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1. Fig 23 19 6 11 GAS VALVE fig 24 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 pipes connections Please note the sealing washers Q must be discarded and replaced with new sealing washers Disconnect the compensation pipe from the gas valve The gas valve can now be removed Replace in the reverse order Check and adjust burner pressure settings WARNING A GAS TIGHTNESS CHECK MUST BE CARRIED OUT 6 12 BURNER fig 25 Carry out component removal procedure as described in 6 4 Unscrew and remove the air box front cover fig 20 Locate and remove the six screws around the inner combustion cover and remove Disconnect the spark plug cable connection slide off the lower cable grommet from the seat of the air distribution box remove the burner fixing screws and remove with the spark plug attached and corresponding cables Replace in the reverse order 6 13 MAIN HEAT EXCHANGER fig 26 Carry out component removal procedure as described in 6 4 Unscrew and remove the air chamber front cover fig 20 Locate and remove the six screws around the inner combustion cover and remove Remove locking pins and disconnect the pipes from the flow and return connections on the heat exchanger Disconnect the hot and cold connections on the
2. Bend Reduction in maximum flue length for each bend 45 bend 0 5 metre 90 bend 0 8 metre Twin flue accessories Part No Description Length 20006933 Twin adapter kit N A MOUNTING THE BOILER The fixing holes for the wall mounting bracket should now be drilled and plugged an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely Once the bracket has been secured to the wall mount the appliance onto the bracket INSTALLATION OF TWIN ADAPTOR KIT fig 12 amp 13 e Insert the exhaust connection manifold A onto the appliance flue outlet e Remove the blanking plate located to the left of the appliance flue outlet and using the same screws install the air inlet plate B e 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 e 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 14 Fig 12 Fig 13 HORIZONTAL TERMINATION fig 14 The twin flue system must be converted
3. Fit the appropriate flash Fig 15 plate to the roof and insert a vertical flue terminal through the flashing plate from the 130mm 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 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 100mm clip gasket amp 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 13 to the maximum equivalent flue length between the boiler and vertical flue assembly see fig 14 Ensure that any horizontal sections of the flue system have a minimum 1 maximum 3 fall back to the boiler 1 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 Remove any bur
4. Vokera heating for life Compact 28 SE High efficiency combi boiler Users Instructions Installation 4 Servicing Instructions C THESE INSTRUCTIONS TO BE RETAINED BY USER Users instructions 3A 5 Air supply 3A 6 Water circulation 3A 7 Electrical supply 3A 8 Mounting on a combustible surface 3A 9 Timber framed buildings 3A 10 Inhibitors 3A 11 Showers 3A 12 Declaration of conformity 36 Things you should know Page Installation Page 1 1 Gas appliances 1 4 1 Delivery 12 1 2 Electrical supply 1 4 2 Contents 12 1 3 Guarantee registration card 1 4 3 Unpacking 12 1 4 Appliance Log Book UK only 1 4 4 Preparation for mounting the appliance 12 1 5 How does it work 1 4 5 Fitting the flue 12 1 6 Dimensions 1 4 6 Connecting the gas amp water 15 1 7 Clearances required 1 4 7 Electrical connections 16 1 8 Frost protection system 1 1 9 Appliance status indicators 1 Commissioning Page 5 1 Gas supply installation 17
5. 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 tightness water tightness and the electrical integrity of the appliance 7 2 APPLIANCE MODES 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 and the low pressure fault code will be indicated 7 2 1 SELECTOR SWITCH IN THE OFF RESET POSITION When the selector switch is in the OFF RESET position the following functions are active Active functions e frost protection system e pump amp actuator anti block 7 2 2 ON BOARD FUNCTIONS e CO FUNCTION the CO function when activated will allow the appliance to run a t CH maximum DHW maximum or minimum output whilst a combustion analysis check or a mechanical gas valve calibration is being carried out Whilst the CO function is active all other functions are disabled minimum power operating period anti cycle set point etc Once enabled the CO function will remain active for a 15 minute period or until the function is manually deactivated FROST PROTECTION this function is only active when there are no requests for he
6. 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 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 18 3 6 6 FILLING POINT A method for initial filling of the system and replacing water lost during servicing etc directly from the mains supply is provided see fig 8 This method of filling complies with the current Water Supply Water Fittings Regulations 1999 and Water Bylaws 2000 Scotland If an alternative location is preferred it should be connected as detailed in fig 8 3 6 7 LOW PRESSURE SEALED SYSTEM An alternative method of filling the system would be from an independent make up vessel or tank mounted in a position at least 1 metre above the highest point in the system and at least 5 metres above the boiler see fig 9 The cold feed from the make up vessel or tank must be fitted 9 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
7. G Gas connection 2 en mo on 19 O Hot water outlet y Cold water inlet Fig 4 R F G O SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE 1 1 PRINCIPLE COMPONENTS e A fully integrated electronic control board featuring electronic temperature control anti cycle control pump over run self diagnostic fault indicator Heat exchanger Electronic ignition with flame supervision Pump Fan Expansion vessel Water pressure switch Pressure gauge Safety valve 1 2 MODE OF OPERATION at rest When the appliance is at rest and there are no requests for heating or hot water the following functions are active e frost protection system the frost protection system protects the appliance against the risk of frost damage if the primary temperature falls to 5 C the appliance will function on minimum power until the temperature on main reaches 35 C e anti block function the anti block function enables the pump to be energised for short periods when the appliance has been inactive for more than 24 hours 1 3 MODE OF OPERATION Heating When there is a request for heat via the 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 circuit to ensure flame stability at the burner Once successful ignition has been achie
8. Rotate and remove the AAV assembly J Replace in the reverse order 6 8 WATER PRESSURE SWITCH fig 22 Carry out component removal procedure as described in 6 4 Locate and remove the locking pin M from the water pressure switch N Remove the wiring Carefully withdraw the switch Replace in the reverse order 6 9 FLOW THERMISTOR fig 4 pos 10 Carry out component removal procedure as described in 6 4 Unclip and remove the air chamber front cover Unclip the flow thermistor from the flow outlet pipe Disconnect thermistor electrical plug Replace in the reverse order 6 10 PRINTED CIRCUIT BOARD fig 23 Carry out component removal procedure as described in 6 4 Pull the control fascia forward and lower it Push the clips O which secure the PCB cover remove cover after carefully taking note of all wiring connections and jumper tag configu ration Unhook and remove connection block Disconnect all wiring from the PCB locate and remove the PCB securing screws remove the required PCB Replace in the reverse order ensuring that the position of the 2 control knobs are correctly aligned with the respective potentiometers on the PCB Ensure that the correct jumper tag configuration has been respected It will be necessary to check the functioning of the PCB is set for the correct boiler type application Fig 20 Fig 21
9. VESSEL Carry out the component removal procedure as described in 6 4 You must ensure that the boiler is completely drained of water Using a suitable pressure gauge remove dust cap on expansion vessel and check the charge pressure The correct charge pressure should be 1 0 bar 0 1 bar If the charge pressure is less use a suitable pump to increase the charge NOTE You must ensure the drain valve is in the open position whilst re charging takes place Replace the dust cap and carry out the relevant commissioning procedure section 5 7 6 EXTERNAL FAULTS 4 4 Light signals and faults The control panel has two led that indicate the boiler operating status Green led Flashing Flashing with frequency 0 5 second on 3 5 seconds off boiler in standby there is no flame Flashing with frequency 0 5 second on 0 5 second off temporary stop of the appliance due to the following self restoring faults water pressure switch standby time 10 minutes approximately differential air pressure switch standby time 10 minutes approximately transitory waiting for ignition In this phase the boiler waits for restoration of working conditions If after standby time the boiler will not restore regular operation stop will be permanent and light signalling will be red Fast flashing frequency 0 1 sec on 0 1 sec off duration 0 5 input output function S A R A Italian acronym for Environment Automatic Adjustme
10. drain cocks Except where providing useful heat pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing Particular attention should be paid to pipes passing through ventilated areas such as under floors loft space and void areas 3A 6 2 AUTOMATIC BY PASS The appliance has a built in automatic by pass consequently there is no requirement for an external by pass however the design of the system should be such that it prevents boiler cycling 3A 6 3 DRAIN COCKS These must be located in accessible positions to facilitate draining of the appliance and all water pipes connected to the appliance 3A 6 4 AIR RELEASE POINTS These must be positioned at the highest points in the system where air is likely to be trapped They should be used to expel trapped air and allow complete filling of the system 3A 6 5 EXPANSION VESSEL 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 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 18 3A 6 6 FILLING POINT A method for initial filling of the system and replacing water lost during servicing etc is provided see fig 8 You should ensure this method of filling complies with the local water authority regulat
11. 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 J T VTT TT HH IU _ _ pot LI TIT aR T T TN Ha Residual head x 100 mbar 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 Fig 6 Fig 7 C Key Location Minimum distance A Below an opening window air brick etc 300 mm B Above an opening window air brick etc 300 mm C To the side of an opening window air brick etc 300 mm D Below gutter drain pipe etc 25 mm E Below eaves 25 mm F Below balcony car port roof etc 25 mm G To the side of a soil drain pipe etc 25 mm 60mm for 80 125 5 flue H From internal external corner 25 mm 60mm for 80 125 5 flue 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 R To the side of a boundary 300 mm S To the side of an opening or window on a pitched roof 600 mm T Below an opening or window on a pitched roof 2
12. heat exchanger Disconnect the electrical plugs from the primary thermistor the heat exchanger can now be withdrawn from the appliance Replace in the reverse order Ensure all seals are in good condition taking care to ensure they are replaced correctly 6 14 AUTOMATIC BY PASS fig 27 Carry out component removal procedure as described in 6 4 Remove the circulator as described in 6 5 Using a hooked piece of wire carefully withdraw the by pass cartridge S1 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 20 Fig 24 Fig 25 Fig 27 6 15 EXPANSION VESSEL REMOVAL fig 28 Carry out component removal procedure as described in 6 4 Disconnect the flexible expansion pipe from the vessel fig 28 Locate and remove the 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 15 1 DHW FLOW RESTRICTOR fig 29 Carry out the component removal procedure as described in 6 4 Remove the DHW inlet pipe from the DHW heat exchanger Using a small screwdriver gently ease the flow restrictor C2 from its seating Re
13. store the casing and screws safely until required Re fit in the reverse order remove retaining screw from under the control fascia and lower gently until it rests 4 7 2 APPLIANCE TERMINAL BLOCK The appliance terminal block is located on the rear of the control fascia Remove the casing as described in 4 7 1 Gently pull the control panel forwards and down Locate the terminal block cover fig 18 NOTE If the appliance is to be used without the use of external controls a link must be fitted across the CN5 terminal on the PCB to allow basic operation of the boiler via the mode selector switch If it is anticipated that external controls will be required please 16 refer to the wiring diagrams in section 8 for more detailed information 4 7 3 CONNECTING THE MAINS 230V INPUT Unhook and remove the terminal block cover 230V Pass the cable through the cable anchorage point Connect the supply cable wires LIVE NEUTRAL amp EARTH to their corresponding terminals L N amp E on the appliance high voltage terminal block When connecting the EARTH wire ensure 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 unless additional external controls are to be fitted see section 8 The securing screw on the cable anchorage should now be tightened This must be done before the terminal block cover is re fitted in its positio
14. 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 l 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 S 813 when the terminal is 0 5 metres or less below plastic guttering or 1 metre or less below painted eaves 3A 5 AIR SUPPLY The following notes are intended for general guidance only This appliance is a room sealed fan flued boiler consequently it does not require a permanent air vent for combustion air supply When installed in a cupboard or compartment ventilation for cooling purposes is also not required 3A 6 WATER CIRCULATION Specific recommendations are given in l 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
15. the end of the terminal to the end of the outer 100mm pipe The internal trim should be fitted to the flue pipe before connection of the 90 bend Dimension Y H 135 mm Max 833 mm Dimension X Fig 13 EXTENDING THE FLUE The horizontal flue system can be extended using bends and or extensions from the Uni Flue range see 4 5 1 Connect the bend supplied with the terminal kit to the top of the boiler using the clips screws 4 gaskets supplied The additional bends amp extensions have an internal push fit connection care should be taken to ensure thatthe 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 using the clips screws 4 gaskets supplied see fig 11 4 14 The interior trim should be fitted at this point NOTE When cutting an extension to the required length you must ensure that the excess is cut from the plain end of the extension and that the inner 60mm pipe is 7 5mm longer than outer 100mm pipe see fig 8 4 8A Remove any burrs and check that any 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 exterior trim can now be fitted Fig 14 4 5 2 CONCENTR
16. 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 10 INHIBITORS Vokera recommend that an inhibitor suitable for use with 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 Water treatment of the complete heating system including the boiler should be carried out in accordance with I S 813 and the Domestic Water Treatment Association s DWTA code of practice 3A 11 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 12 DECLARATION OF CONFORMITY A Declaration of Conformity as defined in 1 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 11 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
17. to the required value drain off some water from the appliance drain valve until the required figure registers on the pressure gauge see fig 1 5 11 REGULATING THE CENTRAL HEATING SYSTEM Fully open all radiator and circuit valves and run the appliance for both heating and hot water until heated water is circulating If conditions are warm remove any thermostatic heads Adjust radiator return valves and any branch circuit return valves until the individual return temperatures are correct and are approximately equal 5 11 1 REGULATING THE DHW FLOW RATE The appliance is fitted with a flow rate restrictor that limits the maximum flow rate that can be drawn through the appliance 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 available to Vokera spare parts The spare flow rate restrictors can be fitted to either increase or decrease the maximum flow rate 5 11 2 FLOW RATE RESTRICTOR The boiler is supplied with the following flow restrictor Compact 24 SE 10 litres flow restrictor 17 5 12 FINAL CHECKS e ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS VALVE ARE TIGHT AND CHECKED FOR TIGHTNESS e ENSURE THE APPLIANCE FLUE SYSTEM IS FITTED CORRECTLY AND IS PROPERLY SECURED e ENSURE ALL PIPE WORK IS RE CHECKED FOR TIGHTNESS e RE FIT APPLIANCE CASING e COMPLETE BENCHMARK CHECKLIST FOR UK O
18. wait 5 6 seconds and take it then to the desired position summer or winter mode If the boiler does not restore normal operation contact the Technical Assistance Service Green flashing led red flashing led When the LEDs flash simultaneously it is a domestic water probe alarm and water pressure switch alarm after transient phase The boiler works regularly but stability of the domestic hot water temperature is not guaranteed Contact the Technical Assistance Service for a control When the LEDs flash alternatively it means that there is a calibration procedure in progress 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 amp Neutral connections at the appliance terminal strip Repeat above test on the Live 4 Earth connections at the appliance terminal strip NOTE Should it be found that the fuse has failed but no fault is indicated a
19. 0 Maximum pressure downstream DHW valve mbar 9 70 Minimum pressure downstream CH valve mbar 1 90 Minimum pressure downstream DHW valve mbar 1 30 GAS PRESSURE CHECK pas tae CC E DOWNSTREAM olE31 6a e lo e lel le FROM THE GAS CONNECTION 8 CNT ONG JP5 JP4 JP3 JP2 JP VALVE o1E35 dl gt 1 f O J VE A oje 3 CN8 FASTON 0olE 33 O Pa Ol O CONNECTIONS p1 u P PROTECTION COVER MAXIMUM POWER ADJUSTMENT NUT DHW MINIMUM ADJUSTMENT RED SCREW JP1 Bridge to enable function calibration JP2 Bridge to adjust maximum heating JP3 Bridge to select MTN LPG 23 7 4 COMBUSTION ANALYSIS TEST To carry out the combustion analysis proceed as follows open the hot water tap to its maximum output set the mode selector to summer and the domestic hot water temperature selector to the maximum value remove the screw of the combustion analysis inlet cover and insert the probes power the boiler The appliance works at maximum output and it is possible to check combustion After analysis is complete close the hot water tap remove the probe from the analyser and close the combustion analysis inlet fastening carefully the screw previously removed 7 5 CHECKING THE EXPANSION
20. 000 mm V From a vertical terminal to an adjacent opening window air brick etc call Vokera technical for advice W From a vertical terminal to an adjacent vertical terminal 300 mm only if both terminals are the same hight SECTION 3 GENERAL REQUIREMENTS UK This appliance must be installed by a competent person in accordance with the Gas Safety Installation 4 Use Regulations 3 1 RELATED DOCUMENTS The installation of this boiler must be in accordance with the relevant requirements of the Gas Safety Installation amp 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 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
21. 49 45 bend pair 220mm 2359059 90 bend N A 529 Wall bracket 5 N A Using the template provided A mark and drill a 125mm hole for the passage of the flue pipe The hole should have a 1 drop from the boiler to outside to eliminate the possibility of rainwater entering the appliance via the flue 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 RETURN FLOW GAS HOT OUTLET COLD INLET re I GE IN maak IN N lt p Pa IH Extension I l g 7 5 mm Fig 11 FITTING THE HORIZONTAL FLUE KIT Carefully measure the distance from the centre of the appliance flue outlet to the face of the outside wall dimension X see fig 7 Ensure the inner 60mm pipe is fully inserted into the outer 100mm pipe when the inner pipe is fully inserted it stands proud of the outer pipe by 7 5mm Add 32mm to dimension X to give the overall flue length dimension Y NOTE The standard horizontal flue kit part no 2359029 is suitable for a distance dimension Y of up to 865mm The telescopic flue kit part no 2359119 is suitable for a distance dimension Y of up to 600mm Dimension Y is measured from
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23. Getting started Page 5 2 The heating system 17 2 1 Before switching ON 3 5 3 Initial filling of the system 17 2 2 Appliance controls 3 5 4 Initial flushing of the system 17 2 3 Lighting the boiler 3 5 5 Pre operation checks 17 2 4 Adjusting the heating temperature 3 5 6 Initial lighting 17 2 5 Adjusting the hot water temperature 3 5 7 Checking gas pressure 4 combustion analysis 17 2 6 Explanation of features 3 5 8 Final flushing of the heating system 17 2 7 Automatic temperature control 3 5 9 Setting the boiler operating temperature 17 5 10 Setting the system design pressure 17 How to Page 5 11 Regulating the central heating system 18 3 1 How to top up the system pressure 3 5 12 Final checks 18 3 2 How to reset the appliance 3 5 13 Instructing the user 18 3 3 How to shut down the system for short periods 3 3 4 How to shut down the system for long periods 3 Servicing Page 3 5 How to care for the appliance 3 6 1 General 18 6 2 Routine annual servicing 18 What if Page 6 3 Replacement of components 18 4 1 What if suspect a gas leak 4 6 4 Component removal procedure 18 4 2 What if have frequently top up the system 4 6 5 Pump assembly 19 4 3 What if the appliance Is due its annual service 4 6 6 Safety valve 19 4 4 What if need to call an engineer 4 6 7 Lower automatic air release valves 19 6 8 Water pressure switch 19 Setting the Vokera Page 6 9 Flow thermistor 19 5 1 Setting the Vokera mechanical clock 4 6 10 Return thermistor 19 6 11 Printed ci
24. HECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission this equipment to the manufacturer s instructions may invalidate the warranty but does not affect statutory rights Customer Name Lola Telephone Number Address Boiler Make and Model Boiler Serial Number ft ft ft tt tt j j j j l j Y l Y 1 lll Commissioned by print name CORGI ID Number Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer Room Thermostat Compensation Control Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer Timer Combination Boiler Heating Zone Valves Fitted Not Required E Hot Water Zone Valves Fitted Not Required Thermostatic Radiator Valves Fitted Not Required Automatic Bypass to System Fitted m Not Required Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance wi
25. IC VERTICAL FLUE The appliance can be used with either the Vokera 60 100mm concentric Uni flue system or the optional Vokera twin flue system Total flue length 60 100 Up to 1 85 metre From 1 85 to 2 7 metre From 2 7 to 3 7 metre From 3 7 to 4 4 metre Restrictor required 43 mm diameter 45 mm diameter 47 mm diameter Not installed NOTE These instructions relate only to the Vokera 60 100mm concentric flue system For specific details on the installation of the Vokera twin flue system please refer to the instructions supplied The vertical flue terminal can be connected directly to the appliance flue outlet Alternatively an extension or bend can be connected to the appliance flue outlet if desired however if additional bends are fitted a reduction must be made to the maximum flue length see table below Reduction for bends Bend Reduction in maximum flue length for each bend 45 bend 1 metre 60 100 90 bend 1 5 metre 60 100 Vertical flue terminal and accessories Part No Description Length 2359039 Vertical flue terminal 1 0 metre 531 Pitched roof flashing plate N A 532 Flat roof flashing plate N A 2359069 750 mm extension 750 mm 2359079 1500 mm extension 1500 mm 2359049 45 bend pair N A 2359059 90 bend N A 529 Wall bracket 5 N A Using the dimensions given in fig 12 as a reference mark and cut a 125mm hole in the ceiling and or roof
26. It is recommended that the condensate drain kit should be fitted in the vertical plane however it can be fitted horizontally with care Fit the first bend to the condensate drain kit or exhaust connection manifold by firmly pushing in to position Using the two holes in the exhaust connection manifold as a guide drill a 3 mm hole in each and secure using the screws provided Connect the air inlet pipe to the air baffle as above 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 50 mm into the female socket of the previous piece The condensate drain trap must be connected to the drain in accordance with building Regulations or other rules in force 4 6 CONNECTING THE GAS AND WATER The appliance is supplied with an accessory pack that includes service valves Theservice valves are for welding The accessory pack contains sealing washers etc for use with the service valves NOTE It will be necessary to hold the valve with one spanner whilst tightening with another 4 6 1 GAS fig 16 The appliance is supplied with a 22mm service valve connect a 22mm pipe to the inlet of the valve and tighten both nuts NOTE It will be necessary to calculate the diameter of the gas supply pipe to ensure the appliance has an adequate supply of gas 4 6 2 FLOW amp RETURN fig 16 The appliance is supplied with 22mm servi
27. N O O NI LE 3 8 y O T Eqo ol 19 lH 1W OLNI EE 1 E3o O L ES o l 9 6N9 F3 SAI LES O VN dN E ol E o O Zd Id l cl AN AN C3o ow F cLNO CE na z EJ re NG ee ay MIME MES O a 22 16 9NI 490 19 10198UU09 ya Lw par aniq UMNO Su 27 SECTION 9 EXPLODED DIAGRAMS Table 1 701 31 703 POS DESCRIPTION 28 SE 1 Frame assembly 20020300 12 Quick primer pressure gauge 20005580 18 Cover 20005574 20 Printed circuit board MP08 20005569 21 Led light guide 20013352 26 Control panel 20035608 27 Knob 20013055 31 Case Assembly 20035613 90 Fuse R3478 226 Clip R5128 660 Ignition transformer 20013354 700 Cable R1547 701 Combustion cable 20013349 702 Power wiring harness 20005572 703 Low tension cable 20013350 28 Table 2 201 KA POS DESCRIPTION 28 SE 2 Connection R10022658 7 By pass valve R2047 22 Safety valve R2907 23 Fitting union R10022499 24 Flow governor R9430 25 Pipe R10023950 26 Dhw actuator R10022349 27 Heating cock R1789 28 Connection R1790 30 Water supply stop cock R7099 36 Pipe 20013353 48 Cock 20000533 63 Pipe 20035609 201 Washer R5026 265 Washer R5236 266 Washer R5237 288 Ring R6898 289 Clip R2223 290 Clip R2165 300 Clip R2222 303 Fitting union R2217 351 Nut R1823 353 Nut R1824 604 Clip 20000539 609 D
28. NLY Complete details of the boiler controls installation and commissioning in the Benchmark checklist at the back of this book It is important that the Benchmark checklist is correctly completed and handed to the user Failure to install and com mission 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 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 Explaintothe userthatfor continued safe and efficientoperation the appliance must be serviced annually by a competent person IMPORTANT To validate the appliance warranty it s necessary to register the appliance details with us The warranty can be registered in several ways e by completing the warranty registration card and posting to us using the envelope supplied e online at vokera co uk e for UK residents by
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30. TS 1 amp 2 FLUES amp VENTILATION REQUIREMENTS BS 5449 PART 1 FORCED CIRCULATION OF HOT WATER SYSTEMS BS 5482 PART 1 DOMESTIC BUTANE amp PROPANE GAS BURNERS IN PERMAMENT DWELLINGS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 6798 INSTALLATION OF BOILERS OF RATED NOT EXCEEDING 60kW 10 2 TECHNICAL DATA Gas Pressures Compact 24 SE Inlet pressure 37 0 mbar Heating maximum gas rate kg hr 2 35 DHW maximum gas rate kg hr 2 35 Heating minimum gas rate kg hr 0 99 DHW minimum gas rate kg hr 0 82 Maximum burner pressure mbar 35 8 Heating minimum burner pressure mbar 6 9 DHW minimum burner pressure mbar 5 0 Injector size mm 0 76 CO maximum output 7 9 CO minimum output 3 0 CO maximum output ppm 70 CO minimum output ppm 160 10 3 GAS CONVERSION OPERATIONS Converting the appliance to another gas type can be performed easily once the boiler is installed The boiler is designed to operate with methane gas G20 according to the product label It is possible to convert the boilers from one gas type to another by using the appropriate kit supplied upon request Methane conversion kit LPG conversion kit For disassembly refer to instructions below remove power supply from the boiler and close the gas tap remove in sequence shell air distribution box over and combustion chamber cover fig 20 disconnect t
31. al supply Always remove any links between TA amp TA on the CN5 PCB terminal see fig 39 e The room thermostat connection is low voltage 24 Vdc e Do not connect any controls or auxiliary equipment to the low voltage terminal strip other than that approved supplied by Vokera Ltd 26 MECHANICAL CLOCK RADIO FREQUENCY RECEIVER N DO o 2 4 1 de 8 230 V N L Fermale connector r Fuse 3 19A F al 7 TI M3 det BN QJ Male connector 7 TET _ D sess o o o g lt c SO Fig 39 Room Thermostat 24 Vdc e ZA NOTE Use contacts free of voltage 0 2 4 1 Hv Fermale connector SEE lt Male connector 7 FFF 230 V On Fuse 3 15A F i s LLA OJOO pa aadi css ee O SE Fig 40 FUNCTIONAL DIAGRAM ion is advisable L N E connect NOTE Fig 41 OPA ve sowy Woo abpluq SNO pasnun FNI SI0OPBUL09 ZLNO LNO YI IMs Binssald Ja J0 SIW1
32. ase 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 tightness rectifying any leaks 5 4 INITIAL FLUSHING OF THE SYSTEM 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 amp return service valve Drain the boiler and system from the lowest points Open the drain valve full bore to remove any installation debris from the boiler prior to lighting Refill the boiler and heating system as described in 5 3 5 5 PRE OPERATION CHECKS Before attempting the initial lighting of the appliance the following checks must be carried out e 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 8 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 setto 1 BAR ensure the flue system has been fitted properly and in accordance with the instructions e ensure all appliance service valves are open 5 6 INITIAL LIGHTING Ensure the electrical supply to the appliance is switched on Ensure any external controls are switched to an ON position and are calling for heat Move th
33. ating or HW If the temperature drops below 5 C the boiler will operate on minimum power until the temperature of the thermistor reaches 35 C Thereafter the pump amp fan will over run for 30 seconds ANTI CYCLE FUNCTION the anti cycle function ensures the burner remains switched off for at least 3 minutes after the set point hysterisis set point 5 deg for CH heat request PUMP ANTI BLOCK FUNCTION when there has been no heating or HW request for 24 hours the anti block cycle is activated The pump will be activated for a period of 30 seconds e SARA function the SARA function permits the boiler when the set point is within the SARA range to automatically adjust raise the heating flow outlet temperature should the room thermostat contacts remain closed for more that 20 minutes 7 2 3 HEATING MODE With all controls calling for heat the pump and fan will run When the fan runs it proves the air pressure switch The air pressure switch delivers current to the PCB and enables an ignition sequence to begin The ignition sequence begins with the energising of the gas valve and a simultaneous sparking at the spark sense electrode This will continue for approximately 10 seconds or until successful ignition has been established If no ignition has been established within the ten seconds the ignition attempt will be terminated and the appliance will go to lockout The appliance monitors the setting of the heating potenti
34. calling 0870 607 0281 e for ROI residents by calling 056 6655057 SECTION 6 SERVICING INSTRUCTIONS 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 compo nent be replaced only with a genuine Vokera spare part It should be remembered that although certain generic components may look similar they will be specific to an individual appliance or product range Use of non genuine Vok ra spare parts could invalidate your warranty and may pose a potential safety hazard The frequency of servicing will depend upon the particular installation conditions but in general once per year should be sufficient 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 GAS SAFE registered personnel or other suitably qualified 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 shou
35. ce 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 8 return pipe work after the service valve connections 4 6 3 COLD WATER INLET fig 16 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 HOTWATER OUTLET fig 16 The appliance is supplied with a 15mm outlet connection connect a 15mm pipe to the outlet connection and tighten both nuts A mm m L vui 1 deg 17mm 1 metro Fig 14 Hi Jil Sor FS Es Fig 15 Condensate drain kit T F A a a gr Fig 15A 15 Cold water inlet stopcock filling valve Hot water outlet Gas cock C H flow valve C H return valve 4 6 5 SAFETY VALVE fig 16 Connect the safety valve connection pipe to the safety valve outlet Connect a discharge pipe to the other end of the safety valve connection pipe and tighten The discharge pipe must have a continuous fall away from the appliance to outside and allow any water to drain away thereby eliminating the possibility of freezing The discharge pipe must terminate in a position where any water possibly boiling discharges safely without causing damage or injury but
36. correct way up 4 2 CONTENTS Contained within the carton is e the boiler the wall bracket carton template an accessories pack containing appliance service connections and washers the instruction pack containing the installation servicing user instructions guarantee registration card and a 3 amp fuse 4 3 UNPACKING Atthe 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 4 4 PREPARATION FOR MOUNTING THE AP PLIANCE 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 ofthe appliance with respect to hidden obstructions such as pipes cables etc When the position of the appliance has been decided using the template supplied carefully mark the position of the wall mounting bracket see fig 10 and flue hole if applicable 4 5 FLUE RESTRICTOR RING To ensure maximum efficiency of the appliance it may be necessary to fit one of the supplied flue restrictor rings to the appliance flue outlet 4 5 1 FITTING THE FLUE The top flue outlet permits both horizontal and vertical f
37. 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 e connect test leads between the Live amp Neutral connections at the appliance terminal strip 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 amp Earth connections at the appliance terminal strip The meter should read approximately 230V ac If so proceed to next stage If not see 7 7 4 connect test leads between the Neutral amp Earth connections at the appliance terminal strip The meter should read approximately O 15Vac If so polarity is correct If not see 7 7 4 7 7 4 REVERSED POLARITY OR SUPPLY FAULT Repeat the above tests at the appliance isolator if testing reveals correct polarity and or supply at the isolator re check wiring and connections between the isolator and the appliance If tests on the isolator also reveal reversed polarity or a supply fault consult the local electricity supplier for advice 7 7 5 RESISTANCE TO EARTH CHECK Isolate the appliance from the electrical supply and using a suitable multi meter carry out a resistance test Connect test leads between the Live amp Earth connections at the appliance terminal strip If the meter reads ot
38. e gas meter and contact your installer or local gas supplier If you require further advice please contact your nearest Vokera office 4 2 WHAT IF HAVE FREQUENTLY TO TOP UP THE SYSTEM If the system regularly requires topping up it may be indicative of a leak Please contact your installer and ask him to inspect the system 4 3 WHAT IF THE APPLIANCE IS DUE ITS AN NUAL SERVICE Advice for tenants only Your landlord should arrange for servicing Advice for homeowners Please contact Vokera Customer Service 0844 3910999 UK or 056 7755057 ROI if you would prefer a Vokera service engineer or agent to service your appliance Alternatively your local GAS SAFE registered engineer may be able to service the appliance for you 4 4 WHAT IF NEED TO CALL AN ENGINEER If you think your boiler may have developed a fault please contact your installer or Vokera Customer Services 0844 3910999 UK or 056 7755057 ROI have all your details to hand including full address and postcode relevant contact numbers and your completed appliance log book INSTALLATION AND SERVICING INSTRUCTIONS INTRODUCTION The Compact 28 SE is a standard efficiency combination boiler horizontal or vertical applications The Compact 28 SE can also with an output to CH 8 DHW of 28kW This appliance by be used with the Vokera twin flue system The Compact 28 SE design incorporates electronic ignition circulating pump is approved for use with C12 C32 type
39. e 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 l S 813 for detailed guidance on this aspect A compartment used to enclose the appliance must be designed 10 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 tightness 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
40. e selector switch to the ON position the appliance will now operate as described in 1 2 Should the appliance fail to ignite refer to 5 6 and or section 7 mode of operation parameter setting 4 faultfinding 5 7 CHECKING GAS PRESSURE AND COM BUSTION ANALYSIS The appliance is factory set and requires no additional adjustment once installed However to satisfy the requirements of GSIUR 26 9 I S 813 ROI it will be necessary to gas rate the appliance using the gas meter that serves the appliance If the installation does not include a gas meter for example LPG and there are no means by which to calculate the gas rate then a combustion analysis test must be carried out in accordance with BS 7967 UK to ensure the appliance is left working safely and correctly Additionally if the gas valve has been adjusted replaced or the appliance has been converted for use with another gas type then it becomes necessary to carry out a combustion analysis check to ensure that correct combustion is occurring If there are no means to gas rate the appliance and or carry out a combustion analysis check then it will not be possible to complete the commissioning procedure Details on how to carry out the combustion analysis can be found in section 7 IMPORTANT It s imperative that a sufficient dynamic gas pressure is maintained at all times Should the dynamic gas pressure fall below an acceptable level the appliance may malfunction or sus
41. ection system is reliant on the appliance having a permanent electrical supply and being in a non fault condition 1 9 APPLIANCE STATUS INDICATORS Your boiler is equipped with 2 status LED indicators the Green LED indicates that the flame is present the Red LED indicates the appliance has detected a fault Fig 1 DHW TEMPERATURE GREEN LED RED LED SELECTOR PRESSURE GAUGE SELECTOR SWITCH HEATING TEMPERATURE SELECTOR BOILER STATUS LED Green LED Boiler is working responding to a heating hot water request Red LED Boiler has identified a fault and has failed safe Refer to instructions on how to reset DHW TEMPERATURE SELECTOR Move the selector clockwise to increase the hot water outlet temperature or counter clockwise to reduce the temperature PRESSURE GAUGE Ensure the system pressure is set correctly minimum 0 5 bar MODE SELECTOR SWITCH HEATING TEMPERATURE SELECTOR Mode selector switch Hot water only Select this position if you want the boiler to supply hot water only no heating Hot water temperature selector move the selector clockwise to increase the heating outlet temperature or counter clockwise to reduce the temperature range 37 C 60 C IN Heating amp hot water Select this position when you want the boiler to respond to a heating and hot water request from the time clock programmer 8 Se a Ae h Heating temperature selector move the selector 4 N c
42. eft unoccupied for any length of time especially during the winter the system should be thoroughly drained of all water The gas water and electricity supply to the house should also be turned off For more detailed advice contact your installer 3 5 HOW TO CARE FOR THE APPLIANCE To clean the outer casing use only a clean damp cloth Do not use any control valve scourers or abrasive cleaners Fig 2 control temporary valve connection flow return double _ A pipe check valve supply pipe APPLIANCE STATUS LED AND FAULT CODES Alarm type Led RED Led GREEN Action Purge cycle mode active NA BLINKING BLINKING Alarm high limit thermostat Final BLINKING OFF Reset appliance Call engineer if fault re occurs Alarm system water pressure Final ON ON Check refill system pressure reset check Call engineer if fault re occurs Alarm safety shutdown and or Final ON OFF Reset appliance internal fault Call engineer if fault re occurs Temporary fault Temporary OFF BLINKING None Service operation NA BLINKING BLINKING None Flame ON NA OFF ON None Fault sensors DHW Final BLINKING BLINKING Reset appliance Call engineer if fault re occurs Fault sensors CH Final ON OFF Reset appliance Call engineer if fault re occurs Boiler stand by NA OFF BLINKING None 4 WHAT IF 4 1 WHAT IF SUSPECT A GAS LEAK If you suspect a gas leak turn off the gas supply at th
43. ent copy can be obtained from Vokera customer services 1 THINGS YOU SHOULD KNOW 1 1 GAS APPLIANCES Gas Safety Installations and Use Regulations UK In the interests of your safety and that of others it is a legal requirement that all gas appliances are installed and correctly maintained by a competent person and in accordance with the latest regulations 1 2 ELECTRICAL SUPPLY Please ensure that this appliance has been properly con nected to the electrical supply by means of a double pole isolator or un switched socket and that the correct size of fuse 3 AMP has been fitted Warning this appliance must be earthed 1 3 GUARANTEE REGISTRATION CARD Please take the time to fill out your guarantee registration card The completed warranty card should be posted within 30 days of installation 1 4 APPLIANCE LOG BOOK UK only A logbook section can be found at the rear of the appliance installation booklet This important document must be completed during the installation commissioning of your boiler All GAS SAFE registered installers carry a GAS SAFE ID card and have a registration number These details should be recorded in the Benchmark logbook section within the installation booklet You can check your installers details by calling GAS SAFE direct on 08004085500 Failure to install and commission the appliance in accordance with the manufacturers instructions may invalidate the warranty This does not affect your statu
44. etector 20000713 619 Pressure 20003181 Table 3 28 SE R2204 R10023603 20002906 20035019 R10023948 R10023946 R10023947 R2226 R5026 R2258 R2223 R2165 R10022726 R10027352 Expansion vessel Pipe Air vent bottle Heat exchanger Pipe NTC sensor Pump Pipe Washer Washer High limit Clip Washer POS DESCRIPTION Clip 12 201 287 289 290 299 520 30 Table 4 28 SE 0023904 0023902 0023901 0025985 0023996 20035533 R10020838 R10020897 R10023928 20005586 R5023 R R R R R Main burner injector manifold Burner Spark ignition electrode Gas pipe Gas valve solenoid Air box bottom 3 4 gas cock Cover assembly Hole cover Gas valve Washer POS DESCRIPTION 31 Table 5 25 POS DESCRIPTION 28 SE 2 Back insulatin panel R10023909 3 Combustion chamber insulation panel R2231 4 Combustion chamber insulation panel R10023910 10 Fan R10023907 11 Pressure tube R10024191 12 Fan connection R10021972 20 Fumes testing connection pipe R10021973 22 Flue flange O 43 20020311 22 Flue flange O 45 20020309 22 Flue flange O 47 20020310 25 Pressure switch R10023908 27 Nut screw R10020625 28 Clip R10020626 32 SECTION 10 LPG INSTRUCTIONS 10 1 RELATED DOCUMENTS BS 5440 PAR
45. flue applications This expansion vessel safety valve pressure gauge and automatic appliance is designed for use with a sealed system only by pass consequently they are not intended for use on open vented The Compact 28 SE is produced as room a sealed category Systems 112H3 appliance suitable for internal wall mounting applications This booklet is an integral part of the appliance It is therefore only Each appliance is provided with a fan powered flue outlet necessary to ensure that the booklet is handed to the person with an annular co axial combustion air intake that can be responsible for the property in which the appliance is located rotated horizontally through 360 degrees for various installed A replacement copy can be obtained from Vokera customer services General layout 11 1 Drain valve 2 Safety valve 19 3 Pressure switch 4 Pump 10 5 Bottom auto air vent AAV 13 6 Spark Electrode Sensing Electrode ith 7 Burner 9 jji III 8 High limit thermostat 9 Flow thermistor NTC 8 E 10 Air pressure switch 11 Flue outlet amp air intake 12 Pressure tube negative 15 13 Fan 14 Main heat exchanger Aj AAP I 12 Tis o 9 IL rca 16 Ignition transformer 6 Mao 17 Domestic hot water sensor YE 18 DHW flow switch C a A 19 Gas valve D SIR y I T JHH ARES NA j M R Heating return connection A Lee F Heating flow connection B Iya
46. he Domestic Water Treatment Association s DWTA code of practice 3 11 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 control valve control valve E temporary connection flow return double A pipe check valve eae Fig 8 pipe Make up vessel or tank Automatic E air vent E N D Non return Stopcock KO valve z LO Heating return Fig 9 SECTION 3A GENERAL REQUIREMENTS EIRE This appliance must be installed by a competent person in accordance with and defined by the Standard Specification Domestic Gas Installations Declaration 1 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 ETC National Rules for Electrical Installations and l S 813 Annex K When an appliance is installed in a room or internal space containing a bath or shower the applianc
47. he jumper JP2 to store the heating maximum value remove the jumper JP1 to store the heating minimum value and to get out the calibration procedure reconnect the compensation inlet to the air distribution box Disconnect the pressure gauge and retighten the pressure test point screw To finish the calibration function without storing the set values proceed as follows a set the mode selector to position OFF b remove power supply voltage The calibration function is automatically finished without storing minimum and maximum values after 15 minutes of its activation The function is automatically finished also in case of definitive stop or lockout Also in this case function conclusion DOES NOT provide values storing Note To calibrate only maximum heating it is possible to remove the jumper JP2 to store the maximum and then get out from the function without storing the minimum setting the mode selector to OFF or removing the voltage from the boiler After each intervention on the adjustment element of the gas valve seal it with sealing varnish When adjustment is complete restore set temperature with the ambient thermostat to the desired temperature set the heating water temperature selector to the desired position Close the instrument panel pull the shell back in place MULTIGASTABLE Methane gas G20 Maximum pressure downstream CH valve mbar 9 7
48. he spark plug cable connection slide off the lower cable grommet from the seat of the air distribution box remove the burner fixing screws and remove burner with the spark plug attached and corresponding cables using a socket or spanner remove the injectors and the washers and replace them with the ones in the kit Use and assemble the washers contained in the kit also in case of manifolds without washers reinsert the burner in the combustion chamber and tighten the screws fixing it to the gas manifold place the cable grommet with the spark plug cable in its seat in the air distribution box restore connection of the spark plug cable refit the combustion chamber cover and the cover of the air distribution box overturn the control instrument panel towards the boiler front part open the card cover on the control card if the conversion is from methane gas to LPG insert the jumper in position JP3 if the conversion is from LPG to methane gas remove the jumper from position JP3 reposition the components previously removed restore voltage to the boiler and reopen the gas tap with boiler in operation check correct seal of the gas feeding circuit Connections Conversion must be carried out by qualified personnel After conversion adjust the boiler again following the indications in specific section and apply the new identification label contained in the kit 33 GAS BOILER SYSTEM COMMISSIONING C
49. her than infinity there is a fault that must be isolated carry out a detailed continuity check to identify the location of the fault These series of checks must be carried out before attempting any faultfinding procedures on the appliance On completion of any task that required the disconnection and re connection of any electrical wiring or component these checks must be repeated 7 8 FAULT FINDING Before attempting any faultfinding the electrical checks as detailed in 7 7 must be carried out Isolate the appliance from the electrical supply Disconnect any external controls from terminal plug CN5 fig 39 and insert a link wire between the two wires at the TA connections NOTE 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 Should the boiler fail to respond the internal fuses and connectors should be checked to ensure integrity and continuity 7 9 COMPONENT VALUES amp CHARACTERISTICS COMPONENT VALUE Fan 230Vac Pump 230Vac Ignition transformer 230Vac Gas valve 230Vac Room thermostat connection 24Vdc NTC thermistor dry contact 10Kohm NTC thermistor wet contact 10Kohm FUNCTION VALUE Standard Heating temperature range min max C 40 80 DHW temperature range min max C 37 60 75 maximum CH time 15 min Heating OFF hys
50. iance will go to lockout When ignition has been established the appliance will quickly achieve and maintain the desired hot water temperature see 5 13 The appliance monitors the setting of the hot water potentiometer against the temperature of the secondary thermistor and increases or decreases current to the modulating coil this in turn adjusts the burner pressure thus enabling the temperature to be maintained to within a few degrees When the temperature of the secondary thermistor exceeds the setting of the hot water potentiometer ignition will be terminated until the temperature drops NOTE The primary thermistor will overide the secondary thermistor if the temperature of the primary thermistor exceeds 80 C When the mode selector switch is set to heating and hot water the pump will over run for 30 seconds after any demand for heating or water has been satisfied When the mode selector switch is set to hot water only the fan will over run for one minute if the temperature of the primary thermistor exceeds 55 C ATTENTION Gas type and appliance output must be set according to the specific appliance specification Vokera accepts no responsibility if the gas type is not correctly adjusted according to the respective appliance specification as detailed on the appliance data badge 7 3 ADJUSTMENTS The boiler has already been adjusted by the manufacturer If it is necessary to adjust it again for example after extraordinar
51. inal is supplied with a built in converter box and cannot be shortened e A 130mm hole is required for the passage of the concentric terminal through the ceiling and or root 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 e 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 e You must ensure that the entire flue system is properly supported and connected Ensure that any horizontal sections of pipe have a 1 to 3 fall towards the appliance to allow any condensate that forms in the flue system to drain via the condensate drain 17mm per 1000mm 19 4 5 4 INSTALLATION OF CONDENSATE DRAIN KIT The condensate drain kit must be fitted within 1 metre of the appliance flue outlet
52. ions 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 9 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 3A 6 8 FREQUENT FILLING Frequent filling or venting of the system may be indicative of a leak Care should be taken during the installation of the appliance to ensure all aspects of the system are capable of withstanding pressures up to at least 3 bar 3A 7 ELECTRICAL SUPPLY The appliance is supplied for operation on 230V 50Hz electrical supply it must be protected with a 3 amp fuse The method of connection to the mains electricity supply must allow for complete isolation from the supply The preferred method is by using a double pole switch with a contact separation of at least 3 5 mm 3 high voltage category The switch must only supply the appliance and its corresponding controls i e time clock room thermostat etc 3A 8 MOUNTING ON A COMBUSTIBLE SURFACE If the appliance is to be fitted on a wall of combustible material a sheet of fireproof material must protect the wall 3A 9 TIMBER FRAMED BUILDINGS If the appliance is to be fitted in a
53. is still visible 4 7 ELECTRICAL CONNECTIONS The boiler is supplied with a 2 metre fly lead This lead can be used for connection to the electrical supply Connect the fly lead to a fused plug or fused isolator in the following way e brown wire to LIVE supply e blue wire to NEUTRAL supply e green yellow to EARTH connection Insert the supplied 3 AMP fuse into the fused isolator or fused plug Should the fly lead be unsuitable refer to 4 7 3 for details on how to connect the electrical supply directly to the boiler The electrical supply must be as specified in section 3 3A A qualified electrician should connect the appliance to the electrical supply 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 appli ance 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 fig 17 To gain internal access to the appliance you must first remove the casing proceed as outlined below e locate and unscrew the 2 screws A that secure the outer casing to the appliance lift the casing upward to disengage it from the top locating hooks and then remove
54. kera co uk www vokera ie Sales General Enquires T 0844 391 0999 F 0844 391 0998 Vokera Ireland West Court Callan Co Kilkenny T 056 7755057 F 056 7755060 Vokera Limited reserve the right to change specification without prior notice Consumers statutory rights are not affected A Riello Group Company Company Reg No 1047779 Cod 20029904 03 11 Ed 0
55. ld 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 4 Check and adjust ifnecessary the system design pressure see 5 10 18 e Carry out an analysis of the flue gases see 7 5 and visually check the condition of the entire flue assembly e Compare the results with the appliance design specification Any deterioration in performance must be identified and rectified without delay e Check that the burner and main heat exchanger 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 REMOVAL PROCEDURE To remove a component access to the interior of the appliance is essential Isolate the appliance from the electrical supply and remove the fuse And when necessary close all service valves on the appliance remove the appliance casing as described in section 4 7 1 and drain the water content from the appliance via the drain valve Ensure some water absorbent cloths are available t
56. lockwise to increase the heating outlet temperature or 4 MS IN NY 2 Y Y NJ counter clockwise to reduce the temperature range NLA 40 C 80 C for standard central heating _ The automatic temperature control function SARA is set within position 4 and 6 AMP 7 IKA 5 Boiler at OFF standby Select this position when you want the boiler to be switched off for short periods days or if the boiler requires to be reset Pressure gauge shows the current pressure of your heating system the gauge should be set between 1 and 1 5 BAR When the appliance is operating the gauge may rise or fall slightly this is quite normal The minimum permissible level for the safe and efficient operation of the appliance is 0 5 BAR Should the pressure fall below 0 5 BAR the boiler may lockout correct pressure value 2 GETTING STARTED 2 1 BEFORE SWITCHING ON Before switching the appliance on please familiarise yourself with how to isolate the appliance from the gas water and elec tricity supplies how to check and top up if necessary the system water pressure the time clock or programmer if fitted any external thermostats and their functions the appliance controls 2 2 APPLIANCE CONTROLS see fig 1 The appliance controls are situated on the lower front of the appliance The appliance controls include pressure gauge appliance mode selector te
57. luding Benchmark Checklist and Service Record has been explained and left with the customer Yes Commi ssioning Engineer s Signature Customer s Signature Toconfirm satisfactory demonstration and receipt of manufacturer s literature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer J encAmar COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls SERVICE 1 Date Energy Efficiency Checklist completed Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE3 Date Energy Efficiency Checklist completed Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE5 Date Energy Efficiency Checklist completed Engineer Name Company Name Teleph
58. lue applications to be considered alternatively the Vokera twin flue system can be utilised if longer flue runs are required 4 5 2 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 60 100mm concentric Uni flue system or the optional Vokera twin flue system Total flue length 60 100 Up to 0 85 metre From 0 85 to 1 7 metre From 1 7 to 2 7 metre From 2 7 to 3 4 metre Restrictor required 43 mm diameter 45 mm diameter 47 mm diameter Not installed NOTE These instructions relate only to the Vokera Uni Flue 60 100m m concentric flue system The appliance flue outlet elbow can be rotated through 360 on its vertical axis In addition the flue may be extended from 12 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 1 metre 60 100 90 bend 1 5 metre 60 100 Horizontal flue terminals and accessories Part No Description Length 2359029 Horizontal flue kit 833 mm dimension X 2359119 Telescopic flue kit 2359069 750 mm extension 750 mm 2359079 1500 mm extension 1500 mm 2359089 Telescopic extension 350 490 mm 23590
59. m of 80 C if standard CH mode is selected 2 5 ADJUSTING THE HOT WATER TEMPERATURE Rotate the temperature selector clockwise to increase counter clockwise to decrease to the desired temperature setting The temperature can be set from a minimum of 37 C to a maximum of 60 C If the temperature at the outlet is still not sufficiently hot enough it may be necessary to reduce the flow of water at the hot water outlet tap NOTE If the appliance fails to ignite during the ignition sequence it will enter a lockout condition Should this occur please allow a period of at least two minutes before re setting the appliance 2 6 EXPLANATION OF FEATURES Although the Vokera Compact SE has been designed for simplicity of use it utilises the latest in boiler technology enabling a host of functions to be carried out simultaneously 2 7 AUTOMATIC TEMPERATURE CONTROL The automatic temperature control function SARA permits the boiler when the heating temperature selector is set within 4 and 6 sector to automatically adjust raise the heating The activation and the disable of the function is visualized by blinking the green led 3 3 HOW TO SHUT DOWN THE SYSTEM FOR SHORT PERIODS The system and boiler can be shut down for short periods by simply turning the time clock to the off position It is also advisable to turn off the main water supply to the house 3 4 HOW TO SHUT DOWN THE SYSTEM FOR LONG PERIODS If the house is to be l
60. mperature selector burner ON mode green fault indicator red servicing mode indicator red yellow optional integral time clock programmer if fitted NOTE The appliance frost protection is active in all the boiler modes Thetemperature selectors can be used to vary the temperature of the water that circulates around your radiators and the water that flows from your hot water taps The temperature range is adjustable between 40 C and 80 C for the central heating and between 37 C and 60 C for the hot water When the status indicator Green is lit it indicates that the flame is present and the burner is ON When the fault indicator Red is lit it indicates that the appliance has identified a possible fault and performed a safety lockout Theintegral time clock when fitted can be used to switch the heating on and off at pre determined intervals 3 HOWTO 3 1 HOW TO TOP UP THE SYSTEM PRESSURE fig 1 2 The system pressure must be checked periodically to ensure the correct operation of the boiler The needle on the gauge should be reading between 1 and 1 5 BAR when the boiler is in an off position and has cooled to room temperature If the pressure requires topping up use the following instructions as a guide Locate the filling valve connections usually beneath the boiler see fig 2 Attach the filling loop to both connections Open the filling valve slowly until you hear water ente
61. n NOTE It is the installer s responsibility to ensure that the appliance is properly Earthed Vokera Ltd cannot be held responsible for any damages or injuries caused as a result of incorrect Earth wiring Fig 17 Fig 18 SECTION 5 COMMISSIONING 5 1 GAS SUPPLY INSTALLATION Inspect the entire installation including the gas meter test for tightness and purge Refer to BS 6891 I S 813 in ROI for specific instruction 5 2 THE HEATING SYSTEM The appliance contains components that may become damaged or rendered inoperable by oils and or debris that are residual from the installation of the system consequently it is essential that the system be flushed in accordance with the following instructions 5 3 INITIAL FILLING OF THE SYSTEM Ensure both flow and return service valves are open remove appliance casing as described in 4 7 1 identify the automatic air release valves AAV and loosen the dust cap s by turning the cap anti clockwise one full turn Ensure all manual air release valves located on the heating system are closed Connect the filling loop as shown in fig 5 slowly proceed to fill the system by firstly opening the inlet valve connected to the flow pipe and then turning the lever on the fill valve to the open position 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 rele
62. nt System By setting the heating water temperature selector to the area marked by AUTO temperature value from 55 to 65 C the S A R A self adjusting system is activated the boiler varies the delivery temperature according to the closing signal of the ambient thermostat When the temperature set with the heating water temperature selector is reached a 20 minutes count begins If during this period the ambient thermostat still requests heat the value of the set tempera ture automatically increases by 5 C When the new value is reached other 20 minutes count begins If during this period the ambient thermostat still requests heat the value of the set temperature automatically increases by 5 C This new temperature value is the result of the temperature set manually with the heating water temperature selector and the increase of 10 C of the S A R A function After the second increasing cycle the temperature value is restored to the value set by the user and the above mentioned cycle is repeated until the ambient thermostat request is fulfilled 24 Fixed green if there is flame the boiler works regularly Red led The red led indicates a boiler lockout due to the following faults Fixed flame lockout air pressure switch intervention after transient phase NTC heating probe ACF electronic fault alarms Flashing limit thermostat intervention To reset operation place the mode selector on OFF stand by
63. ntil the pressure gauge reads the value indicated in table reconnect the modulator electrical connection close the domestic hot water tap carefully refit the protection cap of the adjustment screws 7 3 2 Minimum and maximum heating electric adjustment The electric adjustment function is activated and deactivated exclusively by the jumper JP1 The function can be enabled in the following way by powering the card with the jumper JP1 inserted and the mode selector in winter position independently from the possible presence of other operation request by inserting the jumper JP1 with the mode selector in winter position without heat request in progress By activating the function the burner is ignited through simulation of heat request in heating To perform calibration operations proceed as follow switch off the boiler remove the shell and access the card insert the jumper JP1 to enable the knobs placed on the control panel to the minimum and maximum heating adjustment functions make sure that the mode selector is in winter position power the boiler N Electric card in voltage 230 Volt turn the heating water temperature adjustment knob B until it reaches the heating minimum value as indicated in the multigas table insert the jumper JP2 turn the domestic hot water temperature adjustment knob C until it reaches the heating maximum value as indicated in the multigas table remove t
64. o catch any residual water that may drip from the appliance or removed component Under take a complete commissioning check as detailed in section 5 after replacing any component ALWAYS TEST FOR GAS TIGHTNESS IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED OR DISTURBED 6 4 1 AIR BOX FRONT COVER REMOVAL fig 20 Locate the 4 screws and remove air box front cover 6 5 PUMP ASSEMBLY fig 21 Carry out component removal procedure as described in 6 4 Disconnect and remove the pump outlet pipe A from the pump assembly combustion chamber connection Remove the expansion pipe locking pin from the top of the pump assembly and withdraw the flexible pipe Locate and remove the pressure gauge securing pin and disconnect the pressure gauge from the pump assembly Disconnect the electrical wiring from the pump s electrical connection point Locate and remove the 2 securing screws E at the rear of the pump assembly Remove locking pin F from pump base and lift pump assembly clear of the hydraulic manifold The pump assembly can now be removed from the appliance Replace carefully in the reverse order 6 6 SAFETY VALVE fig 22 Carry out component removal procedure as described in 6 4 Disconnect the outlet pipe from the safety valve remove safety valve locking pin H from the hydraulic manifold Replace in the reverse order 6 7 LOWER AUTOMATIC AIR RELEASE VALVE fig 21 Carry out component removal procedure as described in 6 4
65. ometer against the temperature of the primary thermistor and increases or decreases current to the modulating coil this in turn adjusts the burner pressure thus enabling the temperature to be maintained to within a few degrees see section 5 10 When the temperature of the primary thermistor exceeds the setting of the heating potentiometer ignition will be terminated and the appliance will anti cycle for three minutes timer delay When a new ignition sequence begins the output of the appliance is set at minimum for two minutes NOTE Any demand for hot water has the priority If there is a demand for hot water whilst the appliance is anti cycling the timing will be cancelled once the demand for hot water has been satisfied 22 7 2 4 HOT WATER MODE Opening a hot water outlet and enabling a flow rate of 2 litres or more causes the domestic water flow switch to activate Activation of the domestic hot water flow switch allows the fan to run When the fan is running it proves switches the air pressure switch The air pressure switch delivers current to the PCB and enables an ignition sequence to begin The ignition sequence begins with the energising of the gas valve and a simultaneous sparking at the spark sense electrode This will continue for aproximately 10 seconds or until successful ignition has been established If no ignition has been established within the ten seconds the ignition attempt will be terminated and the appl
66. on 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 3 GAS SUPPLY The gas meter as supplied by the gas supplier must be checked to ensure that it is of adequate size to deal with the maximum rated input of all the appliances that it serves Installation pipes must be fitted in accordance with BS 6891 Pipe work from the meter to the appliance must be of adequate size Pipes of a smaller size than the appliance gas inlet connection must not be used The installation must be tested for tightness in accordance with BS6891 If the gas supply serves more than one appliance it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time 3 4 FLUE SYSTEM The terminal should be located where the dispersal of combustion p
67. one Number CORGI ID Number Comments Signature SERVICE7 Date Energy Efficiency Checklist completed Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE9 Date Energy Efficiency Checklist completed Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature Yes Yes Yes Yes Yes Nol Nol Nol Nol Nol SERVICE 2 Date Energy Efficiency Checklist completed Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE4 Date Energy Efficiency Checklist completed Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE6 Date Energy Efficiency Checklist completed Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE 8 Date Energy Efficiency Checklist completed Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE 10 Date Energy Efficiency Checklist completed Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature Yes Yes Yes Yes Yes No L No L No L No L No L 37 Vokera heating for life Registered address Vokera Ltd Borderlake House Unit 7 Riverside Industrial Estate London Colney Herts AL2 1HG enquiries vokera co uk www vo
68. ons Page 3 9 Timber framed buildings 10 10 1 Related documents 33 3 10 Inhibitors 10 10 2 Technical data 33 3 11 Showers 10 10 3 Converting the appliance gas type 33 10 4 Gas supply 33 10 5 Gas supply installation 33 e dee RE rage 10 6 Checking the CO and adjusting the gas valve 33 3A 2 Location of appliance 10 3A 3 Gas supply 10 Benchmark 35 36 3A 4 Flue system 10 USERS INSTRUCTIONS INTRODUCTION Dear Customer Your Vokera Compact SE boiler has been designed to meet and exceed the very latest standards in gas central heating technology and if cared for will give years of reliable use and efficiency Please therefore take some time to read these instructions carefully Do s and Don t s Do ensure that the system pressure is periodically checked Do ensure that the boiler should not be used by children or unassisted disabled people Do ensure that you know how to isolate the appliance in an emergency Do ensure that you are familiar with the appliance controls Do ensure that your installer has completed the appliance log book section Do not attempt to remove the appliance casing or gain internal access Do not hang clothes etc over the appliance Do not forget to have the appliance serviced annually This booklet is an integral part of the appliance It is therefore necessary to ensure that the booklet is handed to the person responsible for the property in which the appliance is located installed A replacem
69. or less below plastic guttering or 1 metre or less below painted eaves 3 5 AIR SUPPLY The following notes are intended for general guidance only This appliance is a room sealed fan flued boiler consequently it does not require a permanent air vent for combustion air supply When installed in a cupboard or compartment ventilation for cooling purposes is also not required 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 BS 5440 PART 1 FLUES BS 5440 PART 2 FLUES amp VENTILATION BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW BS 6891 LOW PRESSURE INSTALLATION PIPES BS 7074 PART 1 APPLICATION SELECTION AND INSTALLTION OF EXPANSION VESSELS AND ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS installation of the appliance in a room or internal space containing a bath or shower 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 provisi
70. place in the reverse order Ensure all seals are in good condition taking care to ensure they are replaced correctly 6 15 2 DHW FLOW SWITCH fig 30 Carry out component removal procedure as described in 6 4 Remove the locking pin Disconnect and remove the cold water inlet pipe from the DHW flow switch 4 DHW heat exchanger Disconnect the wiring to the DHW flow switch Slacken and unscrew the inlet connection Unscrew the nut E2 Lift the DHW flow switch housing from its seating If necessary remove the locking pin F2 from the DHW flow switch 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 6 15 4 DHW THERMISTOR fig 31 Carry out component removal procedure as described in 6 4 Locate and disconnect the electrical plugs from the DHW thermistor Gently ease the thermistor assembly J2 from the DHW outlet pipe Replace in the reverse order Fig 28 A a a x e SO R gt gt C2 Fig 30 Fig 31 21 SECTION 7 CHECKS
71. pressure drop below the rated tolerance e air pressure switch to ensure safe operation of the burner e ahigh limit thermostat that over rides the temperature control circuit to prevent or interrupt the operation of the burner e flame sensor that will shut down the burner when no flame signal is detected e a safety valve which releases excess pressure from the primary circuit j Heat Primary exchanger thermistor es 2 2 Q C O O O O Expansion vessel Secondary thermistor Bottom AAV e Pressure Pump switch Ll Safety AM valve E T DHW flow switch Automatic by pass Drain valve CH CH DHW DHW return flow outlet inlet Fig 5 SECTION 2 TECHNICAL DATA 2 1 Central Heating Compact 28 SE Heat input kW 30 20 Maximum heat output kW 60 80 C 28 24 Minimum working pressure 0 25 0 45 bar Maximum working pressure 3 bar Minimum flow rate 350 l h 2 2 Domestic Hot Water Compact 28 SE Heat input kW 30 20 Flow Rate AT35 C 11 6 l min Maximum inlet pressure 6 bar Minimum inlet pressure 0 15 bar Minimum flow rate 2 l min 2 3 Gas Pressure
72. pressures up to at least 3 bar 3 7 ELECTRICAL SUPPLY The appliance is supplied for operation on 230V 50Hz electrical supply it must be protected with a 3 amp fuse The method of connection to the mains electricity supply must allow for complete isolation from the supply The preferred method is by using a double pole switch with a contact separation of at least 3 5mm 8 high voltage category The switch must only supply the appliance and its corresponding controls i e time clock room thermostat etc Alternatively an un switched shuttered socket with a fused 3 pin plug both complying with BS 1363 is acceptable 3 8 MOUNTING ON A COMBUSTIBLE SURFACE If the appliance is to be fitted on a wall of combustible material a sheet of fireproof material must protect the wall 3 9 TIMBER FRAMED BUILDINGS If the appliance is to be fitted in a timber framed building it shouldbe fitted in accordance with the Institute of Gas Engineers publication IGE UP 7 Guide for Gas Installations in Timber Frame Buildings 3 10 INHIBITORS Vokera recommend that an inhibitor suitable for use with 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 Water treatment of the complete heating system including the boiler should be carried out in accordance with BS 7593 and t
73. rcuit board 19 Installation and Servicing instructions 6 12 Gas valve 20 Design principles 4 operating sequence Page 6 13 Electrodes 20 1 Principle components 6 6 14 Flue fan 20 1 2 Mode of operation at rest 6 6 15 Burner 20 1 3 Mode of operation heating 6 6 16 Main heat exchanger 21 1 4 Mode of operation Hot water 6 6 17 Automatic by pass 21 1 5 Safety devices 6 6 18 Expansion vessel removal 21 24 Central Festina cage Checks adjustments and fault finding Page 25 Domestic hot water 7 7 1 Checking appliance operation 23 2 3 Gas pressures 7 7 2 Appliance modes of operation 23 2 4 Expansion vessel 7 7 3 Checking the CO amp adjusting the valve 23 55 Dimensions 7 7 4 Combustion analysis test 24 26 Clearances 7 7 5 Checking the expansion vessel 24 57 Connections 7 7 6 External faults 24 2 8 Electrical 7 ql Electrical checks 24 2 9 Flue details concentric 7 7 8 Fault finding _ 25 2 9A Flue details twin pipes 7 7 9 Component values amp characteristics 25 2 9B Flue details 80 125 7 210 Efficiency 7 Wiring diagrams Page 211 Emissions 7 8 1 External wiring 26 2 12 Pump duty 8 8 2 Typical control applications 26 8 3 Other devices 26 General requirements UK Page 3 1 Related documents 39 Exploded diagrams Page 3 2 Location of appliance 9 9 1 Table 1 28 33 Gas supply 9 9 2 Table 2 29 3 4 Flue system 9 93 Table 3 30 3 6 Water circulation 9 9 5 Tables 32 3 7 Electrical supply 10 3 8 Mounting on a combustible surface 10 L P G instructi
74. ring the system Close the filling valve when the pressure gauge on the boiler reads between 1 and 1 5 BAR see fig 1 Remove the filling loop from the connections 3 2 HOW TO RESET THE APPLIANCE When the red fault LED is illuminated the appliance will require to be reset manually Before resetting the boiler check what action is required to be taken using the information on the fault code table below Allow a period of two minutes to elapse before rotate the mode selector knob across the bd position see fig 1 IMPORTANT If the appliance requires to be reset frequently it may be indicative of a fault please contact your installer or Vokera Customer Services for further advice 2 3 LIGHTING THE BOILER Ensure the gas and electrical supply to the boiler are turned on Turn the mode selector switch to the ON position When there is a request for heating or hot water via the time clock or programmer the boiler will begin an ignition sequence When the appliance reaches the CH set temperature the burner will go off for a minimum period of approximately 3 minutes When the programmer time clock or external thermostats heating request has been satisfied the appliance will switch off automatically 2 4 ADJUSTING THE HEATING TEMPERATURE Rotate the temperature selector clockwise to increase counter clockwise to decrease to the desired temperature setting The temperature can be set from a minimum of 40 C to a maximu
75. roducts is not impeded and with due regard for the damage and discoloration that may occur to building products located nearby The terminal must not be located in a place where it is likely to cause a nuisance see fig 7 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 pipes should have a gradient to ensure air is carried naturally to air release points and that water flows naturally to drain cocks Except where providing useful heat pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing Particular attention should be paid to pipes passing through ventilated areas such as under floors loft space and void areas 3 6 2 AUTOMATIC BY PASS The appliance has a built in automatic by pass consequently there is no requirement for an external by pass however the design of the system should be such that it prevents boiler cycling 3 6 3 DRAIN COCKS These must be located in accessible positions to facilitate draining of the appliance and all water pipes connected to the appliance The drain cocks must be manufactured in accordance with BS 2879 3 6 4 AIR RELEASE POINTS These must be positioned at the highest points in the system where air is likely to be trapped They should be used to expel trapped air and allow complete filling of the system 3
76. rogrammable room thermostats fig 40 e programmable RF room thermostats fig 39 e low voltage 24Vdc room thermostat CN5 fig 39 8 3 OTHER DEVICES 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 HC5 HC6 www energyefficiency gov uk 8 4 VOKERA LOWER COVER MECHANICAL CLOCK fig 3 The Vokera lower cover mechanical clock kit product code 20025081 is entirely suitable for the Compact 24SE and eliminates the need for an external time control The kit is comprised of the following e lower cover e mechanical clock e wiring harness e instructions Isolate the appliance from the electrical supply remove the boiler casing se 4 7 1 and locate the terminal block cover see 4 7 2 Connect the spade connections of the wiring harness to the terminal block identify the 2 black wiring black color or black cable indication and connect to the room thermostat terminal block CN5 see fig 39 identify the blue and brown wiring blue brown color or blue brown cable indication and connect to the M3 terminal block see fig 39 Refit the appliance terminal block and the boiler casing Fit the cover kit to the boiler IMPORTANT The boiler must always be supplied with a permanent 230V electric
77. rs and check that any seals are located properly You mustensurethatthe entire flue systemis properly supported and connected 4 5 3 TWIN FLUE SYSTEM The Vokera twin flue system enables greater flue distances to be achieved 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 Total flue length 80 Up to 3 3 metre From 3 3 to 7 7 metre From 7 7 to 11 11 metre From 11 11 to 14 14 metre Restrictor required 43 mm diameter 45 mm diameter 47 mm diameter Not installed GUIDANCE NOTES ON TWIN FLUE INSTALLATION e The flue must have a fall back of 1 back to the appliance to allow any condensate that forms 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 e Ensure that the entire flue system is adequately supported use at least one bracket for each extension e Extreme care must be taken to ensure that no debris is allowed to enter the flue system at any time e Asthe exhaust outlet pipe can reach very high temperatures it must be protected to prevent persons touching the hot surface Reduction for bends
78. s Compact 28 SE Inlet pressure G20 20 0 mbar Maximum burner pressure mbar 9 7 Minimum burner pressure mbar 1 9 Heating maximum gas rate m3 hr 3 19 Minimum gas rate m3 hr 1 34 Injector size mm 1 35 2 4 Expansion Vessel Compact 28 SE Capacity 8 litres Maximum system volume 74 litres Pre charge pressure 1 bar 2 5 Dimensions Compact 28 SE Height mm 780 Width mm 450 Depth mm 328 Dry weight kg 41 2 6 Clearances Compact 28 SE Sides 12mm Top 150mm from casing or 25mm above flue elbow whichever is applicable Bottom 150mm Front 500mm 2 7 Connections Compact 28 SE Flow amp return 22mm Gas 22mm DHW hot amp cold 15mm Safety valve 15mm 2 8 Electrical Compact 28 SE Power consumption Watts 125W Voltage V Hz 230 50 Internal fuse 3 15A T for PCB 3 15A F for connections block External fuse 3A 2 9 Flue Details concentric Compact 28 SE Maximum horizontal flue length 60 100mm 3 40m Maximum vertical flue length 60 100mm 4 40m 2 9A Flue Details twin pipes Compact 28 SE Maximum horizontal flue length 80mm 80mm 14m 14m Maximum vertical flue length 80mm 80mm 14m 14m 2 10 Efficiency Compact 28 SE SEDBUK 81 38 2 11 Emissions Compact 28 SE CO maximum output 6 9 CO minimum output 2 7 CO maximum output ppm 90 CO minimum output ppm 160 NOx rating class 3 2 12 PUMP DUTY Fig 6 shows the flow rate available after allowing for pressure loss through the appliance
79. tain damage 5 8 FINAL FLUSHING OF THE HEATING SYSTEM The system shall be flushed in accordance with BS 7593 I S 813 ROI Should a cleanser be used it must be suitable for copper heat exchangers It shall be from a reputable manufacturer and shall be administered in strict accordance with the manufacturers instructions and the DWTA code of practice NOTE Chemicals used to cleanse the system and or inhibit corrosion must be pH neutral i e they should ensure that the level of the pH in the system water remains neutral Premature failure of certain components can occur if the level of pH in the system water is out with normal levels 5 8 1 INHIBITORS See Section 3 General Requirements 5 9 SETTING THE FLOW OUTLET TEMPERA TURE The flow outlet temperature can be adjusted between 40 C 80 C for standard CH system by using the Heating thermostat knob see fig 1 5 9 1 SETTING THE DHW OUTLET TEMPERATURE The DHW outlet temperature can be adjusted between 37 C 60 C via the DHW thermostat knob see fig 1 5 10 SETTING THE SYSTEM DESIGN PRESSURE The design pressure should be a minimum of 0 5 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
80. terisis C SP 5 Heating ON hysterisis C SP 5 DHW OFF hysterisis C SP 5 DHW ON hysterisis C SP 4 Anti cycle delay 3 min Pump over run 30 sec Low output min output 96 Min 25 CO function max temp C 90 CO re light temp C 78 CO function time 15 min Flow NTC max temp C 90 High limit thermostat C 105 Maximum differential C 35 IGNITION CONTROL VALUE Ignition attempts before L O lockout 1 Re ignition attempts after loss of flame signal 1 APPLIANCE STATUS LED AND FAULT CODES When the boiler detects a temporary fault condition the appropriate led indication is shown If when the fault is final the pump will perform a 60 second post circulation and red LED will be illuminated See table on page 4 25 SECTION 8 WIRING DIAGRAMS 8 1 EXTERNAL WIRING To allow basic operation of the boiler via the mode selector switch a link must be fitted across the CN5 terminals on the PCB 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 0844 391 0999 8 1 1 EXTERNAL WIRING LIMITATIONS Any external wiring must remain within the limits as detailed room thermostat 30 metres 8 2 TYPICAL CONTROL APPLICATIONS The appliance can be used with the following controls e single channel voltage free time clocks fig 39 e p
81. th BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record GR lr R dtm Burner Operating Pressure if applicable ma OR GasiniPressuwel o mba Central Heating Flow Temperature Central Heating Return Temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes has a water scale reducer been fitted Yes No What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate Ll mh oR HE bw Burner Operating Pressure at maximum rate mbar__OR Gas Inlet Pressure at maximum rate L mbar Cold Water Inlet Temperature C Hot water has been checked at all outlets Yes Temperature C Water Flow Rate l min CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 Yes ALL INSTALLATIONS If required by the manufacturer record the following CO OR CO ppm OR CO CO Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature inc
82. to the dedicated concentric flue kit for termination e The horizontal terminal is supplied with a built in converter box and cannot be shortened e A 130mm hole is required for the passage of the concentric terminal through the wall e 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 level 130mm hole for the passage of the horizontal flue terminal 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 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 VERTICAL TERMINATION fig 15 The twin flue system must be converted to the dedicated concentric flue kit for termination e The vertical term
83. tory rights 1 5 HOW DOES IT WORK Your Compact SE boiler supplies heated water to your radiators and hot water to your hot water taps The central heating is controlled via a time clock and any thermostats that your installer may have fitted The boiler will light when it receives a request from the time clock via any thermostat that may be installed or whenever a hot water outlet tap is opened Your Compact SE boiler lights electronically and does not have a pilot light In the unlikely event of a fault developing with your boiler the supply of gas to the burner will be terminated automatically 1 6 DIMENSIONS Compact 24 SE HEIGHT 715 mm WIDTH 405 mm DEPTH 248 mm 1 7 CLEARANCES REQUIRED ABOVE 150 mm BELOW 150 mm LEFT SIDE 12 mm RIGHT SIDE 12 mm FRONT 600 mm 1 8 FROST PROTECTION SYSTEM The Compact SE is equipped with a built in frost protection system this enables the boiler to over ride the time controls even if switched off and operate the burner and or pump should the temperature drop below 5 C for the main and for the DHW line In particular the burner will be in ON status until the main temperature reaches 35 C for CH appliance and 55 C for DHW appliance Please note that the frost protection system is designed to protect the appliance only should frost protection be required for the heating system additional controls may be required NOTE The frost prot
84. ved 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 tem perature 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 Hot water When there is a request for DHW via a hot water outlet or tap the fan is started the air pressure switch will give the signal voltage to the control PCB At this point an ignition sequence is enabled Ignition is sensed by the electronic circuit 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 set point 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 e a water pressure switch that monitors system water pressure and will de activate the pump fan and burner should the system water
85. y maintenance after replacement of gas valve or after gas conversion carry out the following procedure The maximum output adjustment must be carried out in the sequence indicated exclusively by qualified personnel remove the shell unscrewing the fixing screws A unscrew by two turns the screw of the pressure test point downstream the gas valve and connecting the pressure gauge disconnect the compensation inlet of the air distribution box 7 3 1 Maximum power and minimum domestic hot water adjustment Fully open the hot water tap on the control panel set the mode selector to summer turn the domestic hot water temperature selector to its maximum power the boiler setting the system main switch to ON check that the pressure on the pressure gauge is stable or with a multimeter in series to the modulator make sure that the modulator supplies the maximum available current 120 mA for G20 and 165 mA for LPG carefully prise out the protection cap of the adjustment screws using a screwdriver witha 10mm spanner use the adjustment nut of the maximum output in order to obtain the value indicated in table disconnect the modulator electrical connection wait until the pressure on the pressure gauge is stable at minimum value paying attention not to press the internal shaft with a Phillips screwdriver turn the red adjustment screw to regulate the domestic hot water minimum temperature and calibrate u

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