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2. COMPONENT VALUE Fan 230Vac Pump 230Vac Valve actuator 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 hysterisis 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 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 Flue NTC max temp C 125 Maximum differential C 35 IGNITION CONTROL VALUE Ignition attempts before L O lockout 5 Re ignition attempts after loss of flame signal 5 APPLIANCE STATUS AND FAULT CODES When the boiler detects a temporary fault condition the ap propriate code is shown when the fault is final the pump will perform a 60 second post circulation and fault code will be displayed See table on page 4 27 7 10 ADJUSTMENTS The boiler has already been adjusted by the manufacturer during production If the adjustments need to be made again for example after extraordinary maintenance replacement of the gas v
3. Engineer Name Service 8 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 9 Date Engineer Name Service 10 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature COMMISSIONING CO AND COMBUSTION RATIO CHECK BEFORE CO AND COMBUSTION RATIO CHECK NOTE The boiler installation instructions should have been followed gas type verified and gas supply pressure rate checked as S E required prior to commissioning must not be adjusted during commissioning As part of the installation process ESPECIALLY WHERE A FLUE unless this action is recommended following HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER contact with Vokera technical If any such INSTALLER visually check the EE of the whole flue system to confirm tt at al The air gas ratio valve is factory set and adjustment is recommended and further SET BOILER TO MAXIMUM RATE In accordance with section 7 3 7 4 set boiler to operate at maximum rate full load condition Allow sufficient time for combustion to stabilise CHECK CO AND COMBUSTION RATIO AT MAXIMUM RATE With boiler st
4. 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 the 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 amp faultfinding 5 7 CHECKING GAS PRESSURE AND COMBUS TION ANALYSIS The appliance is factory set so should require 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 and carry out a combustion analysis check in accordance with BS 7967 UK to ensure that correct combustion is occurring see flow chart on page 37 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 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
5. 5 3 1 MANUAL AIR RELEASE fig 27 When the boiler has been filled for the first time or the system has been drained and refilled it will be necessary to release any air that may have become trapped within the appliance heat exchanger Slacken the bleed screw until water is released and then close IMPORTANT THERE ARE NO OTHER MANUAL AIR RE LEASE VALVES LOCATED ON THE APPLIANCE Fig 27 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 fol lowing checks must be carried out ensure all gas service valves from the meter to the appliance are open and the supply pipe has been properly purged e ensure the proper electrical checks have been carried out see 7 8 particularly continuity polarity and resistance to earth e ensure the 3 AMP fuse supplied with the appliance has been fitted e ensure the system has been filled vented and the pressure set to 1 BAR e ensure the flue system has been fitted properly and in ac cordance with the instructions
6. Xj tN e o 3 Q LJ L o i 2 at R F G O Fig 5 q Joo E N General layout Domestic hot water heat exchanger Drain valve Three porte valve actuator Safety valve Pump Bottom auto air vent AAV Main heat exchanger Flues thermistor NTC Fan assembly with mixer 10 Silencer 11 Flue gas analysis test point 12 Flue outlet amp air intake Ignition transformer Top AAV De aerator Spark Electrode Sensing Electrode 17 Flow thermistor NTC High limit thermostat 18 Expansion vessel 19 Pressure switch 20 Return thermistor NTC 2 21 Gas valve 22 Domestic hot water sensor 23 Condense trap 24 DHW flow switch Heating return connection Heating flow connection Gas connection Hot water outlet Cold water inlet Toong SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE 1 1 PRINCIPLE COMPONENTS Afully integrated electronic control board featuring electronic temperature control anti cycle control pump over run self diagnostic fault indicator full air gas modulation Aluminium heat exchanger Electronic ignition with flame supervision Integral high head pump Fan Expansion vessel Water pressure switc
7. Depending on plant engineering requirements or regional flue gas emission limits it is however COs a curve Qnheating CO emissions s a p p m Heat output kW possible to modify this value referring to the graphs below HTG curve Qnheating 6400 6000 5600 5200 4800 4400 4000 3600 3200 2800 2400 Fan rotations rpm 2000 1600 1200 Heat output kW Compact 29A The boiler is supplied with the adjustments shown in the table Depending on plant engineering requirements or regional flue gas emission limits it is however COs a curve Qnheating 150 130 CO emissions s a p p m Heat output kW 7 10 1 CHECKING THE FAN SPEED Locate the CO button see Fig 44 pos SW1 Select the main selector switch to the ON position press the CO button once the display will then scroll through the fan speeds along with the relevant icon 7 10 2 THERMOREGULATION To set the temperature regulation curve locate potentiometer P3 By turning P3 the curve is shown on the LCD display The user can adjust the temperature of the heating system indirectly by changing the required room temperature from between 15 C amp 25 C this will allow the PCB to recalculate the system tempera
8. Initial filling of the system 19 2 2 Appliance controls 3 5 4 Initial flushing of the system 19 2 3 Lighting the boiler 3 5 5 Pre operation checks 19 2 4 Adjusting the heating temperature 3 5 6 Initial lighting 19 2 5 Adjusting the hot water temperature 3 5 7 Checking gas pressure amp combustion analysis 19 2 6 Explanation of features 3 5 8 Final flushing of the heating system 19 2 7 Automatic temperature control 3 5 9 Setting the flow outlet temperature 19 5 10 Setting the system design pressure 19 How to Page 5 11 Regulating the central heating system 20 3 1 How to top up the system pressure 4 5 12 _ Final checks 20 3 2 How to reset the appliance 4 5 13 Instructing the user 20 3 3 How to shut down the system for short periods 4 3 4 How to shut down the system for long periods 4 Servicing Page 3 5 How to care for the appliance 4 6 1 General 20 6 2 Routine annual servicing 20 What if Page 6 3 Replacement of components 20 4 1 What if suspect a gas leak 5 6 4 Component removal procedure 21 4 2 What if have frequently top up the system 5 6 5 Bump assembly 21 4 3 What if the appliance is due its annual service 5 6 6 Safety valve 21 4 4 What if need to call an engineer 5 6 7 Lower automatic air release valves 21 6 8 Water pressure switch 21 Setting the Vok ra Page 6 9 Flow thermistor 21 5 1 Setting the Vok ra mechanical clock 6 10 Return thermistor 21 W 6 11 _ Printed circuit board 21 Installation and Servicing instructio
9. adjustment screw Press the combustion analysis button a third time to reach the number of rotations corresponding to the minimum out put table 2 Check the CO2 value table 5 if the value does not match the value given in the table use the gas valve minimum adjustment screw To exit the combustion analysis function turn the control knob Remove the flue gas probe and refit the plug Close the instrument panel and refit the housing The combustion analysis function is automatically deactivat ed if the board triggers an alarm In the event of a fault during the combustion analysis cycle carry out the reset procedure table 1 MAXIMUM NUMBER OF METHANE LIQUID FAN ROTATIONS GAS G20 GAS G31 Compact 25A heating DHW 49 61 49 61 rpm Compact 29A heating DHW 53 62 52 60 rpm table 2 METHANE LIQUID GAS MINIMUM NUMBER OF GAS G20 G31 FAN ROTATIONS 14 14 rpm table 3 METHANE LIQUID GAS SOFT LIGHT FAN SPEED GAS G20 G31 40 40 rpm table 4 METHANE LIQUID GAS Max CO GAS G20 G31 9 0 10 5 table 5 METHANE LIQUID GAS Min CO GAS G20 G31 9 5 10 5 possible to modify this value referring to the graphs below HTG curve Qnheating Fan rotations rpm Heat output kW Compact 25A The boiler is supplied with the adjustments shown in the table
10. 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 ONACOMBUSTIBLE SURFACE If the appliance is to be fitted on a wall of combustible material there is no requirement to protect the wall 3A 9 TIMBER FRAMED BUILDINGS If the appliance is to be fitted in a timber framed building it should be fitted in accordance with LG 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 Vok ra recommend that an inhibitor suitable for use with aluminium 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 1 5 813 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 mus
11. temporary pen is required to be taken using the information on the fault code clean damp connection table below Allow a period of two minutes to elapse before rotate cloth Do not d F the mode selector knob across the position see fig 1 IMPORTANT Spe S If the appliance requires to be reset frequently it may be indica Ge ene A 4 tive of a fault please contact your installer or Vok ra Customer Rate A Services for further advice ES Soe check valve supply pipe Fig 3 FAULT CODES 7 ALARM CODE CAUSE ALARM TYPE ACTION St AUTOSTOP Final Call engineer CL CALL FOR SERVICE Temporary then final Call engineer A01 X lt l Sla flame not sensed Final Reset check appliance operation A02 A Limit thermostat fault Final Reset check appliance operation A03 Q Fan tacho signal fault Final Reset check appliance operation check fan A S Check refill system pressure reset check A04 let A Insufficient system water pressure Final appliance operation AUG A DHW thermistor fault Temporary Check DHW thermistor Primary flow thermistor fault Temporary Check primary thermistor check wiring A07 O Primary flow thermistor over temperature Temporary then final Reset check appliance operation A Reset check appliance operation check Temperature differential Final thermistors Return thermistor fault Temporary Check return thermistor check wiring A08 D Return thermistor over temperature Temporary then final Reset check appliance
12. 6 4 Unclip and remove the air chamber front cover Remove the AAV locking pin K from the deaerator assembly and remove the AAV assembly L Replace in the reverse order 6 8 WATER PRESSURE SWITCH fig 32 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 5 pos 17 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 RETURN THERMISTOR fig 5 pos 20 Carry out component removal procedure as described in 6 4 Unclip the return thermistor from the return inlet pipe Discon nect thermistor electrical plug Replace in the reverse order 6 11 PRINTED CIRCUIT BOARD fig 33 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 tak Fig 29 pO Fig 30 21 ing note of all wiring connections and jumper tag configuration Unhook and remove connection block P Disconnect all wiring from the PCB locate and remove the PCB securing screws remove the required PCB Replace in the reverse o
13. 6 metre 60 100 1 5 metre 80 125 Horizontal flue terminals and accessories Part No Description Length 29450120 Horizontal flue kit 900mm 29450121 Telescopic flue kit 455 630mm 522 Plume management kit 1370mm 29450123 90 degree bend N A 29450124 45 degree bends pair N A 29450125 500mm extension 500mm 29450126 1000mm extension 1000mm 29450127 2000m extension 2000mm 29450128 Telescopic extension 372 519mm 529 Wall bracket pack 5 208mm Using the template provided A mark and drill a 125mm hole for the passage of the flue pipe The hole should be drilled to ensure any condense fluid that forms is allowed to drain back to the appliance see fig 13 The fixing holes for the wall mounting bracket should now be drilled and plugged an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely Once the bracket has been secured to the wall mount the appliance onto the bracket Fig 11 Terminal or Outer clamps x extension Fig 12 FITTING THE TELESCOPIC HORIZONTAL FLUE KIT In some instances It may necessary to cut the inner 60mm pipe of the flue bend at the point indicated fig 13a pos A to allow for easier insertion to the boiler flue spigot FITTING THE HORIZONTAL FLUE KIT Carefully measure the distance from th
14. 7 1 Set the flue gas analyser to read CO and insert the probe into the flue analysis test point Y1 Z1 fig 41 Restore the electrical supply to the boiler and switch the boiler to the OFF mode Have access to the printed circuit board locate and open the closing plug on the dash board L2 fig 44 locate and press the CO button see fig 44 pos SW1 The appliance will now operate in CO mode for approximately 15 minutes CO FUNCTIONS ACTION ON THE BUTTON DISAPLY combustion analysis mode press once burner running at maximum heating ACO ill A gas valve maximun setting press twice burner running at maximum DHW ACO bo A gas valve minimum setting press three time burner running at minimum ACO NT A NOTE 1 Any additional pressing of CO button after the third time the burner switched between maximum DHW and minimum l 2 To restart the CO function it is necessary to pass throught the O position with the main selector switch 33 10 6 2 GAS VALVE MAXIMUM SETTING Set the CO button at maximum see 10 3 1 once the maximum is obtained check that it corresponds with the appropriate CO value Maximum for the respective appliance If the CO read ing is correct proceed to gas valve minimum setting 10 7 2 However if the CO reading is incorrect the maximum gas pressure must be adjusted as follows using a 2 5mm Allen key very slowly turn the maximum ad justment screw see fig 45 _ clo
15. System Fitted H Not Required H Boiler Interlock Provided _ ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used CENTRAL HEATING MODE Measure and Record Gas Rate Burner Operating Pressure if applicable Central Heating Flow Temperature Central Heating Return Temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate Burner Operating Pressure at maxim Cold Water Inlet Temperature 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 ca OR sl lom OR CO CO Raio The heating and hot water system complies with the appropriate Building Regulations Yes H The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes H The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes L The manufacturer s literature including Benchmark Checklist and Service Reco
16. basic operation of the boiler via the mode selector switch If external controls are to be added to the system they must be connected to the appliance as shown in the following diagrams For advice on controls that are not featured in this book please contact Vok ra 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 49 e single channel voltage free time clocks room thermostats fig 50 programmable RF room thermostats fig 49 e low voltage 24Vdc room thermostat CNB fig 49 8 3 OTHER DEVICES Contact the controls manufacturer and or Vok ra technical department should you require more specific information on the suitability of a particular control Further guidance on the recom mended 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 4 The Vok ra lower cover mechanical clock kit product code 20025081 is entirely suitable for the Compact A range and eliminates the need for an external time control The kit is comprised of the following lower cover e mechanical clock wiring harness instructions Isolate the appliance from the electrical supply remove t
17. clockwise to increase V range 37 C 60 C The display shows the temperature values adjustment knob to the symbol activates the pre heating function Bring the domestic hot water temperature adjustment knob back to the required po sition The activation of this function is indicated on display with the P icon ON This function keeps the water in the domestic hot water exchanger hot to reduce standby times when a request is made The display shows the delivery temperature of the heating water or the domestic hot water according to the current request To deactivate the pre heat function rotate the domestic hot water temperature adjustment knob back to the symbol Bring the domestic hot water temperature adjustment knob back to the required position This function cannot be activated when the boiler is OFF function selector to OFF position 5 DHW pre heat function Turning the domestic hot water temperature Heating amp hot water Select this position when you want the boiler to re spond to a heating and hot water request from the time clock programmer Heating temperature selector move the selector clockwise to increase the heating outlet temperature or counter clockwise to reduce the temperature range 40 C 80 C for standard central heating The automatic temperature control function SARA is set within the blank bullet points The display shows the temperature values Wl Boiler at OFF standby Select this posit
18. 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 other 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 CHARACTERIS TICS
19. 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 10 The cold feed from the make up vessel or tank must be fitted with an approved non return valve and stopcock for isolation purposes The feed pipe should be connected to the return pipe as close to the boiler as possible 3 6 8 FREQUENT FILLING Frequent filling or venting of the system may be indicative of a leak Care should be taken during the installation of the appliance to ensure all aspects of the system are capable of withstanding pressures up to at least 3 bar 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 3 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 there is no requirement to protect the wall 3 9 TIMBER FRAMED BUILDINGS If the appliance is to be fitt
20. in 6 4 Remove the locking pin Q1 that secures the cover R1 to the hydraulic manifold Using a hooked piece of wire carefully withdraw the by pass cartridge S1 and or DHW non return cartridge T1 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 6 18 EXPANSION VESSEL REMOVAL fig 39 Carry out component removal procedure as described in 6 4 Disconnect the flexible expansion pipe from the vessel Unscrew the nut that secures the vessel to the lower frame Locate and remove the screw U1 that secures the vessel to the top The expansion vessel can now be removed Replace in the reverse order Ensure all seals are in good condition taking care to ensure they are replaced correctly 6 19 CONDENSE TRAP REMOVAL fig 40 Carry out component removal procedure as described in 6 4 Disconnect the the locking pin V1 that secures the trap to the air condense pipe Disconnect the lower rubber condense pipe from the condense trap Carefully remove the condense trap For cleaning unlock the upper and lower closing plug W1 Replace in the reverse order Fig 37 23 6 20 FLUE COLLECTOR REMOVAL fig 41 Carry out component removal procedure as described in 6 4 Remove the air chamber front cover Remove the heat exchang er as per 6 16 L
21. is obtained check that it corresponds with the appropriate CO value Maximum for the respective appliance see 2 11 If the CO reading is correct proceed to gas valve minimum setting 7 3 3 However if the CO reading is incorrect the maximum gas pressure must be adjusted as follows using a 2 5mm Allen key very slowly turn the maximum ad justment screw see fig 45 clockwise to decrease counter clockwise to increase until the correct value is displayed on the CO analyser allow time for the analyser to stabilise 7 3 3 GAS VALVE MINIMUM SETTING Set the CO button at minimum see 7 3 1 once the minimum is obtained check that it corresponds with the appropriate CO value Minimum for the respective appliance see 2 11 If the CO reading is correct proceed to completion 7 3 4 However if the CO reading is incorrect the minimum gas pressure must be adjusted as follows e locate the minimum adjustment screw fig 45 using a suit able screwdriver remove the protection plug e using a 4mm Allen key very slowly turn the minimum adjust ment screw see fig 45 clockwise to increase counter clockwise to decrease until the correct value is displayed on the CO analyser allow time for the analyser to stabilise 7 3 4 COMPLETION On completion of the combustion analysis check and or any gas valve adjustment refit the plug fig 44 L2 and move the mode selector throught di position Remove the test p
22. operation Temperature differential inverted Final Reset check pump ensure there G suf ficient circulation around heating circuit s Flue thermistor or flue thermistor Check flue thermistor counter at power A09 Q counter fault Temporary on check flue thermistor check wiring Flue thermistor over temperature Final Reset check appliance operation alse flame emporar one A False fl Ti y N ow temperature thermostat fau emporary eck low temperature thermosta A Low ture th tat fault T Check low t ture th tat j alibration a one Adj Calibrat N N ACO Q Service operation Na None Purge cycle mode active Na None P Preheating function active Na None P blinking Preheating function running Na None 6 Flame ON Na None Hours Stand by Na None OFF Na None 4 WHAT IF 4 1 WHAT IF SUSPECT A GAS LEAK If you suspect a gas leak turn off the gas supply at the gas meter and contact your installer or local gas supplier If you require further advice please contact your nearest Vok ra 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 5 SETTING THE VOKERA 5 1 SETTING THE VOKERA MECHANICAL CLOCK If your boiler has been installed with the Vok ra mechan
23. plugged an ap propriate 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 attach the rear flue terminal to the appliance using the previously retained screws and fix the telescopic terminal to the correct length wall thickness en suring that the terminal will protrude through the wall by the correct distance At this point lift the appliance and carefully insert the terminal into and through the wall ensuring that the holes in the appliance back frame are aligned with the studs on the wall bracket iz Fig 15 EXTENDING THE FLUE Connect the bend supplied with the terminal kit to the top of the boiler using clamp supplied see fig 12 The additional bends amp extensions have push fit connections care should be taken to ensure that the correct seal is made when assembling the flue system Connect the required number of flue exten sions or bends up to the maximum equivalent flue length to the flue terminal see fig 12 22 The flue system should have a minimum of 1 maximum of 3 rise from the boiler to outside to ensure any condense fluid that forms is allowed to drain back to the appliance NOTE When cutting an extension to the
24. point If the temperature continues to rise and exceeds the set point by 5 C hysterisis the burner will shut down A new ignition sequence will be enabled when the 3 minute anti cycle has been performed and the temperature at the primary thermistor has dropped 5 C hysterisis below the set point 7 2 4 DHW MODE With the selector switch in either the hot water only or heating amp hot water position the appliance will operate in the hot water mode whenever a DHW outlet is opened A flow rate exceeding 2 litres per minute will activate the DHW flow switch whereupon the pump and fan will be activated via the flow temperature sensor When the fan is sensed to be operating correctly tacho signal the ignition sequence commences Ignition is sensed by the electronic circuitry to ensure flame stability at the burner Once successful ignition has been achieved the electronic circuit allows the gas rate to achieve the modulation value NOTE When the request for heating and or hot water has been satis fied the appliance pump and fan may continue to circulate to dissipate any residual heat within the appliance ATTENTION Gas type and appliance output must be set according to the specific appliance specification Vok ra accepts no responsi bility if the gas type is not correctly adjusted according to the respective appliance specification as detailed on the appliance data badge 7 3 CHECKING THE CO AND ADJUSTING THE GAS VALVE Iso
25. same wall Horizontally from a terminal on the same wall From a structure to the side of the vertical terminal From the top of the vertical terminal to the roof flashing To the side of a boundary To the side of an opening or window on a pitched roof Below an opening or window on a pitched roof From a vertical terminal to an adjacent opening window air brick etc From a vertical terminal to an adjacent vertical terminal Minimum distance 300 mm 300 mm 300 mm 25 mm 25 mm 25 mm 25 mm 60mm for 80 125 5 flue 25 mm 60mm for 80 125 5 flue 300 mm 600 mm 1200 mm 1200 mm 1500 mm 300 mm 300 mm As determined by the fixed collar of the vertical terminal 300 mm 600 mm 2000 mm call Vokera technical for advice 300 mm only if both terminals are the same hight 9 SECTION 3 GENERAL REQUIREMENTS UK This appliance must be installed by a competent person in ac cordance with the Gas Safety Installation amp 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 LEE 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 recomme
26. the appliance Care should be exercised when determining the position of the appliance with respect to hidden obstructions such as pipes cables etc When the position of the appliance has been decided using the template supplied carefully mark the position of the wall mounting bracket see fig 11 and flue hole if applicable 4 5 FITTING THE FLUE The top flue outlet permits both horizontal and vertical flue ap plications to be considered alternatively the Vok ra twin flue system can be utilised if longer flue runs are required 4 5 1 CONCENTRIC HORIZONTAL FLUE For concentric vertical flue see 4 5 2 For twin flue applications see 4 5 3 The appliance can be used with either the Vok ra condensing 60 100mm concentric flue system or the optional 80 125mm concentric flue system NOTE These instructions relate only to the Vok ra condensing 60 100mm concentric flue system For specific details on the installation of the 80 125mm concentric flue system please refer to the instructions supplied The appliance flue outlet elbow can be rotated through 360 on its vertical axis In addition the flue may be extended from the outlet elbow in the horizontal plane see 2 9 Areduction 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 3 metre 60 100 1 0 metre 80 125 90 bend 1
27. the dynamic gas pressure fall below an acceptable level the appliance may malfunction or sustain 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 Aluminium heat exchangers It shall be from a reputable manu facturer 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 t
28. 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 3 metre 60 100 1 0 metre 80 125 90 bend 1 6 metre 60 100 1 5 metre 80 125 Vertical flue terminal and accessories Part No Description Length 29450122 Vertical flue terminal 1000mm 531 Pitched roof flashing plate N A 532 Flat roof flashing plate N A 29450123 90 degree bend N A 29450124 45 degree bends pair N A 29450125 500mm extension 500mm 29450126 1000mm extension 1000mm 29450127 2000mm extension 2000mm 29450128 Telescopic extension 372 519mm 529 Wall bracket pack 5 208mm Using the dimensions given in fig 13 as a reference mark and cut a 125mm hole in the ceiling and or roof 67 5 135 202 5 130 175 RTN FLOW GAS HOT COLD 140 Fig 18 Fit the appropriate flashing plate to the roof and insert the ver tical flue terminal through the flashing plate from the outside ensuring that the collar on the flue terminal fits over the flashing The fixing holes for the wall mounting bracket should now be drilled and p
29. 1000mm 0225835 2 0m extension pair 2000mm 0225840 45 bend pair N A 0225845 90 bend pair N A 0225850 Twin bracket 5 N A 0225855 Single bracket 5 N A 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 ap pliance onto the bracket 15 INSTALLATION OF TWIN ADAPTOR KIT fig 19 amp 20 e Insert the exhaust connection manifold A onto the appliance flue outlet Remove the blanking plate located to the left of the appliance flue outlet and using the same screws install the air inlet plate B Using the hole in the exhaust connection manifold as a guide drill a 3mm hole in the appliance flue spigot and secure the exhaust manifold connection to the flue spigot using the screw provided C 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 B c E amp Y Fig 19 Fig 20 HORIZONTAL TERMINATION fig 21 The twin flue system must be converted to t
30. AFE registered installers carry a GAS SAFE ID card and have a registration number These details should be re corded in the Benchmark commissioning checklist 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 will invalidate the warranty This does not affect your statutory rights 1 5 HOW DOES IT WORK Your Compact A 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 A 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 A 25 29 HEIGHT 715 mm WIDTH 405 mm DEPTH 250 mm 1 7 CLEARANCES REQUIRED ABOVE 150 mm 8 BELOW 150 mm e LEFT SIDE 12mm 2 lt 42 RIGHT SIDE T 12 mm gt ee FRONT 600 mm 1 8 FROST PROTECTION SYSTEM The Compact A is equipped with a built in frost protection system this enables the boiler to over ride the time cont
31. ANSION 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 cor rect 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 Before carrying out any faultfinding or component replacement ensure the faultis not attributable to any aspect of the installation 7 6 1 INSTALLATION FAULTS Symptom Possible cause No ignition Check wiring check electrical supply Check pipe work No hot water No heating Check external controls Fault Possible cause Fault code Check gas supply check flue system check polarity 7 7 ELECTRICAL CHECKS Any electrical checks must be carried out by a suitably quali fied 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
32. Biy uo1auuoo 16710916 104 dys eut EN Jayawonusjod buijeay pue yms 10109192 Ld AVSL osl Jeud3 xg d pajei6ajui wnipauw SIA YM god UIEN IV L 6ND L ji See gt Ws UU GURU RUA EEEREN Eo o E L OLND v L T L dee eee TE HLN afg A mam Al FH FH FH F lt 2 SSE eno 8 o vno la E e SSR 8 S 3 O1TO10110110 HH TAHA ale i F 7 LIND S giel a 3 SgS 3 GEAR 1 118 Ss SHG IS 3 zno Seat eai T 5 Z QL 13 es S G L ZND 9 4 ldi veL gt PS ut E 7 H T HHHH THA HH HH FH TEND A Halla Tad BEIT Ol Ge d o A a a D a 8 L mo WV i S Lf SdM wug SIMHA E E Td G td et e ite ge T 7 EIND IN e LMS ec td 2 S o SND OND BND O d L df ZdfEdf pdr Sdf 9df Zdr IC Pact ae SIS S ano BBBBBBE OZ E W ISSE T T PF y H E auci W Gelz Nergis EE T NC JAYA SYD T C J EW apoipaja a i meds Y E iine 1 NI sped al i S L NOEZ ahia em TISI umoiq d 32 SECTION 9 LPG INSTRUCTIONS 9 1 RELATED DOCUMENTS BS 5440 PARTS 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 9 2 TECHNICAL DATA Gas Pressures Compact 25A C
33. D SERVICING INSTRUCTIONS INTRODUCTION All installers are asked to follow the Benchmark Scheme by adhering to the Code of Practise which can be obtained from www centralheating co uk The Compact A comprises a range of high efficiency combina tion boilers with outputs to DHW of 25kW and 30kW respec tively These appliances by design incorporate electronic ignition circulating pump expansion vessel safety valve pres sure gauge and automatic by pass The Compact A range is produced as room sealed category IIZH3P appliances suitable for internal wall mounting applica tions only Each appliance is provided with a fan powered flue outlet with an annular co axial combustion air intake that can be rotated horizontally through 360 degrees for various horizontal or vertical applications The Compact A can also be used with the Vok ra twin flue system The Compact A is approved for use with C13 amp C33 type flue applications These appliances are designed for use with a sealed system only consequently they are not intended for use on open vented systems 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 replacement copy can be obtained from Vok ra customer services S
34. IES 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 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 per taining 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 com bustion 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 Acompartment used to enclose the appliance must be designed and constructed specifically for this purpose An existing com partment 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 ap
35. NCTION when there has been no heating or HW request for 24 hours the anti block cycle is activated The pump will be activated fora period of 30 seconds ACTUATORANTI BLOCK FUNCTION when there has been no heating or HW request for 24 hours the anti block cycle is activated The divertor valve actuator will motor briefly to the heating position and then back to the DHW position The pump will run briefly e SARA function the SARA function permits the boiler when the set pointis 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 e DHWPRE HEAT FUNCTION when the DHW pre heat func tion is enabled the appliance will light periodically to maintain the temperature of the DHW heat exchanger When the DHW thermistor and the primary thermistor fall below 35 C and 55 C respectively the boiler will fire on minimum 25 power until the primary thermistor exceeds 55 C Thereafter the pump will over run for a period of 30 seconds 7 2 3 HEATING MODE With the selector switch in the heating amp hot water position and any additional controls time clock programmer room thermostat etc calling for heat the appliance will operate in the heating mode The pump and fan will be activated via the flow temperature sensor When the fan is sensed to be operating correctly tacho signal the ignition sequence com mences Ignition is s
36. S PROPERLY SECURED e ENSURE ALL PIPE WORK IS RE CHECKED FOR TIGHT NESS e RE FIT APPLIANCE CASING e COMPLETE BENCHMARK CHECKLIST FOR UK ONLY Complete details of the boiler controls installation and com missioning 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 will 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 Explain to the user that for continued safe and efficient operation the appliance must be serviced annually by acompetent person IMPORTANT To validate the appliance warranty it s necessary to register the appliance details with us The warranty can be registered in sever
37. Vokera heating for life Compact A High efficiency combi boiler Users Instructions Installation amp Servicing Instructions C Compact A 25 G C N 47 364 17 Compact A 29 G C N 47 364 18 THESE INSTRUCTIONS TO BE RETAINED BY USER THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Users instructions Things you should know Page Installation Page 1 1 Gas appliances 1 4 1 Delivery 13 1 2 Electrical supply 1 4 2 Contents 13 1 3 Guarantee registration card 1 4 3 Unpacking 13 1 4 Appliance Log Book UK only 1 4 4 Preparation for mounting the appliance 13 1 5 How does it work 1 4 5 Fitting the flue 13 1 6 Dimensions 1 4 6 Connecting the gas amp water 17 1 7 Clearances required 1 4 7 Electrical connections 18 1 8 Frost protection system 1 1 9 Appliance status indicators 1 Commissioning Page 5 1 Gas supply installation 19 Getting started Page 5 2 The heating system 19 2 1 Before switching ON 3 5 3
38. al is supplied with a built in converter box and cannot be shortened 16 e A130mm hole is required for the passage of the concentric terminal through the ceiling and or roof Depending on site conditions it may be preferable to install the terminal assembly prior to fitting the twin flue pipes Fit the appropriate flashing plate to the roof and insert the ver tical 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 con nection 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 sup ported and connected Ensure that any horizontal sections of pipe have a fall of be tween 1 amp 3 towards the appliance 1 17mm per 1000mm dale eS 1 deg 17mm SS A EH ETO Fig 21 gt E Esch E _ Fig 22 4 6 CONNECTING THE GAS AND WATER The ap
39. al ways 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 calling 0870 607 0281 e for ROI residents by calling 056 6655057 SECTION 6 SERVICING INSTRUCTIONS 6 1 GENERAL Once the appliance has been serviced the benchmark Service Record must be completed For UK only It is important that the Benchmark Service Record is correctly completed and handed to the user Failure to install and commission the appliance to the manufacturers instructions will invalidate the warranty To ensure the continued safe and efficient operation of the ap pliance it is recommended that it is checked and serviced at regular intervals To ensure correct and safe operation of the appliance it is essential that any worn or failed component be replaced only with a genuine Vok ra 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 haz ard 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 Vok ra engineer an approved service agent British Gas GAS SAFE registered personnel or other suita
40. alve or conversion from methane gas to LPG ob serve the following procedures The adjustment of the maximum and minimum output and of the maximum and minimum heating and of slow switch on must be made strictly in the sequence indicated and only by qualified personnel only disconnect the boiler from the power supply turn the heating water temperature selector to its maximum remove the casing as described in 4 7 1 gently pull the control panel forwards and down locate the terminal block cover fig 26 insert the jumpers JP1 and JP3 power up the boiler The display shows ADJ for approximately 4 seconds Next change the following parameters 1 Domestic hot water absolute maximum 2 Minimum 3 Heating maximum 4 Soft light fan speed as follows turn the heating water temperature selector to set the re quired value press the CO button and then skip to the calibration of the next parameter N Live electrical parts 230 V AC The following icons light up on the monitor 1 T during domestic hot water absolute maximum calibra tion 2 EZ during minimum calibration 3 lL during heating maximum calibration 4 p during soft light fan speed calibration End the procedure by removing jumpers JP1 and JP3 to store these set values in the memory THE function can be ended at any time without storing the set values in the memory and retaining the original values as follows remove jumper
41. anelling etc avoid direct contact with any cleaning appliance e g brushes aspirators blowers etc 1 This component does not need any maintenance please do not remove it from its housing save where the O ring may have to be replaced The manufacturer declines all responsibility in cases of damages due to failing to observe the above 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 to catch any residual water that may drip from the appliance or removed component Undertake a complete com missioning 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 28 Locate the 4 screws an
42. appliance specification as detailed on the appliance data badge 34 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 according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer Name SSS Telephone Number Address Boiler Make and Model 7 v krkc C CO rY O YY O rcCcCrrr r Commissioned by print name Das Safe Register Number Company Name Telephone Number Company Address e 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 O Room Thermostat Compensation O Control Time and Temperature Control to Hot Water linder Thermostat and Programmer Timer W Combination Boiler H Heating Zone Valves Fitted H Not Required H Hot Water Zone Valves Fitted H Not Required H Thermostatic Radiator Valves Fitted L Not Required H Automatic Bypass to
43. arry out component removal procedure as described in 6 4 Remove the locking pin G3 that secures the actuator H2 to the heating manifold Disconnect the electrical plug from the actuator Replace in the reverse order 6 20 4 DHW THERMISTOR fig 32 Carry out component removal procedure as described in 6 4 Locate and remove the thermistor locking pin 12 Gently ease the thermistor assembly J2 from the hydraulic manifold Re place in the reverse order 6 20 5 DIVERTOR VALVE ASSEMBLY fig 43 Carry out component removal procedure as described in 6 4 Remove the valve actuator as described in 6 20 3 Locate and remove the locking pin G2 that secures the valve housing cover to the hydraulic manifold Gently prise the valve as sembly from the manifold K2 Replace in the reverse order ensuring that the seating assembly is inserted properly Ensure all seals are in good condition taking care to ensure they are replaced correctly 24 SECTION 7 CHECKS ADJUSTMENTS AND FAULT FINDING 7 1 CHECKING APPLIANCE OPERATION When carrying out any repairs or servicing to the appliance the relevant commissioning procedure must be undertaken to ensure the continued safe operation of the appliance Particular attention should be made to ensure gas tightness water tight ness and the electrical integrity of the appliance 7 2 APPLIANCE MODES OF OPERATION NOTE There must be s
44. ature can be set from a minimum of 40 C toa maximum of 80 C if standard CH mode is selected 2 5 ADJUSTING THE HOT WATER TEMPERA TURE 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 Vok ra Compact A 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 the blank bullet points to automatically adjust raise the heating The activation and the disable of the function is visualized on the display if the heating temperature is selected between 55 65 C 3 HOW TO 3 1 HOW TO TOP UP THE SYSTEM PRESSURE fig 1 2 The system pressure mustbe checked periodically to ensure the correct operation of the boiler The needle on the gauge shou
45. bly qualified personnel The following instruc tions 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 e Check the operation of the appliance and ensure it functions as described in section 7 e Compare the performance of the appliance with its design specification The cause of any noticeable deterioration should be identified and rectified without delay e Thoroughly inspect the appliance for signs of damage or deterioration especially the flue system and the electrical 20 apparatus e Check and adjust if necessary all burner pressure settings see 7 4 e Check and adjust if necessary the system design pressure see 5 10 e Carry out an analysis of the flue gases see 7 5 and visually check the condition of the entire flue assembly Compare the results with the appliance design specification Any deterioration in performance must be identified and recti fied without delay e Check that the main heat exchanger are clean and free from any debris or obstruction e Check and clean if necessary the condense trap to ensure correct operation The flame side of the burner is made of state of the art material Being fragile be particularly careful when handling mounting or disman tling the burner and adjacent components e g electrodes insulation p
46. ckwise to decrease counter clockwise to increase until the correct value is displayed on the CO analyser allow time for the analyser to stabilise 10 6 3 GAS VALVE MINIMUM SETTING Set the CO button at minimum see 10 3 1 once the minimum is obtained check that it corresponds with the appropriate CO value Minimum for the respective appliance If the CO read ing is correct proceed to completion 10 7 3 However if the CO reading is incorrect the minimum gas pressure must be adjusted as follows e locate the minimum adjustment screw fig 37 using a suit able screwdriver remove the protection plug e using a Amm Allen key very slowly turn the minimum adjust ment screw see fig 45 clockwise to increase counter clockwise to decrease until the correct value is displayed on the CO analyser allow time for the analyser to stabilise 10 6 4 COMPLETION On completion of the combustion analysis check and or any gas valve adjustment refit the plug L2 j and move the mode selector to the On position Remove the test probe from the test point and refit the sealing screw s and or cap IMPORTANT AGAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED REPLACED OR DISTURBED ATTENTION Gas type and appliance output must be set according to the specific appliance specification Vok ra accepts no responsi bility if the gas type is not correctly adjusted according to the respective
47. d on the lower front of the appliance The appliance controls include pressure gauge appliance mode selector temperature selector optional integral time clock programmer if fitted NOTE The appliance frost protection is active in all the boiler modes The temperature 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 Refer to the main appliance status table for fault indicator and boiler status The integral digital time clock is used to switch the heating on and off at pre determined intervals 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 pro grammer 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 temper
48. d remove air box front cover 6 5 PUMP ASSEMBLY fig 29 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 B from the top of the pump assembly and withdraw the flexible pipe Locate and remove the pressure gauge securing pin C and disconnect the pressure gauge from the pump assembly Disconnect the electrical wiring from the pump s electrical connection point D 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 30 Carry out component removal procedure as described in 6 4 Disconnect the outlet pipe G 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 29 Carry out component removal procedure as described in 6 4 Remove the expansion pipe locking pin B from the pump as sembly and remove the expansion pipe Locate and remove the AAV locking pin I from the pump assembly and remove the AAV assembly J Replace in the reverse order 6 7 1 TOP AUTOMATIC AIR RELEASE VALVE fig 31 Carry out component removal procedure as described in
49. dance 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 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
50. e centre of the appliance flue outlet to the edge of the finished outside wall dimension X Add 65mm to dimension X to give you Dimension Y see fig 13 Measure dimension Y from the terminal end of the con centric flue pipe and cut off the excess ensuring any burrs are removed Pass the concentric flue pipe through the previously drilled hole Fit the flue bend to the boiler flue outlet and insert the concentric flue pipe into the flue bend ensuring the correct seal is made Using the clamp gasket and screws supplied secure the flue bend to the appliance flue spigot NOTE Fit the internal white trim to the flue assembly prior to con necting the flue pipe to the bend You must ensure that the entire flue system is properly sup ported 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 13 1imm eye Si Ki 0 degree z T H N 1 3 degree X 65mm Y Fig 13 Fig 13a 4 5 1 2 FITTING THE REAR FLUE fig 15 rear flue outlet only Using the template provided mark and drill a 125mm hole for the passage of the flue pipe The hole should be drilled LEVEL to ensure any condense fluid that forms is allowed to drain back to the appliance The fixing holes for the wall mounting bracket should now be drilled and
51. e sapped L case is correctly replaced andi all other commissioning procedures are completed Vokera heating for life Registered address Vok ra Ltd Borderlake House Unit 7 Riverside Industrial Estate London Colney Herts AL2 1HG enquiries vokera co uk www vokera co uk www vokera ie Sales General Enquires T 0844 391 0999 F 0844 391 0998 Vok ra Ireland West Court Callan Co Kilkenny T 056 7755057 F 056 7755060 Vok ra 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 20072155 07 13 Ed 1
52. e to the safety valve outlet and tighten The discharge pipe must have a continuous fall away from the appliance to outside and allow any water to drain away thereby eliminating the possibility of freezing The discharge pipe must terminate in a position where any water possibly boiling discharges safely without causing damage or injury but is still visible 4 6 6 CONDENSE PIPE During normal operation the boiler produces condense which is collected in a trap located in the lower part of the boiler A flexible pipe condense outlet pipe is connected to the outlet of the trap The flexible pipe must be connected to a plastic waste pipe only The plastic waste pipe must have a minimum of a 3 fall towards the drain Any external run of pipe should be insulated to prevent the risk of freezing 4 6 7 CONNECTING THE CONDENSATE OUTLET Gently pull the condense outlet pipe down from its location inside the boiler until approximately 100mm protrudes from the underside of the boiler care should be taken to ensure that the pipe connection to the trap remains secure Connect a suitable plastic not copper pipe no less than 21mm diameter to the outlet pipe and ensure it discharges in accordance with local building regulations or other rules in force C H flow valve Fig 24 Hot water outlet Gas cock Cold water inlet stopcock C H return valve 17 4 7 ELECTRICAL CONNECTIONS The boiler is supplied with a 2 metre
53. ed in a timber framed building it should be fitted in accordance with the Institute of Gas Engineers publication IGE UP 7 Guide for Gas Installations in Timber Frame Buildings 3 10 INHIBITORS Vok ra recommend that an inhibitor suitable for use with aluminium 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 the 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 temporary Valve connection v flow return double A pipe check valve supply Fig 9 pipe Make up vessel or tank Automatic E air vent E lt E gt e Ka Z Non return Stopcock o valve E LO yo Heating j return Fig 10 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 w
54. ensed 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 75 for a period of 15 minutes The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow temperature sensor consequently a high temperature at the flow sensor results in a lower fan speed As the water tem perature increases the temperature sensors located on the flow pipe of the boiler reduce the fan speed via the electronic circuitry Depending on the load either the water temperature will continue to rise until the set point is achieved or the water temperature will fall whereby fan speed will increase relative to the output required When the boiler has reached the set point hysterisis the burner will switch off The built in anti cycle device prevents the burner from re lighting for approximately 3 minutes When the temperature of the flow sensor falls below the set point hysterisis the burner will re light NOTE If the spark sensing electrode does not sense ignition the appli ance will re attempt ignition a further 4 times then go to lockout When the set point has been reached the position of the heating temperature selector as measured at the primary thermistor the appliance will begin the modulation phase whereby the fan and gas valve will continuously modulate to maintain the set
55. essures Compact A 25 Compact A 29 Inlet pressure G20 20 0 mbar 20 0 mbar Heating maximum gas rate m3 hr 2 12 2 64 DHW maximum gas rate m3 hr 2 64 3 07 Minimum gas rate m3 hr 0 53 0 63 Injector size mm 5 1 5 6 Silencer flange mm fitted 31 2 4 Expansion Vessel Compact A 25 Compact A 29 Capacity 8 litres Maximum system volume 74 litres Pre charge pressure 1 bar 2 5 Dimensions Compact A 25 Compact A 29 Height mm 715 Width mm 405 Depth mm 250 Dry weight kg 26 27 2 6 Clearances Compact A 25 Compact A 29 Sides 12mm Top 150mm from casing or 25mm above flue elbow whichever is applicable Bottom 150mm Front 600mm 2 7 Connections Compact A 25 Compact A 29 Flow amp return 22mm Gas 15mm DHW hot amp cold 15mm Safety valve 15mm Condense 21mm 2 8 Electrical Compact A 25 Compact A 29 Power consumption Watts 110 119 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 60 100 Compact A 25 Compact A 29 Maximum horizontal flue length 60 100mm 5 85m 4 85m Maximum vertical flue length 60 100mm 6 85m 5 85m 2 9A Flue Details concentric 80 125 Compact A 25 Compact A 29 Maximum horizontal flue length 80 125mm 15 3m 12 8m Maximum vertical flue length 80 125mm 20 3m 17 8m 2 9B Flue Details twin pipes Compact A 25 Compact A 29 Maximum horizontal flue length 80mm 80mm 45m 45m 40m 40
56. 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 brown wire to LIVE supply e blue wire to NEUTRAL supply e green yellow to EARTH connection Insertthe supplied 3 AMP fuse into the fusedisolator orfused 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 THEAPPLIANCE The supply cable from the isolator to the appliance must be 3 core flexible sized 0 75mm to BS 6500 or equivalent Wiring to the appliance must be rated for operation in contact with surfaces up to 90 C 4 7 1 CASING REMOVAL fig 25 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 e store the casing and screws safely until required Re fit in the reverse order e gently
57. 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 amp Earth connections at the ap pliance terminal strip NOTE Should it be found that the fuse has failed but no fault is indi cated a detailed continuity check will be required to trace the fault A visual inspection of components may also assist in locating the fault 7 7 3 POLARITY CHECK With the appliance connected to the electrical supply and us ing 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 ap proximately 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 ap proximately 230V ac If so proceed to next stage If not see 7 7 4 e connect test leads between the Neutral amp Earth connec tions 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
58. ge 3 5 Air supply 10 9 1 Related documents 33 3 6 Water circulation 10 9 2 Technical data 33 3 7 Electrical supply 11 9 3 Converting the appliance gas type 33 3 8 Mounting on a combustible surface 11 9 4 Gas supply j 33 3 9 Timber framed buildings 11 9 5 Gas supply installation 33 3 10 Inhibitors 11 9 6 Checking the CO and adjusting the gas valve 33 3 11 Showers 11 Benchmark 35 36 General requirements EIRE Page 3A 1 Related documents 11 Commissioning 37 3A 2 Location of appliance 11 3A 3 Gas supply 11 3A 4 Flue system 11 3A 5 Air supply 12 3A 6 Water circulation 12 3A 7 Electrical supply 12 3A 8 Mounting on a combustible surface 12 3A 9 Timber framed buildings 12 3A 10 Inhibitors 12 3A 11 Showers 12 3A 12 Declaration of conformity 12 USERS INSTRUCTIONS INTRODUCTION Dear Customer Your Vok ra Compact A boiler has been designed to meet and exceed the very latest standards in gas central heating technol ogy 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 boo
59. h Flue sensor 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 both for CH and DHW For CH line if the main temperature falls to 5 C the appliance will function on minimum power until the tem perature on main reaches 35 C Moreover if the DHW temperature falls to 5 C the appliance will function on minimum power until the temperature on main reaches 55 C e anti block function the anti block function enables the pump and divertor valve actuator 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 achieved the electronic circuitry increases the gas rate to 75 for a period of 15 minutes Thereafter the boiler s output will either be increase to maximum or modulate to suit the set requirement When the appliance reaches the desired temperature t
60. h wiring 18 Fig 25 A Fig 26 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 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 release valves starting at the lowest first It may be necessary to go back and top up the pressure until the entire system has been filled Inspect the system for water tightness rectifying any leaks
61. he boiler casing see 4 7 1 and locate the factory fitted connector plug and connect to the corresponding plug supplied with the mechanical clock wiring harness To add a room thermostat identify the 2 switch wires black red colour in terminal block CN5 and connect the room thermostat wires in series in terminal block CNB see fig 50 Refit the boiler casing Fit the cover kit to the boiler IMPORTANT e The boiler must always be supplied with a permanent 230V electrical supply Always remove the link between TA amp TA on the CN5 PCB terminal see fig 49 e The room thermostat connection is low voltage 24 Vdc Do not connect any controls or auxiliary equipment to the low voltage terminal strip other than that approved supplied by Vok ra Ltd Fermale connector E Male connector 7 black red blue brown HE MECHANICAL CLOCK RADIO FREQUENCY RECEIVER NL Fuse 3 15A F Fig 50 A NOTE Use contacts free of voltage 230 V Out Room Thermostat 24 Vdc Fuse 3 15A F 31 FUNCTIONAL DIAGRAM NOTE L N E connection is advisable Fig 51 1 VGL ost ld
62. he 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 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 stabil ity 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 awater pressure switch that monitors system water pressure and will de activate the pump fan and burner should the system water pressure drop below the rated tolerance e fan speed sensor 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
63. he dedicated con centric flue kit for termination e The horizontal terminal is supplied with a built in converter box and cannot be shortened e A130mm 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 forthe 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 weatherproof ing The interior and exterior trim can now be fitted VERTICAL TERMINATION fig 22 The twin flue system must be converted to the dedicated con centric flue kit for termination e The vertical termin
64. ical clock it can be used and adjusted as follows Setting the time The time of day can be set by grasping the outer edge of the black dial and turning it in a clockwise direction until the correct time is in line with the white pointer Setting the switching times The ON periods are set by sliding the black tappets adja cent to the time periods required to the outer edge of the dial The tappets that remain at the centre of the dial will be the OFF periods The smallest switching time ON or OFF is 15 minutes To select AUTO mode move the selector switch in central position To select ON mode move the selector switch in the bottom position To select OFF mode move the selector switch in the upper position Advice for homeowners Please contact Vok ra Customer Service 0844 3910999 UK or 056 7755057 ROI if you would prefer a Vok ra 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 Ifyou think your boiler may have developed a fault please contact your installer or Vok ra 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 Fig 4 INSTALLATION AN
65. ill set at maximum rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording CO AND COMBUSTION RATIO CHECK First verify that flue integrity has been visually checked in accordance with the Before CO and combustion ratio check box above before proceeding to the Check Is CO less than CO and combustion ratio Check all seals around the GE eg i appliance burner internal flue ratio at maximum rate stage pp less than 0 004 seals door and case seals Rectify where necessary Turn off appliance and call Vokera technical SET BOILER TO MINIMUM RATE helpline for advice In accordance with section 7 3 The appliance must not 7 4 set boiler to operate at be commissioned until Is CO less than minimum rate to minimum problems are identified 350ppm AND load condition Allow sufficient and resolved If CO CO2 ratio time for combustion to stabilise commissioning cannot be less than 0 004 fully completed the appliance must be disconnected from the gas supply in accordance CHECK CO AND 7 Is CO less than COMBUSTION RATIO AT 350ppm AND MINIMUM RATE CO CO2 ratio less With boiler set at minimum than 0 004 rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Boiler is operating satisfactorily No further actions required Ensure test points ar
66. ion to the heat exchanger J1 Gently ease the fan assembly out of its location Once the assembly has been removed the burner K1 can be withdrawn from the heat engine Ensure the seals L1 is in good condition taking care to ensure it is replaced correctly Replace in the reverse order 22 Fig 35 J1 Fig 36 TS 6 16 MAIN HEAT EXCHANGER fig 37 Carry out component removal procedure as described in 6 4 Remove the air chamber front cover Locate and remove the gas pipe locking pin A1 and swing rotate the gas pipe away from the fan assembly B1 if necessary unscrew the gas pipe from the gas valve G1 Disconnect the electrical connections attached to the fan Disconnect the electrode leads and ancillary wiring from their respective connectors Disconnect the flow locking pin M1 return locking pin N1 on the heat exchanger Locate and remove the screws that secure the heat exchanger to the combustion chamber O1 Move the heat exchanger and disconnect it from the flue collector P1 The heat exchanger can now be lifted up and 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 17 AUTOMATIC BY PASS amp DHW NON RETURN VALVE fig 38 Carry out component removal procedure as described
67. ion when you want the boiler to be switched off for short periods days or if the boiler requires to be reset The display shows 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 oper ating 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 DIGITAL DISPLAY KE Displayed when heating mode is active E Displayed when hot water mode is active D Displayed when frost protection function is ac x tive Displayed when hot water pre heat function is enabled Flashes when functioning D Displayed if an alarm or fault has been detected Displayed when low system pressure has been detected y Displayed when an external sensor is connected l to the boiler Displayed if an ignition fault has been detected 2 GETTING STARTED 2 1 BEFORE SWITCHING ON Before switching the appliance on please familiarise yourself with howtoisolate the appliance from the gas water and electricity 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 situate
68. ith the relevant requirements of the local building regulations the current ETCI National Rules for Electrical Installations and the bylaws of the local water undertaking It should be in accordance also with any relevant requirements of the local and or district authority 3A 2 LOCATION OF APPLIANCE The appliance may be installed in any room or internal space although particular attention is drawn to the requirements of the current ETCI National Rules for Electrical Installations and LGS 813 Annex K When an appliance is installed in a room or internal space containing a bath or shower the appliance or any control pertaining to it must not be within reach of a person using the bath or shower The location chosen for the appliance must permit the provision of a safe and satisfactory flue and termination The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the appliance Where the installation of the appliance will be in an unusual location special procedures may be necessary refer to LS 813 for detailed guidance on this aspect A compartment used to enclose the appliance must be de signed and constructed specifically for this purpose An exist ing 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 supplie
69. k 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 re sponsible for the property in which the appliance is located installed A replacement copy can be obtained from Vok ra 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 connected 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 COMMISSIONING CHECKLIST UK only A checklist section can be found at the rear of the appliance installation booklet This important document must be com pleted during the installation commissioning of your boiler All GAS S
70. late the appliance from the electrical supply and remove the appliance casing as described in 4 7 1 to gain access to the printed circuit board locate and open the closing plug on the dash board L2 Restore the electrical supply to the boiler and switch the boiler to the OFF mode locate and press the CO but ton see fig 44 pos SW1 Press the button the number of times according the function requirement as par 7 3 1 Set the flue gas analyser to read CO2 and insert the probe into the flue analysis test point Y1 Z1 fi g 41 use the supplied screwdriver to push the CO botton SW1 Fig 44 7 3 1 CO FUNCTION SETTINGS Locate the CO button see 7 3 Select the main selector switch in position Q CO FUNCTIONS ACTION ON THE BUTTON DISPLAY combustion analysis mode press once burner running at maximum heating ACO ill A gas valve maximun setting press twice burner running at maximum DHW ACO T A A gas valve minimum setting press three time burner running at minimum ACO ll y A NOTE 1 Any additional pressing of CO button after the third time the burner switched between maximum DHW and minimum 2 To restart the CO function it is necessary to pass throught the position with the main selector switch 7 3 2 GAS VALVE MAXIMUM SETTING Set the CO button at maximum see 7 3 1 once the maximum
71. ld 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 3 Attach the filling loop to both connections Open the filling valve slowly until you hear water entering the system Closethe 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 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 advis able 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 left 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 control When the fault code is displayed the appliance will requireto outer cas valve gn be reset manually Before resetting the boiler checkwhataction ing use only
72. lower the control fascia until it rests 4 7 2 APPLIANCE TERMINAL BLOCK The appliance terminal block is located on the rear of the con trol fascia Remove the casing as described in 4 7 1 Gently pull the control panel forwards and down Locate the terminal block cover fig 26 NOTE The appliance comes with a factory fitted link TA to allow basic operation of the boiler via the mode selector switch If itis anticipated that external controls will be required please refer to the wiring diagrams in section 8 for more detailed information 4 7 3 CONNECTING THE MAINS 230V INPUT 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 position NOTE It is the installer s responsibility to ensure that the appliance is properly Earthed Vok ra Ltd cannot be held responsible for any damages or injuries caused as a result of incorrect Eart
73. lugged 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 ap pliance 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 us ing 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 to the maximum equivalent flue length between the boiler and vertical flue assembly see fig 22 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 exten sion Remove any burrs and check that any seals are located properly You must ensure that the entire flue system is properly sup ported and connected 4 5 3 TWIN FLUE SYSTEM The Vok ra 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 ho
74. m Maximum vertical flue length 80mm 80mm 45m 45m 40m 40m 2 10 Efficiency Compact A 25 Compact A 29 SEDBUK 90 0 90 2 2 11 Emissions Compact A 25 Compact A 29 CO2 maximum output 9 0 9 0 CO2 minimum output 9 5 9 5 CO maximum output ppm 180 160 CO minimum output ppm 20 20 NOx rating class 5 class 5 2 12 PUMP DUTY 5 0 Fig 6 shows the flow rate available after allowing for pressure loss through the ap KS pliance for system requirements When using this graph apply only the pressure 4 0 loss of the system The graph is based on a 20 C temperature differential B 35 E o 3 0 2 L D 2 5 Iy S So Q ve 20 S hy 3 Sog g e Sed 1 0 0 5 0 0 0 100 200 300 400 500 600 700 800 900 1000 Fig 7 Flow rate I h Fig 8 Key S lt IND DZ Sr K TL mH D OW T Location Below an opening window air brick etc Above an opening window air brick etc To the side of an opening window air brick etc Below gutter drain pipe etc Below eaves Below balcony car port roof etc To the side of a soil drain pipe etc From internal external corner Above ground roof or balcony level From a surface or boundary facing the terminal From a terminal facing a terminal From an opening in the car port into the building Vertically from a terminal on the
75. ndations 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 LEE wiring regulations and in Scotland the electrical provisions of the Building Regulations with respect to the installation of the appliance in a room or internal space BS 5440 Part 1 when the terminal is 0 5 metres or less below plastic guttering or 1 metre or less below painted eaves 3 5 AIR 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 sup ply 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 Itis recommended that copper tubing to BS 2871 Part 1 is used in conjunction with soldered capillary joints Where possible pipes should have a gradient to ensure air is carried naturally to air release points and that water flows naturally to drain cocks 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 SUPPL
76. ns 6 12 Gas valve 77 Design principles amp operating sequence Page 6 13 Electrodes 22 1 1 Principle components 7 6 14 Flue fan amp mixer 22 1 2 Mode of operation at rest 7 6 15 Burner 22 1 3 Mode of operation heating 7 6 16 Mein heat exchanger 23 1 4 Mode of operation Hot water 7 6 17 _ Automatic by pass amp DHW non return valve 23 1 5 Safety devices 7 6 18 Expansion vessel removal 23 6 19 Condense trap removal 23 Technical data Page 6 20 Flue collector removal 24 2 1 Central heating 8 l SC 2 2 Domestic hot water 8 Checks adjustments and fault finding Page 2 3 Gas pressures 8 CA Checking appliance operation 25 2 4 Expansion vessel 8 7 2 Appliance modes of operation 25 2 5 Dimensions 8 7 3 __Checking the CO amp adjusting the valve 25 2 6 Clearances 8 7 4 Combustion analysis test 26 2 7 Connections 8 7 5 Checking the expansion vessel 26 2 8 Electrical 8 7 6 External faults 26 2 9 Flue details 60 100 8 7 7 Electrical checks 26 2 9A Flue details 80 125 8 7 8 Fault finding 7 27 2 9B Flue details twin pipes 8 7 9 Component values amp characteristics 27 2 10 Efficiency 9 7 10 Adjustments 28 2 11 Emissions 9 2 12 Pump duty 9 Wiring diagrams Page 8 1 External wiring 31 General requirements UK Page 8 2 Typical control applications 31 3 1 Related documents 10 8 3 Other devices z 31 3 2 Location of appliance 10 8 4 Vok ra lower cover mechanical clock 31 3 3 Gas supply 10 3 4 Flue system 10 L P G instructions Pa
77. ocate and remove the screw Y1 that secures the flue gas analysis test point cover Z1 Disconnect the flues thermistor wiring connections Locate and remove the 4 screws A2 Locate and remove the 2 screws A3 Gently ease the condensate collector A4 out off its location Gently ease the flue collector out off its location Replace in the reverse order 6 20 1 DHW FLOW RESTRICTOR fig 42 Carry out the component removal procedure as described in 6 4 Disconnect the cold water inlet pipe at the DHW flow switch B2 Using a small screwdriver gently ease the flow restrictor C2 from its seating Replace in the reverse order Ensure all seals are in good condition taking care to ensure they are replaced correctly 6 20 2 DHW FLOW SWITCH fig 42 Carry out component removal procedure as described in 6 4 Remove the locking pin D2 Disconnect and remove the cold water inlet pipe from the DHW flow switch amp DHW heat ex changer 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 20 3 VALVE ACTUATOR fig 43 C
78. of the system 3A 6 5 EXPANSION VESSEL The appliance has an integral expansion vessel to accom modate 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 Amethod for initial filling of the system and replacing water lost during servicing etc is provided see fig 9 You should ensure this method of filling complies with the local water authority regulations 3A 6 7 LOW PRESSURE SEALED SYSTEM An alternative method of filling the system would be from an independent make up vessel or tank mounted in a position at least 1 metre above the highest point in the system and at least 5 metres above the boiler see fig 10 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 12 3A 7 ELECTRICAL SUPPLY The appliance is supplied for operation on 230V 50Hz electrical supply
79. ompact 29A Inlet pressure 37 0 mbar 37 0mbar Heating maximum gas rate kg hr 1 55 1 94 DHW maximum gas rate kg hr 1 94 2 25 Minimum gas rate kg hr 0 39 0 47 Injector size 3 9 mm 4 3 mm Silencer flange 27 mm 29 mm CO maximum output 10 5 10 5 CO minimum output 10 5 10 5 CO maximum output ppm 190 250 CO minimum output ppm 20 25 9 3 CONVERTING THE APPLIANCE GAS TYPE To convert the appliance to another gas type it is necessary to change the injector and adjust the gas valve CO2 To change the injector see 6 12 1 To replace the flange on the silencer see 6 15 e To adjust CO2 values see 10 6 9 4 GAS SUPPLY The gas supply must be connected to the appliance by a com petent LPG installer and must be of sufficient size to supply the appliance at its maximum output An existing supply must be checked to ensure that it is of adequate size to deal with the maximum rated input of this and any other appliances that it serves 9 5 GAS SUPPLY INSTALLATION The entire installation including the meter must be purged and checked for gas tightness 9 6 1 CO FUNCTION SETTINGS Locate the CO button see 7 3 Select the main selector switch in position O 9 6 CHECKING THE CO AND ADJUSTING THE GAS VALVE THE GAS VALVE MUST BE SET UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANA LYSER Isolate the appliance from the electrical supply and remove the appliance casing as described in 4
80. otal N B The safety valve 19 is set to lift at 3 BAR 30 metres 45 psig To lower the system pressure 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 Vok ra 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 A 25 8 litres flow restrictor Compact A 29 10 litres flow restrictor 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 I
81. pliance is supplied with an accessory pack that includes service valves The service valves are of the compression type The accessory pack contains sealing washers etc for use with the service valves When connecting pipe work to the val ves tighten the compression end first then insert the sealing washers before tightening the valve to the appliance NOTE It will be necessary to hold the valve with one spanner whilst tightening with another 4 6 1 GAS fig 24 The appliance is supplied with a 15mm service valve connect a 15mm pipe to the inlet of the valve and tighten both nuts NOTE It will be necessary to calculate the diameter of the gas supply pipe to ensure the appliance has an adequate supply of gas 4 6 2 FLOW amp RETURN fig 24 The appliance is supplied with 22mm service valves for the flow and return connections connect a 22mm pipe to the inlet of each valve and tighten both nuts NOTE Depending on system requirements it may necessary to in crease the size of the flow amp return pipe work after the service valve connections 4 6 3 COLD WATER INLET fig 24 The appliance is supplied with a 15mm stopcock connect a 15mm pipe to the inlet of the stopcock and tighten both nuts 4 6 4 HOT WATER OUTLET fig 24 The appliance is supplied with a 15mm outlet connection con nect a 15mm pipe to the outlet connection and tighten both nuts 4 6 5 SAFETY VALVE fig 24 Connect the safety valve connection pip
82. pliances that it serves Instal lation 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 con nection 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 appli ance when they are in use at the same time 3 4 FLUE SYSTEM The terminal should be located where the dispersal of combustion products is not impeded and with due regard for the damage and discoloration that may occur to building products located nearby The terminal must not be located in a place where it is likely to cause a nuisance see fig 8 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 10 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 a
83. ppliance 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 accord ance with BS 2879 3 6 4 AIR RELEASE POINTS These must be positioned at the highest points in the system where air is likely to be trapped They should be used to expel trapped air and allow complete filling of the system 3 6 5 EXPANSION VESSEL The appliance has an integral expansion vessel to accom modate 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 9 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 9 3 6 7 LOW PRESSURE SEALED SYSTEM An alternative method of filling the system would be
84. r 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 Instal lation 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 con nection must not be used The installation must be tested for tightness in accordance with LS 813 If the gas supply serves more than one appliance it must be ensured that an adequate supply is maintained to each appli ance when they are in use at the same time 3A 4 FLUE SYSTEM The terminal should be located where the dispersal of combustion products is not impeded and with due regard for the damage and discoloration that may occur to building products located nearby The terminal must not be located in a place where it is likely to cause a nuisance see 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 11 the terminal must be protected by a guard of durable material The guard must be fitted centrally over the terminal Refer to LS 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 gui
85. rd has been explained and left with the customer Yes H Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval 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 Engineer Name Service 2 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 3 Date Engineer Name Service A Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 5 Date Engineer Name Service 6 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Operative ID No Comments Comments Signature Signature Service 7 Date
86. rder ensur ing 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 output type and application Details on setting fan speeds can be found in section 7 10 6 12 GAS VALVE fig 34 Carry out component removal procedure as described in 6 4 The gas valve must be changed as complete unit Disconnect the electrical plug and leads from the gas valve slacken and unscrew gas valve inlet and outlet connections Please note the sealing washers Q must be discarded and replaced with new sealing washers Disconnect the compensation pipe R Unscrew gas pipe connections S T 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 CAR RIED OUT 6 12 1 INJECTOR fig 34 Carry out component removal procedure as described in 6 4 Unscrew and remove gas pipe connections S T Locate and remove the injector U inside the valve Replace in the reverse order Check and adjust burner pressure settings WARNING A GAS TIGHTNESS CHECK MUST BE CAR RIED OUT 6 13 ELECTRODES fig 35 Carry out component removal procedure as described in 6 4 Remove the air chamber front cover Disconnect the electrode leads and ancillary wiring from their respecti
87. required length you must ensure that the excess is cut from the plain end of the extension see fig 12 22 Remove any burrs and check that all seals are located properly You must ensure that the entire flue system is properly supported and connected Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing The interior and exterior trim can now be fitted Fig 16 Using the screws and washers provided secure the applian ce onto the wall bracket and tighten with a suitable spanner Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing The exterior wall trim can now be fitted Part No 29450133 Description Length 825mm Rear flue terminal 4 5 2 CONCENTRIC VERTICAL FLUE The appliance can be used with either the Vok ra condensing 60 100mm concentric flue system or the optional 80 125mm concentric flue system NOTE These instructions relate only to the Vok ra condensing 60 100mm concentric flue system For specific details on the installation of the 80 125mm concentric flue system please refer to the instructions supplied The vertical flue terminal can be connected directly to the ap pliance flue outlet Alternatively an extension or bend can be connected
88. robe from the test point and refit the sealing screw s and or cap IMPORTANT AGAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED REPLACED OR DISTURBED 7 4 COMBUSTION ANALYSIS TEST To carry out the combustion analysis proceed as follows e Turn the function selector in OFF position e Turn the hot water temperature selector in position Fe e Wait for burner ignition about 6 seconds The display shows ACO TL Q and the boiler operates at maximum heating e Insert the flue gas analyser probe into the flue gas test point see fig 41 e Operate the boiler in combustion analysis mode see 7 3 1 and compare the values with those shown in section 2 Nat Gas or section 9 LPG If different adjust the gas valve ac cording to 7 3 1 7 3 2 amp 7 3 3 e The combustion analysis function remains active for 15 minutes it is possible to interrupt in advance moving the mode selector switch in desired position Mf L bring the domestic hot water temperature adjustment knob back to the required position e Note If a measured CO CO2 ratio of 0 004 1 or less AND a CO reading of less than 350ppm cannot be achieved please contact Vokera technical for advice 26 Maximum screw Compensation pipe connection Inlet gas pressure connection Minimum screw fig 45 7 5 CHECKING THE EXP
89. rols 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 appli ance 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 protection 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 a large LCD display that indicates the appliance operating status MODE SELECTOR SWITCH HOT WATER TEMPERATURE HEATING SELECTOR DISPLAY TEMPERATURE PRESSURE GAUGE SELECTOR HOT WATER 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 Wee Hot water only Select this position if you want the boiler to supply hot water only no heating the DHW outlet temperature or counter clockwise to reduce the temperature Hot water temperature selector move the selector
90. s JP1 and JP3 before all 4 parameters have been set set the function selector to OFF RESET cut the power supply waiting for 15 minutes after it is connected A Calibration can be carried out without switch on the boiler N By turning the heating selection knob the monitor au tomatically shows the number of rotations expressed in hundreds e g 25 2 500 rpm GAS VALVE CALIBRATION Connect the boiler to the power supply Open the gas tap Set the function selector to di OFF RESET monitor off remove the casing as described in 4 7 1 gently pull the control panel forwards and down locate the terminal block cover fig 26 Press the CO button N Live electrical parts 230 V AC Wait for burner ignition The display shows ACO The boiler operates at maximum heat output The combustion analysis function remains active for a limit ed time 15 min if a delivery temperature of 90 C is reached the burner is switched off It will be switched back on when this temperature drops below 78 C Insert the analyser probe in the ports provided in the air distribution box after removing the screws from the cover Press the combustion analysis button a second time to reach the number of rotations corresponding to the maxi mum domestic hot water output table 1 Check the CO2 value table 4 if the value does not match 28 the value given in the table use the gas valve maximum
91. t 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 5 813 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 SECTION 4 INSTALLATION 4 1 DELIVERY Due to the weight of the appliance it may be necessary for two people to lift and attach the appliance to its mounting The appliance is contained within a heavy duty cardboard carton Lay the carton on the floor with the writing the correct way up 4 2 CONTENTS Contained within the carton is the boiler the wall bracket carton template an accessories pack containing appliance service connections and washers the instruction pack containing the installation servicing amp user instructions guarantee registration card and a 3 amp fuse 4 3 UNPACKING At the top of the carton pull both sides open do not use a knife unfold the rest of the carton from around the appliance carefully remove all protective packaging from the appliance and lay the accessories etc to one side Protective gloves should be used to lift the appliance the appliance back frame should be used for lifting points 4 4 PREPARATION FOR MOUNTING THE AP PLIANCE The appliance should be mounted on a smooth vertical sur face which must be capable of supporting the full weight of
92. the burner e flame sensor that will shut down the burner when no flame signal is detected e flue sensor a safety valve which releases excess pressure from the primary circuit La Top AAV Main heat exchanger t w j Flow temperature gt sensor Return temperature Expansion sensor vessel Bi D Ee Bottom Pressure DHW tem switch AAV La perature DHW hea Sonson exchanger DHW non return valve gt Pump Safety valve T Diverter valve Automatic by pass Drain N valve Flow regu lator DHW flow switch A CH CH DHW DHW Fig 6 return flow outlet inlet SECTION 2 TECHNICAL DATA 2 1 Central Heating Compact A 25 Compact A 29 Heat input kW 20 00 25 00 Maximum heat output kW 60 80 C 19 50 24 45 Minimum heat output kW 60 80 C 4 91 5 90 Maximum heat output kW 30 50 C 20 84 26 23 Minimum heat output kW 30 50 C 5 36 6 40 Minimum working pressure 0 25 0 45 bar Maximum working pressure 2 5 bar Minimum flow rate 350 I h 2 2 Domestic Hot Water Compact A 25 Compact A 29 Heat input kW 25 00 29 00 Flow Rate AT35 C 10 20 11 9 Maximum inlet pressure 6 bar Minimum inlet pressure 0 15 bar Minimum flow rate 2 I min 2 3 Gas Pr
93. ture required the default temperature for calculating the curve is 20 C The graph below can be used to determine the correct curve setting REFERENCE TEMPERATURE 15 C REFERENCE REFERENCE TEMPERATURE 25 C ROOM TEMPERATURE CURVE OFFSET 90 80 70 60 50 40 30 2 W X lt wi a im gt Yr wi l W a 30 25 20 15 10 5 0 5 EXTERNAL TEMPERATURE C CLIMATIC CURVES 3 0 2 5 2 0 100 FLOW OUTLET TEMPERATURE C EXTERNAL TEMPERATURE C T80 Maximum set point for standard T range JP7 removed T45 Maximum set point for low T range JP7 inserted JP7 REMOVED JP7 INSERTED TQ TU L 4 IL SS 880 opman Lon IT ee ee agO HUH d EE gp HR N12 ong Fi CN6 CNS fe Y Jp7JP6JP5JP4JP3JP2JP1 L B ER 5 cue S Se BESERRR FA 3 Ge i re 4 SWT O ine es SW o CN13 ZZ EIR elie GD ca e ER CN14 p3 P2 E Sma Z de a Fig 47 30 SECTION 8 WIRING DIAGRAMS 8 1 EXTERNAL WIRING The appliance comes with a factory fitted TA link to allow
94. ufficient system water pressure min 0 5 bar to ensure the water pressure switch is activated If there is in sufficient 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 pump amp actuator anti block 7 2 2 ON BOARD FUNCTIONS COFUNCTION the CO function when activated will allow the appliance to run at CH maximum DHW maximum or minimum output whilsta 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 e FROST PROTECTION this function is only active when there are no requests for heating or HW If the temperature drops below 5 C the boiler will operate on minimum power until the temperature of the thermistors reaches 35 C for CH and 55 C for DHW Thereafter the pump amp fan will over run for 30 seconds e 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 e PUMP ANTI BLOCK FU
95. ve connectors Re move the retaining screws V for electrode Remove the spark ignition electrode W Remove the flame sensor electrod Y 6 14 FLUE FAN amp MIXER fig 36 37 Carry out component removal procedure as described in 6 4 Remove the air chamber front cover Locate and remove the gas pipe locking pin A1 and swing rotate the gas pipe away from the fan assembly B1 if necessary unscrew the gas pipe from the gas valve G1 Locate and slacken the silencer H1 Locate and remove the sense electrode To remove the fan E1 disconnect the electrical connections attached to the fan locate and remove the four screws F1 Gently ease the fan from its location To remove the mixer C1 locate and remove the three screws D1 the mixer can be removed after the fan removal Replace in the reverse order Ensure all seals are in good condition taking care to ensure they are replaced correctly 6 15 BURNER fig 36 Carry out component removal procedure as described in 6 4 Remove the air chamber front cover Locate and remove the gas pipe locking pin A1 and swing rotate the gas pipe away from the fan assembly B1 if necessary unscrew the gas pipe from the gas valve G1 Locate and slacken the silencer H1 disconnect the electrical connections attached to the fan Disconnect the electrode leads and ancillary wiring from their respective connectors Locate and remove the screws 11 which secure the burner assembly in posit
96. wever the twin flue system must be converted to the dedicated concentric flue kit for termination It is essential that the installation of the twin flue system be carried out in strict accordance with these instructions GUIDANCE NOTES ON TWIN FLUE INSTALLATION e The flue must have a have a minimum 1 maximum 3 1 17mm per 1000mm fall back to the appliance to allow any condensate that may form in the flue system to drain via the condensate drain Consideration must also be given to the fact that there is the possibility of a small amount of condensate dripping from the terminal Ensure that the entire flue system is adequately supported use at least one bracket for each extension As the exhaust outlet pipe can reach very high temperatures it must be protected to prevent persons touching the hot surface e The condensate drain pipe must be connected in accordance with building regulations Reduction for bends Bend Reduction in maximum flue length for each bend 45 bend 1 0 metre 90 bend 1 5 metre Twin flue accessories Part No Description Length 0225805 Horizontal flue terminal 1 0 metre 0225810 Vertical flue terminal 1 0 metre 359 Twin adapter kit N A 531 Pitched roof flashing plate N A 532 Flat roof flashing plate N A 0225815 Condensate drain kit N A 0225820 0 25m extension pair 250mm 0225825 0 5m extension pair 500mm 0225830 1 0m extension pair

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