 1 08/03/2000

TEST A : CHECKING OPERATION OF ELECTRONIC

CONTROL BOARD AT START UP

MAINS

ON 3 WAY

VALVE BETWEEN

TERMINALS

M11.1 & M11.3

ON PCB

YES

CHECK &/OR REPLACE

REPLACE PCB

WIRING OR CONNECTIONS

AND 3 WAY VALVE

IS THE

3 WAY VALVE

IN DHW

POSITION?

YES

TURN ON HOT

TAP

PUMP

RUNNING

YES

SWITCH ON/OFF

YES

START

SELECTOR TO

DHW POSITION

GREEN LED

ALIGHT

REPLACE CONTROL

BOARD

REPLACE

CONTROL

BOARD

THERE 5 Vdc

BETWEEN TERMINALS

M5.5 & M5.6

ON PCB

CHECK WIRING AND

CONNECTIONS OR

DHW FLOW SWITCH

ON PUMP

CONNECTOR

ON PUMP

YES

MAINS

M15.1 &

M15.2

YES

MAINS

YES

THERE 0 Vdc

BETWEEN TERMINALS

M5.5 & M5.6

ON PCB

YES

THERE 0 - 1 Vdc

BETWEEN TERMINALS

M3.11 & M3.10

ON PCB

FAN RUNNING

MAINS

ON FAN

CONNECTOR

M12.1 &

M12.2

YES

REPLACE FAN

YES

MAINS

ON FAN

CHECK &/OR

REPLACE

WIRING AND

CONNECTIONS

YES

REPLACE

WIRING OR

CONNECTIONS

REPLACE PUMP

CHECK FLUE GAS TUBE,

DIFFERENTIAL ANALOG

PRESSURE SWITCH AND

WIRING OR

CONNECTIONS

REPLACE

CONTROL

BOARD

CHECK WIRING

AND

CONNECTIONS

BETWEEN TERMINALS

YES

THERE 24 Vdc

BETWEEN TERMINALS

M5.3 ON PCB & WHITE WIRE

ON HIGH LIMIT

THERMOSTAT

YES

THERE 24 Vdc M5.3 AND M3.3

ON PCB

REPLACE THE

CONTROL BOARD

RESET THE

HIGH LIMIT

THERMOSTAT

GREEN LED

LIGHT

YES

REST AR T THE

TEST

THERE 24 Vdc

BETWEEN TERMINALS

M5.3 ON PCB & RED WIRE

ON HIGH LIMIT

THERMOSTAT

YES

THERE 24 Vdc

BETWEEN TERMINALS

M5.3 AND M3.4

ON PCB

CHECK WIRING AND

CONNECTIONS

CHECK WIRING AND

CONNECTIONS,

HIGH LIMIT

THERMOSTAT OR

PCB

YES

THERE 24 Vdc

BETWEEN TERMINALS

M5.3 AND M3.5

ON PCB

CHECK

COMBUSTION AND

CHECK &/OR

REPLACE BURNER

THERMISTOR AND

WIRING

YES

REPLACE THE

CONTROL BOARD

RED LED

FLASHING

NOYES

SHOWING

FAULT

CODE

YES

5 Vdc

BETWEEN TERMINALS

M2.1 & M2.2 ON DISPLAY

BOARD

5 Vdc

BETWEEN

TERMINALS

M9.1 & M9.2 ON

CONTROL

BOARD

YES

REPLACE DIGITS

BOARD

YES

CHECK AND/OR

REPLACE WIRING

OR CONNECTIONS

WITH DISPLAY BOARD

FAULT

CODE 01

SHOWING

FAULT

CODE 02

SHOWING

REPLACE THE

BICOULORED

LED ASSEMBLY

YES

BICOULORED

LED ASSEMBLY

YES

REPLACE THE DIGITS BOARD

YES

SWITCH ON/OFF

SELECTOR TO

OFF POSITION

SWITCH MODE

SELECTOR TO

DHW POSITION

MAINS

PRESENT BETWEEN

M16.L & M16.N ON

CONTROL

BOARD

RECHECK SUPPLY FUSE

& CONNECTORS TO

BOILER TERMINALS

REPLACE

CONTROL

BOARD

YES

CHECK FUSES

F1 AND F2 ON

CONNECTION

BOARD

FUSE OK

REPLACE FUSE

REST AR T THE

HIGH LIMIT STAT

GREEN LED

CHECK WIRING AND

CONNECTIONS ,HIGH

LIMIT THERMOST . AND

CONTROL BOARD

LIGHT

GREEN LED

LIGHT

YES

REST AR T THE

TEST

IGNITION

CONTROL OK

REPLACE

IGNITION

CONTROL

REST AR T THE

TEST

YES

REPLACE

CONTROL

BOARD

VOKERA

LINEA PLUS AG

Rev. 1 08/03/2000

TEST B : CHECK CONTROL

IN DHW MODE

START

TURN MODE

SELECTOR SWITCH TO

DHW.

DHW STAT AT MAX.

TURN ON TAP

DOES

BURNER

LIGHT

CHECK BOILER

STARTUP:

TEST A

YES

THERE A

VOLTAGE >4 Vdc

BETWEEN TERMINALS

M3.10 & M3.11

ON PCB

YES

TURN DHW

THERMOSTAT AT

MIN.

FAN

ON?

YES

D.A.P.S.

OK?

YES

CHECK FLUE VENTURI TUBE

CHECK FAN, WIRING AND CONNECTIONS,

DIFFERENTIAL ANALOG

PRESSURE SWITCH AND

CONTROL BOARD

REPLACE DIFFERENTIAL

ANALOG PRESSURE

SWITCH

BURNER AND FAN

SWITCH OFF

YES

TURN DHW

THERMOSTAT AT

MAX.

WATER FLOW

TEMPERATURE

>40 ˚C

YES

REPLACE

CONTROL

BOARD

WAIT WATER

FLOW

TEMPERATURE

>40 ˚C

YES

START

SWITCH ON BOILER

AND SELECT MODE

TO WINTER C/H THERMOSTAT AT

MAX.

MAKE A LINK

BETWEEN PIN M16.TA

AND M16.TA ON

CONTROL BOARD

IS THE

3 WAY VALVE

ON CH

POSITION?

VOKERA

LINEA PLUS AG Rev. 1 08/03/2000

TEST C: CHECK CONTROL

IN C/H MODE

DOES

BURNER

LIGHT

CHECK BOILER

STARTUP

TEST A

YES

THERE A

VOLTAGE >4 Vdc

BETWEEN TERMINALS

M3.10 & M3.11

ON PCB

YES

TURN CH

THERMOST AT TO

MIN.

YES

CHECK &/OR

REPLACE 3

WAY VALVE

VENTURI TUBE

PRESENT BETWEEN

M11.1 & M11.2 ON

FAN

ON?

YES

D.A.P.S.

OK?

YES

CHECK FLUE

MAINS

CONTROL

BOARD

CHECK FAN, WIRING

AND CONNECTIONS,

DIFFERENTIAL ANALOG

PRESSURE SWITCH AND

CONTROL BOARD

REPLACE DIFFERENTIAL

ANALOG PRESSURE

SWITCH

REPLACE

CONTROL

BOARD

BURNER AND FAN

SWITCH OFF

YES

TURN CH

THERMOSTAT AT MAX.

WATER FLOW

TEMPERATURE

>40 ˚C

REPLACE

CONTROL

WAIT WATER FLOW

TEMPERATURE

>40 ˚C

YES

BOARD

END

REPLACE

IGNITION CONTROL

YES

SPARK AT

ELECTRODE

YES

IGNITION

YES

LOCKOUT

AFTER

IGNITION

YES

CHECK SENSING

ELECTRODE

AND LEAD

SENSING

ELECTRODE

AND LEAD

REPLACE SENSING

ELECTRODE

AND LEAD

REPLACE IGNITION CONTROL

IGNITION

CONTROL

YES

THERE MAIN

BETWEEN TERMINALS

M14.1 & M14.2

ON PCB

THERE 0 Vdc

BETWEEN TERMINALS

M5.3 & M5.4

ON PCB

YES

THERE MAIN

BETWEEN TERMINALS

L & N ON

IGNITION

CONTROL

CHECK WIRING

YES

CHECK SPARK

ELECTRODE AND

LEAD OR REPLACE

IGNITION CONTROL

0 VDC

ON BOILER

FLOW

SWITCH

CHECK WIRING

CONNECTIONS

AND

CONNECTIONS

YES

AND

YES

CHECK WIRING

AND

CONNECTIONS

REPLACE GAS VALVE

THERE A

VOLTAGE > 0.5 Vdc

BETWEEN TERMINALS

M3.11 ON PCB & GRAY

WIRE ON D.A .P.

SWITCH

GAS

VALVE

OK YES

CHECK GAS

CHECK THE FAN,

VENTURI

AND/OR D.A.P.S

THERE A

VOLTAGE > 0.5 Vdc

BETWEEN TERMINALS

M3.11 & M3.10

ON PCB

YES

FLOW

SWITCH

YES

CHECK WATER

FAULT CODE SHOWING 03

YES

DOES THE

FLOW SWITCH PIN

OPERATE

FAULT CODE SHOWING 04

FAULT CODE SHOWING 06

FAULT CODE SHOWING 07

YES

REPLACE

CONTROL BOARD

YES

CHECK DHW

NTC SENSOR OR

CONNECTION

YES

NTC SENSOR OR

CHECK FLOW

CONNECTION

YES

THE BOILER

FLOW SWITCH

OPERATE

YES

CHECK THE

WIRING AND/OR

THE CONTROL

BOARD

CHECK AND/OR REPLACE THE

DIAPHRAGM.

CHECK THE CORRECT WATER DP

CHECK THE WATER CIRCUIT.

CHECK IF THE PUMP IS ON 3a SPEED

CHECK/

REPLACE THE BOILER FLOW

SWITCH

FAULT CODE SHOWING 08

FAULT CODE SHOWING d1

FAULT CODE SHOWING d2

YES

CHECK COMBUSTION

AND BURNER

THERMISTOR OR

CONNECTION

CHECK CONDENSATE

LEVEL, SENSOR

OR WIRING

CHECK CONDENSATE

SENSOR

AND WIRING

REPLACE

CONTROL BOARD

WAIT WATER

FLOW

TEMPERATURE

< 80 ˚C

YES

BURNER AND FAN

SWITCH ON

WAIT 3 MIN.

BURNER AND FAN

SWITCH ON

WATER FLOW

TEMPERATURE

>80 ˚C

REPLACE

CONTROL

BOARD

REPLACE

CONTROL

BOARD

YES

VOLTAGE < 1 Vdc

BETWEEN TERMINALS

M3.10 & M3.11

TIMER JUMPER

THERE A

ON PCB

YES

REMOVE

JUMPER

REST AR T THE

TEST

THERE A

VOLTAGE >4 Vdc

BETWEEN TERMINALS

M3.10 & M3.11

ON PCB

YES

REMOVE THE LINK

BETWEEN PIN M16.TA

AND M16.TA ON

CONTROL BOARD

WAIT 30 SEC.

BURNER,

YES

FAN AND PUMP

SWITCH

OFF

YES

TIMER JUMPER

ON JP9

REMOVE

JUMPER

REPLACE

CONTROL

BOARD

RESTART

THE TEST

CHECK FAN, WIRING

AND CONNECTIONS,

DIFFERENTIAL ANALOG

PRESSURE SWITCH AND

CONTROL BOARD

FAN

ON?

YES

D.A.P.S.

OK?

END

REPLACE DIFFERENTIAL

ANALOG PRESSURE

SWITCH

YES

CHECK FLUE

VENTURI

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.

controls only the functions of the appliance (Heating & DHW temperature, reset function, fault code display , etc).

● Boiler control with room thermostat

function: whereby the RC05 controls the functions of the appliance (Heating & DHW temperature, reset function, fault code display , etc) and also functions as a room thermostat.

● Boiler control with programmable room

thermostat: whereby the RC05 controls the functions of the appliance (Heating & DHW temperature, reset function, fault code display , etc), and also functions as a programmable room thermostat.

NOTE

If the RC05 is used in the “boiler only” mode, an additional control will be required to switch terminals T A & TA. Full details of the operation of the RC05 and its functions can be found in the installations and users instructions of the RC05.

8.5 VOKERA ROOM THERMOST A T

Connect the Vokera room thermostat to the appliance as detailed in fig. 48 The Vokera room thermostat can be used with the Vokera time clock or any other voltage-free time clock.

Fig. 47

8.2 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 RC05 remote control (part no. 405).

● Vokera external sensor (must be used in

conjunction with the RC05). (Part no.

2359259).

● Single-channel, voltage-free time clocks.

● Programmable room thermostats.

In addition, the appliance can be used in conjunction with a typical ‘S’-Plan system, please contact Vokera technical for further detailed instruction.

NOTE

This appliance is not suitable for use with ‘Y’Plan systems.

8.3 VOKERA TIME CLOCK

See 4.7.4 for detailed instructions on fitting the Vokera time clock.

8.4 VOKERA REMOTE CONTROL

The RC05 remote control must be connected to the appliance as shown in fig. 47. The RC05 can be used in 3-modes:

● Boiler only control: whereby the RC05

Fig. 48

8.6 OTHER CONTROLS

Fig. 49 details typical control applications that are suitable for this appliance. 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.energyefficiency.gov.uk).

Appliance wired to basic voltage-free time clock

red-black

black

blue

white-red

red-black

black

blue

white-red

Appliance wired to basic voltage-free time clock and room thermostat

Fig. 49

Appliance wired to programmable room thermostat

Basic wiring with link between TA & TA (no controls fitted)

FUNCTIONAL DIAGRAM

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

NOTE: L-N-E CONNECTION IS ADVISABLE

R.T. Room thermostat TS H Heat time switch G.V. Gas valve C.S. Condensate sensor D.H.W.F.S. Domestic hot water flow switch P.S. Water pressure switch H.L.T. Hight limit thermostat H.T. Heat thermistor D.H.W.T. Domestic hot water thermistor MOD Modulator F Fan P Pump 3W 3 way motor S.S.E. Spark\Sense electrode OPE Gas valve solenoids B.C.B. (ACF02X) Burner control board B.E.B. Boiler control board S.B. Secondary board JP6 Pre-heating jumper

JP7 Room thermostat or remote control jumper JP8 Natural gas or L.P.G. selector JP9 Timer on- off selector PT1 (S.B.) Selection of 0-reset / winter - summer PT2 Central heating temperature control PT3 DHW temperature control DS1

÷DS2 Temperature / alarm 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 RL3 3 way relay IS01 Fan triac L1 Led OK (green) L2 Led alarm (blink red) TRF1 Transformer D.A.P.S. Differential analogue pressure switch B.T. Burner thermostat

WIRING DIAGRAM

Syntesi 25

Syntesi 29

Syntesi 35

NOTE: L-N-E CONNECTION IS ADVISABLE

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

SECTION 9 EXPLODED DIAGRAMS

362

400

401

226

402

326

POS. DESCRIPTION 25 29 35

1 Frame R01005288 R01005289 R01005290 12 Quick primer pressure gauge R1857 R1857 R1857 16 2A fuse R8968 R8968 R8968 17 100 mA fuse R1947 R1947 R1947 18 Cover R10021849 R10021849 R10021849 19 Ignition module R10021848 R10021848 R10021848 20 Printed Circuit Board R10024390 R10024390 R10024390 26 Instrumental panel R10021951 R10022015 R10022029 31 Case R1880 R1922 R2062 38 Printed Circuit Board R10024558 R10024558 R10024558 39 Spring R1862 R1862 R1862 40 Door panel R10024508 R10024508 R10024508 43 Push-push cover R1864 R1864 R1864 48 Led Light Guide R1858 R1858 R1858 49 Hole cap R8654 R8654 R8654 50 Pin R1867 R1867 R1867 51 Hole cover R1861 R1861 R1861 52 Selector knob kit R01005073 R01005073 R01005073 53 Control knob kit R01005072 R01005072 R01005072 90 3A fuse R3478 R3478 R3478

226 Edge clip R5128 R5128 R5128 326 O ring R1869 R1869 R1869 362 Transformer R10022659 R10022659 R10022659 400 Flat cable R10021117 R10021117 R10021117 401 Clock connection cable R1780 R1780 R1780 402 Clock cable R1980 R1980 R1980

351

353

328

353

351

366

351

366

328

365

292

277

201

285

202

201

202

201

248

200

400

401

POS. DESCRIPTION 25 29 35

1 Domestic water heat exchanger R8036 R8037 R10024627

2 Connection R9807 R9807 R9807

3 Pressure switch R2044 R2044 R2044

4 Non return valve R2908 R2908 R2908

7 By-pass valve R2047 R2047 R1552

9 Heating manifold R10020439 R10020439 R10020439 10 Spring R6862 R6862 R6862

11 Three way valve overhault kit R01005127 R01005127 R01005127 16 Three way valve cover R2904 R2904 R2904 17 Fixing fork wrench R2906 R2906 R2906 18 O ring connection R6919 R6919 R6919 19 Motorized valve R2905 R2905 R2905 22 Safety valve R1806 R1806 R1806 24 Flow governor* R8008 R8009 R9430

26 DHW actuator R10022349 R10022349 R10022349 27 Heating cock R1789 R1789 R1789 28 Connection R1790 R1790 R1790 30 Heating cock R10023567 R10023567 R10023567 31 Venting plugs kit R01005137 R01005137 R01005137 34 Heating cock R10023566 R10023566 R10023566 35 Flexible pipe R10023570 R10023570 R10023570 37 Pipe R1631 R1631 R10023211 40 Pipe R10022125 R10022125 R10023210 41 Connection R2903 R2903 R2903 61 Non return valve R10023569 R10023569 R10023569 62 Filling cock R10023568 R10023568 R10023568 64 Pipe R10023643 R10023643 R10023643

200 Washer R5023 R5023 R5023 201 Washer R5026 R5026 R5026 202 Washer R5041 R5041 R5041 248 Washer R5208 R5208 R5208 277 Screw R6903 R6903 R6903 285 NTC sensor R8484 R8484 R8484 292 O ring R7999 R7999 R7999 328 Clip R1890 R1890 R1890 351 Nut R1823 R1823 R1823 353 Nut R1824 R1824 R1824 365 Nipple R1793 R1793 R1793 366 Clip R1820 R1820 R1820 400 Hydraulic control cable R10024342 R10024342 R10024342 401 Diverter valve cable R1873 R1873 R1873

R10024462 R10024462 R10020041

- R10020041 R1321

* White flow governor R8008 * Blue flow governor R8009 * Red flow governor R9430 * Orange flow governor R10024462 * Beige flow governor R10020041 * Green flow governor R1321

388

500

393

201

SYNTESI 35

200

394

395

396

200

288

200

394

277

200

288

400

285

200

290

202

371

370

398

370

372

289

287

200

POS. DESCRIPTION 25 29 35

1 Expansion vessel R2204 R2204 R2573 2 Flexible pipe R2164 R2164 R2164 3 Circulation pump R10020437 R10020437 R10020438 4 Pump cable R1845 R1845 R1845 5 Automatic air vent bottle R0439 R0439 R0439 6 Pipe R10023195 R10023202 R10023209 7 Pipe R10024312 R10024130 R10024519 8 Heat exchanger R2381 R2378 R10020513

9 Pipe R10021041 R10021041 R10020519 10 Pipe R10023198 R10023203 R10023208 11 Bracket R2940 R2940 R2940 25 Siphon R10023495 R10023495 R10023495 26 Siphon pipe R10023530 R10023530 R10023530 27 Pipe R10024440 R10024132 R10024521 28 Pump lock key R9263 R9263 R9263 40 Siphon plug R10023531 R10023531 R10023531 45 Retarder R10024136 R10024136 R10024136 47 Condensing level detector R10025212 R10025212 R10025212 48 Pipe R10024311 R10024129 R10024518 49 Pipe R10024313 R10024131 R10024520 50 Siphon plug R10024133 R10024133 R10024133

200 Washer 24 x 17 R5023 R5023 R5023 201 Washer 18,5 x 11 R5026 R5026 R5026 202 Washer R5041 R5041 R5041 277 Screw M4 R6903 R6903 R6903 285 Sensor R8484 R8484 R8484 287 Limit thermostat R2258 R2258 R2258 288 O-Ring R6898 R6898 R6898 289 Clip R2223 R2223 R2223 290 Clip R2165 R2165 R2165 370 O-Ring R10023533 R10023533 R10023533 371 Clip R10023532 R10023532 R10023532 372 Clip R2588 R2588 R2588 388 Washer Ø 60 R10021949 R10021949 R10021949 393 O-Ring 4300 R10024141 R10024141 R10024141 394 O-Ring R20 R10024142 R10024142 R10024142 395 O-Ring OR R22 R10024143 R10024143 R10024143 396 Connection R01005292 R01005292 R01005292 398 Clip R10024336 R10024336 R10024336 400 Condensing level detctor cable R10024121 R10024121 R10024121 500 Condensing unit assembly R01005291 R01005291 R01005291

SYNTESI 35

332

SYNTESI 35

351

200

328

200

400

401

POS. DESCRIPTION 25 29 35

1 Air box bottom R10024449 R10024385 R10024516 2 Ambidx air box side R10024166 R10024166 R2059 3 Air box clip R0442 R0442 R0442 4 NG Burner R10023168 R10022980 R10023834 4 LPG burner R10023169 R10025053 R10024626 5 Spark electrode R10022027 R10022027 R10022027

9 NG plate R5172 R5172 10 Gas valve solenoid R10020838 R10020838 R10020838 12 Gas pipe R1839 R1839 R1839 13 Gas valve R10025074 R10025074 R10025074 14 Gas pipe R1840 R1840 R1840 15 Gas cock R1787 R1787 R1787 16 Air box cover R10020216 R10020217 R10020430 17 Washer R5072 R5072 R5072 18 Glass R3139 R3139 R3139 19 Glass flange R4007 R4007 R4007 21 Washer R5905 R5905 R5905

200 Washer R5023 R5023 R5023 328 Clip R1890 R1890 R1890 332 Thermostat R2600 R2600 R2600 351 Nut R1823 R1823 R1823 400 Gas valve cable R10021947 R10021947 R10021947 401 Gas valve coil cable R10022112 R10022112 R10022112

295

300

POS. DESCRIPTION 25 29 35

1 Combustion chamber assembly R6027 R6028 R10020514 2 Combustion chamber back panel R5270 R5316 R10020518 3 Combustion chamber lateral panel R5271 R5271 R5271 4 Combustion chamber front panel R5269 R5315 R10020517

7 Hood assembly R10024310 R10024125 R10024473 10 Fan R10024035 R10024035 R10024035 13 Venturi and pressure tube kit R01005293 R01005293 R01005293 16 Clamp for tube R10024126 R10024126 R10024126 19 Fan flue connection R10024137 R10024137 R10024137 20 Block with combustion analysis check R8085 R8085 R8085 23 Brass cap R8086 R8086 R8086 25 Pressure differential switch R2677 R2677 R2677

295 Silicone tube R1457 R1457 R1457 300 Combustion - fan cable R10024314 R10024120 R10024522

SECTION 10 LPG INSTRUCTIONS

10.1 RELATED DOCUMENTS BS 6798 INSTALLATION OF BOILERS OF RA TED NOT EXCEEDING 60kW BS 5449 PART 1 FORCED CIRCULATION OF HOT W ATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 5440 PART 1 FLUES BS 5482 PART 1 DOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS

10.2 Gas Pressures 25 29 35

Inlet pressure (G31) 37 mbar Burner pressure maximum 35.5 mbar 35.5 mbar 35.4 mbar Burner pressure minimum 6.1 mbar 4.5 mbar 3.4 mbar Maximum gas rate 1.94kg/h 2.25 kg/h 2.72 kg/h Minimum gas rate 0.77 kg/h 0.77 kg/h 0.77 kg/h Injector size (quantity) 12 x 0.75 mm 14 x 0.75 mm 16 x 0.77 mm

Flue details (concentric)

Max horizontal flue length (60/100mm) 5.75m 3.75m 0.75m Max vertical flue length (60/100mm) 6.55m 4.55m 1.55m Max horizontal flue length (80/125mm) 13.80m 11.80m 6.75m Max vertical flue length (80/125mm) 15.30m 13.30m 8.25m

Efficiency

SEDBUK (%) 90.7 89.8 90.5

10.3 CONVERTING THE APPLIANCE GAS TYPE

T o convert the appliance to another gas type it is necessary to change the burner injectors and adjust the gas pressures. It is also necessary to ensure the jumper tag at JP8 is enabled or disabled according to the gas type used.

● To change the injectors see 6.15

● For correct jumper tag configuration see 7.8

10.4 GAS SUPPLY

The gas supply must be connected to the appliance by a competent LPG installer and must be of sufficient size to supply the appliance at its maximum output. An existing supply must be checked to ensure that it is of adequate size to deal with the maximum rated input of this and any other appliances that it serves.

10.5 GAS SUPPLY INSTALLA TION

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

10.6 CHECKING AND ADJUSTING BURNER PRES-

SURE (see fig. 16)

Isolate the appliance from the electrical supply and attach a suitable manometer to the gas valve outlet test point.

10.6.1 SETTING THE MAXIMUM BURNER PRES-

SURE (see fig. 44)

Light the boiler as described in 5.7, fully open a DHW outlet (preferably the bath) and ensure the

HW temperature selector is set at maximum. Allow the appliance to stabilise. Compare the reading on the manometer with the value described in 10.2. 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 counterclockwise to decrease the burner pressure.

10.6.2 SETTING THE MIMIMUM BURNER PRESSURE (see fig. 45)

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 10.2. 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, close the DHW outlet, replace the protective cap, refit the grey wire to the modulating coil, remove the manometer, and tighten the outlet test point.

IMPORTANT, A GAS SOUNDNESS CHECK MUST BE CARRIED OUT.

Cod. 10024509 - 46/03 - Ed. 2

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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“Vokèra”

supports Benchmark

vokera Syntesi 25 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual