44
Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER
Installation& ServicingInstructions
THESE INSTRUCTIONSTO BE RETAINEDBY USER
ContentsDesign principles & operating sequence Page1.1 Principle components 21.2 Mode of operation (at rest) 21.3 Mode of operation (heating or hot water request) 21.4 Safety devices 2
Technical data Page2.1 Central heating 32.2 Gas pressure 32.3 Expansion vessel 32.4 Dimensions 32.5 Clearances 32.6 Connections 32.7 Electrical 32.8 Flue details 32.9 Efficiency 32.10 Adjusting operating parameters 32.11 Emissions 32.12 Pump duty 4
General requirements (UK) Page3.1 Related documents 53.2 Location of appliance 53.3 Gas supply 53.4 Flue system 53.5 Air supply 53.6 Water circulation 53.7 Electrical supply 63.8 Mounting on a combustible surface 63.9 Timber framed buildings 63.10 Condensate disposal 63.11 Inhibitors 6
General requirements (EIRE) Page3A.1 Related documents 83A.2 Location of appliance 83A.3 Gas supply 83A.4 Flue system 83A.5 Air supply 83A.6 Water circulation 83A.7 Electrical supply 93A.8 Mounting on a combustible surface 93A.9 Timber framed buildings 93A.10 Condensate disposal 93A.11 Inhibitors 93A.12 Declaration of conformity 9
Installation Page4.1 Delivery 104.2 Contents 104.3 Unpacking 104.4 Preparation for mounting the appliance 104.5 Fitting the flue 104.6 Connecting the gas & water 134.7 Condensate outlet 134.8 Automatic air release valve 144.9 Electrical connections 144.10 Casing removal 15
Commissioning Page5.1 Gas supply installation 165.2 The heating system 165.3 Initial filling of the system 165.4 Initial flushing of the system 165.5 Pre-operation checks 165.6 Initial lighting 165.7 Final flushing of the heating system 165.8 Inhibitors 165.9 Appliance operating parameters 165.10 Parameters 3 & 4 165.11 Information mode 165.12 Setting the system design pressure 175.13 Regulating the central heating system 175.14 Checking dynamic gas pressure 175.15 Final checks 175.16 Instructing the user 17
Servicing Page6.1 General 186.2 Routine annual servicing 186.3 Replacement of components 186.4 Component removal procedure 186.5 Pump head 186.6 Safety valve 186.7 Automatic air release valve 186.8 Pressure gauge 186.9 NTC thermistors (temperature sensors) 196.10 Printed circuit board (PCB) 196.11 Gas valve 196.12 Fan 196.13 Burner 196.14 Electrode 206.15 Injector 206.16 Automatic by-pass assembly 206.17 Condense trap 206.18 Condense pressure switch 206.19 Combustion cover 206.20 Expansion vessel 216.21 Input & status PCB 21
Checks, adjustments and fault finding Page7.1 Checking appliance operation 227.2 Appliance mode of operation 227.3 Service paameters (5-42) 227.4 Adjusting the gas valve 227.5 1st digit status code 247.6 Temporary fault codes 247.7 Final fault codes 247.8 Diagnostic recall 247.9 Checking the expansion vessel 247.10 External faults (installation) 257.11 Electrical checks 257.12 Fault finding 25
Wiring diagrams Page8.1 Installation of Vokera time clock 318.2 External controls important 31
Exploded diagrams Page9.1 Table 1 369.2 Table 2 379.3 Table 3 389.4 Table 4 399.5 Table 5 40
L.P.G. instructions Page10.1 Technical data 4110.2 Related documents 4110.3 Gas supply 4110.4 Gas supply installation 4110.5 Adjusting the gas valve 41
1
INTRODUCTION
General layout (fig. 1A)
1 Auto by-pass2 Safety valve3 Condense trap4 Pump5 Return sensor (NTC2)6 Gas valve7 Silicone pressure tube8 Flow sensor (NTC1)9 Auto air vent (AAV)10 Flue outlet & air intake11 Flue gas analysis test point12 Burner plate13 Expansion vessel14 Spark/Sensing Electrode15 Heat exchanger16 Pressure switch17 Fan assembly18 Electronic Control Board (PCB)R Heating return connectionF Heating flow connectionG Gas connection
The Pinnacle range of boilers are central heatingcondensing boiler, which – by design – incorporates fullsequence electronic ignition, circulating pump, expansionvessel, safety valve, pressure gauge and automatic by-pass.Pinnacle is produced as a room sealed, category C1, C3,C6 appliance, suitable for wall mounting applicationsonly. Pinnacle is provided with a fan powered flue outlet
with an annular co-axial combustion air intake that can berotated – horizontally – through 360 degrees for varioushorizontal or vertical applications. Pinnacle can also beused with the Vokera twin flue system.This appliance is designed primarily for use with sealedsystems; however it can also be used on an open ventedsystem, provided that the necessary installationrequirements are met.
Fig. 1B
1
23
4
5
67
8
9
10
3
4
5
2
1
6
7
11
13
14
15
16
17
18
10
12
8
9
R F G
Control board (fig. 1B)1 STEP button2 PLUS button3 MODE button4 4 digits display5 Status LED6 RESET button7 MINUS button8 CH button/MEMO button9 Time clock aperture10 Pressure gauge
Fig. 1A
2
SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE
1.1 PRINCIPLE COMPONENTS● A fully integrated electronic control board
featuring differential temperature control,continuous air/gas modulation, anti-cyclecontrol, pump over-run, self-diagnostic faultindicator, electronic ignition with flamesupervision & appliance frost protection
● Cast aluminium mono-block heat exchanger● Low Nox burner with pre-mix● Two-stage gas valve● Pump● Expansion vessel● Pressure gauge● Safety valve
1.2 MODE OF OPERATION (at rest)When there is no demand for heating or hot waterand the appliance remains inactive for a period of24 hours, the pump will be energised for a fewmoments to prevent it from seizing. Should theflow temperature sensor fall below 7 ºC the pumpwill be energised. If the flow sensor temperaturefalls to below 3 ºC the burner will be lit and theappliance will operate at the minimum output untilthe temperature of the flow sensor reaches 10 ºC,whereupon the pump will continue to run in pumpover-run mode.
1.3 MODE OF OPERATON (heating or hot waterrequest)When there is a request for heat via the time clockand/or external controls, the pump will start andthe fan will be activated via the flow temperaturesensor. When the fan is sensed to be operatingcorrectly, the ignition sequence commences. Thespeed of the fan and therefore the output of theboiler is determined by the temperature of thewater sensed by the flow & return temperaturesensors, consequently a high temperature at theflow sensor results in a lower fan speed. As thewater temperature increases, the temperaturesensors – located on the flow and return pipes ofthe boiler – reduce the fan speed via the electroniccircuitry. Depending on the load, either the watertemperature will continue to rise until the set pointis achieved or the water temperature will fallwhereby fan speed will increase relative to theoutput required. When the boiler has reached theset point, the burner will switch off. The built-inanti-cycle device prevents the burner from re-lighting for an adjustable period of time (factorydefault is 3 minutes). When the temperature ofthe flow sensor falls below the set-point, theburner will re-light.
1.4 SAFETY DEVICESWhen the appliance is in use, safe operation isensured by:● a high limit thermostat that interrupts the
operation of the burner;● a differential temperature protection circuit which
interrupts the burner if the temperature
differential is inverted;● a fan speed sensor that checks the correct
operation of the fan, thereby allowing safeoperation of the burner;
● a condense pressure switch that will stop theburner from operating should the condensetrap become blocked;
● a safety valve which releases excess pressurefrom the primary circuit.
Fig. 2
return flowgas
1
Heatexchanger
Expansionvessel
4
NTC1(flow
sensor)
NTC2(returnsensor)
3
SECTION 2 TECHNICAL DATA
Ref. Condition 15 °C, 1013,25 mbar, dry gasNOTE: L.P.G. data refer to section 10
2.1 Central heating 16 26Heat input (gross) 17.7 kW 29 kWMaximum heat output 60/80°C (return & flow temperature) 15.4 kW 25.3 kWMaximum heat output 30/50°C (return & flow temperature) 16.8 kW 26.8 kWMinimum heat output 60/80°C (return & flow temperature) 4.4 kW 7.3 kWMinimum heat output 30/50°C (return & flow temperature) 4.9 kW 8.1 kWMinimum working pressure 0.5 bar 0.5 barMaximum working pressure 3 bar 3 barMinimum flow rate 350 litres per hour 350 litres per hour
2.2 Gas pressureInlet pressure (G20) 20.0 mbar 20.0 mbarMaximum gas rate 1.69 m3/h 2.76 m3/hMinimum gas rate 0.49 m3/h 0.80 m3/hInjector size single injector with six 3.1 mm holes single injector with six 3.8 mm holes
2.3 Expansion vesselCapacity 10 litres 10 litresMaximum system volume 91 litres (approx.) 91 litres (approx.)Pre-charge pressure 1.0 bar 1.0 bar
2.4 DimensionsHeight 820 mm 820 mmWidth 450 mm 450 mmDepth 355 mm 355 mmDry weight 53 kg 53 kg
2.5 ClearancesSides 12 mm 12 mmTop 150 mm from casing or 25 mm above flue elbow (whichever is applicable)Bottom 150 mm 150 mmFront 600 mm 600 mm
2.6 ConnectionsFlow & return 22 mm compression 22 mm compressionGas 15 mm compression 15 mm compressionSafety valve 15 mm compression 15 mm compression
2.7 ElectricalVoltage 230V/~ 50hz 230V/~ 50hzPower consumption 130 W 130 WInternal fuse F2A F2AExternal fuse 3A 3A
2.8 Flue detailsMaximum horizontal flue length (concentric) 10.0 metres 6.45metresMaximum vertical flue length (concentric) 11.0 metres 7.45 metresMaximum twin flue length (horizontal or vertical) 39 m/39 m + terminal 29 m/29 m + terminal
2.9 EfficiencySEDBUK rating 90.3% (Band “A”) 90.3% (Band “A”)
2.10 Adjustable operating parametersPARAMETER MINIMUM MAXIMUM FACTORY SETTINGP. 4 Central heating flow temperature 20 °C 90 °C 75 °CP. 20 Pump over-run 10 seconds 99 m 10 mP. 28 Anti-cycle delay 0 seconds 306 seconds 91.8 seconds
2.11 Emissions 16 26NOx Min. output 20 ppm 15 ppmNOx Max. output 40 ppm 30 ppmCO Min. output 50 ppm 50 ppmCO Max. output 50 ppm 50 ppmCO2 Min. output 9.8% 9.8%CO2 Max. output 9.8% 9.8%CO/CO2 ratio 0.0005 to 1 0.0005 to 1
4
2.12 PUMP DUTYFig. 3 shows the flow rate available – after allowingfor pressure loss through the appliance – forsystem requirements. When using this graphapply only the pressure loss of the system. Thegraph is based on 20 ºC temperature differential.
Fig. 4
Fig. 3
Wat
er p
ress
ure
(m
H20
)
Litres Per Hour
SECTION 3 GENERAL REQUIREMENTS (UK)
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
5,5
6
6,5
7
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
()
Key Location Minimum distance
A Below an opening (window, air-brik, etc.) 300 mmB Above an opening (window, air-brik, etc.) 300 mmC To the side of an opening (window, air-brik, etc.) 300 mmD Below gutter, drain-pipe, etc. 75 mmE Below eaves 200 mmF Below balcony, car-port roof, etc. 200 mmG To the side of a soil/drain-pipe, etc. 150 mmH From internal/external corner or boundary 300 mmI Above ground, roof, or balcony level 300 mmJ From a surface or boundary facing the terminal 600 mmK From a terminal facing a terminal 1200 mmL From an opening in the car-port into the building 1200 mmM Vertically from a terminal on the same wall 1500 mmN Horizontally from a terminal on the same wall 300 mmP From a structure to the side of the vertical terminal 300 mmQ From the top of the vertical terminal to the roof flashing As determined by the fixed collar
of the vertical terminal
5
This appliance must be installed by a competentperson in accordance with the Gas Safety (Instal-lation & Use) Regulations.
3.1 RELATED DOCUMENTSThe installation of this boiler must be in accord-ance with the relevant requirements of the GasSafety (Installation & Use) Regulations, the localbuilding regulations, the current I.E.E. wiringregulations, the bylaws of the local waterundertaking, the Building Standards (Scotland)Regulation and Building Standards (NorthernIreland) Regulations.It should be in accordance also with any relevantrequirements of the local authority and the relevantrecommendations of the following British StandardCodes of Practice.
3.2 LOCATION OF APPLIANCEThe appliance may be installed in any room orinternal space, although particular attention isdrawn to the requirements of the current I.E.E.wiring regulations, and in Scotland, the electricalprovisions of the Building Regulations, withrespect to the installation of the appliance in aroom or internal space containing a bath or shower.
When an appliance is installed in a room orinternal space containing a bath or shower, theappliance or any control pertaining to it must notbe within reach of a person using the bath orshower.The location chosen for the appliance must permitthe provision of a safe and satisfactory flue andtermination. The location must also permit anadequate air supply for combustion purposesand an adequate space for servicing and aircirculation around the appliance.Where the installation of the appliance will be inan unusual location special procedures may benecessary, BS 6798 gives detailed guidance onthis aspect.A compartment used to enclose the appliancemust be designed and constructed specificallyfor this purpose. An existing compartment/cup-board may be utilised provided that it is modifiedto suit.
Details of essential features of compartment/cupboard design, including airing cupboard in-stallations, are given in BS 6798. This applianceis not suitable for external installation.
3.3 GAS SUPPLYThe gas meter – as supplied by the gas supplier– must be checked to ensure that it is of adequatesize to deal with the maximum rated input of allthe appliances that it serves. Installation pipesmust be fitted in accordance with BS 6891.Pipe work from the meter to the appliance mustbe of adequate size. Pipes of a smaller size thanthe appliance gas inlet connection must not beused.The installation must be tested for soundness inaccordance with BS 6891.
If the gas supply serves more than one appliance,it must be ensured that an adequate supply ismaintained to each appliance when they are inuse at the same time.
3.4 FLUE SYSTEMThe terminal should be located where the disper-sal of combustion products is not impeded andwith due regard for the damage and discolorationthat may occur to building products located nearby.The terminal must not be located in a place whereit is likely to cause a nuisance (fig. 4).
In a cold and/or humid water, water vapour maycondense on leaving the terminal; the effect ofsuch pluming must be considered.If installed less than 2 metres above a pavementor platform to which people have access (includingbalconies or flat roofs) the terminal must beprotected by a guard of durable material. Theguard must be fitted centrally over the terminal.Refer to BS 5440 Part 1, when the terminal is 0,5metres (or less) below plastic guttering or 1 metre(or less) below painted eaves.
3.5 AIR SUPPLYThe following notes are intended for generalguidance only.This appliance is a room sealed, fan-flued boiler,consequently it does not require a permanent airvent for combustion air supply.When installed in a cupboard or compartment,ventilation for cooling purposes is also notrequired.
3.6 WATER CIRCULATIONDetailed recommendations are given in BS 5449Part 1 and BS 6798. The following notes are forgeneral guidance only.
BS 5440 PART 1 FLUES
BS 5440 PART 2 FLUES & VENTILATION
BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS
BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW
BS 6891 LOW PRESSURE INSTALLATION PIPES
BS 7074 PART 1 APPLICATION, SELECTION AND INSTALLATION OF EXPANSION VESSELS ANDANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS
6
Fig. 5A
3.6.1 PIPEWORKIt is recommended that copper tubing to BS 2871 Part1 is used in conjunction with soldered capillary joints.Where possible pipes should have a gradient toensure air is carried naturally to air release pointsand that water flows naturally to drain cocks.Except where providing useful heat, pipes shouldbe insulated to avoid heat loss and in particular toavoid the possibility of freezing. Particular atten-tion should be paid to pipes passing throughventilated areas such as under floors, loft-spaceand void areas.
3.6.2 AUTOMATIC BY-PASSThe appliance has a built-in automatic by-pass,consequently there is no requirement for an ex-ternal by-pass, however the design of the systemshould be such that it prevents boiler ‘cycling’.
3.6.3 DRAIN COCKSThese must be located in accessible positions tofacilitate draining of the appliance and all water pipesconnected to the appliance. The drain cocks must bemanufactured in accordance with BS 2879.
3.6.4 AIR RELEASE POINTSThese must be positioned at the highest points inthe system where air is likely to be trapped. Theyshould be used to expel trapped air and allowcomplete filling of the system.
3.6.5 EXPANSION VESSELThe appliance has an integral expansion vessel toaccommodate the increased volume of water whenthe system is heated. It can accept up to 10 litres ofexpansion from within the system, generally this issufficient, however if the system has an unusuallyhigh water content, it may be necessary to provideadditional expansion capacity.
3.6.6 FILLING POINT (fig. 5)A method for initial filling of the system andreplacing water lost during servicing etc. hasbeen provided. This method of filling must complywith the current Water Supply (Water Fittings)Regulations 1999 and Water Bylaws 2000(Scotland). Fig. 5 shows a widely accepted method.
3.6.7 LOW PRESSURE SEALED SYSTEMAn alternative method of filling the system wouldbe from an independent make-up vessel or tankmounted in a position at least 1 metre above thehighest point in the system and at least 5 metresabove the boiler (fig. 5A). The cold feed from themake-up vessel or tank must be fitted with anapproved non-return valve and stopcock for iso-lation purposes. The feed pipe should be con-nected to the return pipe as close to the boiler aspossible.
3.6.8 FREQUENT FILLINGFrequent filling or venting of the system may beindicative of a leak. Care should be taken duringthe installation of the appliance to ensure allaspects of the system are capable of withstand-ing pressures up to at least 3 bar.
3.7 ELECTRICAL SUPPLYThe appliance is supplied for operation on 230V@ 50Hz electrical supply; it must be protectedwith a 3-amp fuse. The method of connection tothe mains electricity supply must allow forcomplete isolation from the supply. The preferredmethod is by using a double-pole switch with acontact separation of at least 3 mm. The switchmust only supply the appliance and itscorresponding controls, i.e. time clock, room ther-mostat, etc. Alternatively an un-switched shutteredsocket with a fused 3-pin plug both complyingwith BS 1363 is acceptable.
3.8 MOUNTING ON A COMBUSTIBLE SURFACEIf the appliance is to be fitted on a wall of combus-tible material, a sheet of fireproof material mustprotect the wall.
3.9 TIMBER FRAMED BUILDINGSIf the appliance is to be fitted in a timber framedbuilding, it should be fitted in accordance with theInstitute of Gas Engineers publication (IGE/UP/7) “Guide for Gas Installations in aTimber FrameBuildings”.
3.10 CONDENSATE DISPOSALWhen choosing a location for the boiler,consideration should be given to the disposal ofthe condensate discharge into a suitable drain orsoil pipe. The condensate outlet pipe must beconnected to the drain in accordance with buildingregulations or other rules in force.
3.11 INHIBITORSVokera recommend that a inhibitor – suitable foruse with aluminium heat exchangers – is used toprotect the boiler and system from the effects ofcorrosion and/or electrolytic action. The inhibitormust be administered in strict accordance withthe manufacturers* instructions.
Make-up vesselor tank
Automaticair-vent
Non-returnvalve
Stopcock
5.0
met
res
min
imum
Heatingreturn
Fig. 5
control valve
temporaryconnection
control valve
flow/returnpipe
double checkvalve supply pipe
7
*Fernox and Sentinel manufacture products thathave proved suitable for use with Vokeraappliances. Vokera Ltd. cannot comment on thesuitability of any other such product with ourappliances.
Fig. 6
CH returnvalve
CH flowvalve
Gas cock
Fig. 6A
CONDENSATETRAP
RETURN FLOW GAS
8
This appliance must be installed by a competentperson in accordance with and defined by, theStandard Specification (Domestic GasInstallations) Declaration (I.S. 813).
3A.1 RELATED DOCUMENTSThe installation of this boiler must be in accordancewith the relevant requirements of the local buildingregulations, the current ETCI National Rules forElectrical Installations, and the bylaws of thelocal water undertaking.It should be in accordance also with any relevantrequirements of the local and/or district authority.
3A.2 LOCATION OF APPLIANCEThe appliance may be installed in any room orinternal space, although particular attention isdrawn to the requirements of the current ETCINational Rules for Electrical Installations, and I.S.813, Annex K.When an appliance is installed in a room orinternal space containing a bath or shower, theappliance or any control pertaining to it must notbe within reach of a person using the bath orshower.The location chosen for the appliance must permitthe provision of a safe and satisfactory flue andtermination. The location must also permit anadequate air supply for combustion purposesand an adequate space for servicing and aircirculation around the appliance. Where theinstallation of the appliance will be in an unusuallocation special procedures may be necessary,refer to I.S. 813 for detailed guidance on thisaspect.A compartment used to enclose the appliancemust be designed and constructed specificallyfor this purpose. An existing compartment/cupboard may be utilised provided that it ismodified to suit.This appliance is not suitable for externalinstallation.
3A.3 GAS SUPPLYThe gas meter – as supplied by the gas supplier– must be checked to ensure that it is of adequatesize to deal with the maximum rated input of allthe appliances that it serves. Installation pipesmust be fitted in accordance with I.S. 813.Pipe work from the meter to the appliance mustbe of adequate size. Pipes of a smaller size thanthe appliance gas inlet connection must not beused. The installation must be tested forsoundness in accordance with I.S. 813.If the gas supply serves more than one appliance,it must be ensured that an adequate supply ismaintained to each appliance when they are inuse at the same time.
3A.4 FLUE SYSTEMThe terminal should be located where the dispersalof combustion products is not impeded and withdue regard for the damage and discoloration thatmay occur to building products located nearby.The terminal must not be located in a place whereit is likely to cause a nuisance (see I.S. 813).In cold and/or humid weather, water vapour maycondense on leaving the terminal; the effect ofsuch pluming must be considered.If installed less than 2m above a pavement orplatform to which people have access (includingbalconies or flat roofs) the terminal must beprotected by a guard of durable material. Theguard must be fitted centrally over the terminal.Refer to I.S. 813, when the terminal is 0.5 metres(or less) below plastic guttering or 1 metre (orless) below painted eaves.
3A.5 AIR SUPPLYThe following notes are intended for generalguidance only.This appliance is a room-sealed, fan-flued boiler,consequently it does not require a permanent airvent for combustion air supply.When installed in a cupboard or compartment,ventilation for cooling purposes is also notrequired.
3A.6 WATER CIRCULATIONSpecific recommendations are given in I.S. 813.The following notes are for general guidanceonly.
3A.6.1 PIPEWORKIt is recommended that copper tubing be used inconjunction with soldered capillary joints.Where possible pipes should have a gradient toensure air is carried naturally to air release pointsand that water flows naturally to drain cocks.Except where providing useful heat, pipes shouldbe insulated to avoid heat loss and in particular toavoid the possibility of freezing. Particular attentionshould be paid to pipes passing through ventilatedareas such as under floors, loft space, and voidareas.
3A.6.2 AUTOMATIC BY-PASSThe appliance has a built-in automatic by-pass,consequently there is no requirement for anexternal by-pass, however the design of thesystem should be such that it prevents boiler‘cycling.
3A.6.3 DRAIN COCKSThese must be located in accessible positions tofacilitate draining of the appliance and all waterpipes connected to the appliance.
SECTION 3A GENERAL REQUIREMENTS (EIRE)
9
3A.6.4 AIR RELEASE POINTSThese must be positioned at the highest points inthe system where air is likely to be trapped. Theyshould be used to expel trapped air and allowcomplete filling of the system.
3A.6.5 EXPANSION VESSELThe appliance has an integral expansion vesselto accommodate the increased volume of waterwhen the system is heated. It can accept up to 10litres of expansion from within the system,generally this is sufficient, however if the systemhas an unusually high water content, it may benecessary to provide additional expansioncapacity.
3A.6.6 FILLING POINTA method for initial filling of the system andreplacing water lost during servicing etc. must beprovided. A typical arrangement is shown infigure 5. You should ensure this method of fillingcomplies with the local water authority regulations.
3A.6.7 LOW PRESSURE SEALED SYSTEMAn alternative method of filling the system wouldbe from an independent make-up vessel or tankmounted in a position at least 1 metre above thehighest point in the system and at least 5 metresabove the boiler (fig. 5).The cold feed from the make-up vessel or tankmust be fitted with an approved non-return valveand stopcock for isolation purposes. The feedpipe should be connected to the return pipe asclose to the boiler as possible.
3A.6.8 FREQUENT FILLINGFrequent filling or venting of the system may beindicative of a leak. Care should be taken duringthe installation of the appliance to ensure allaspects of the system are capable of withstandingpressures up to at least 3 bar.
3A.7 ELECTRICAL SUPPLYThe appliance is supplied for operation on 230V@ 50Hz electrical supply; it must be protectedwith a 3-amp fuse. The method of connection tothe mains electricity supply must allow forcomplete isolation from the supply. The preferredmethod is by using a double-pole switch with acontact separation of at least 3 mm. The switchmust only supply the appliance and itscorresponding controls, i.e. time clock, roomthermostat, etc.
3A.8 MOUNTING ON A COMBUSTIBLE SURFACEIf the appliance is to be fitted on a wall ofcombustible material, a sheet of fireproof materialmust protect the wall.
3A.9 TIMBER FRAMED BUILDINGSIf the appliance is to be fitted in a timber framedbuilding, it should be fitted in accordance with I.S.813 and local Building Regulations.The Institute of Gas Engineers publication (IGE/UP/7) ‘Guide for Gas Installations in Timber Frame
Buildings’ gives specific advice on this type ofinstallation.
3A.10 CONDENSATE DISPOSALWhen choosing a location for the boiler,consideration should be given to the disposal ofthe condensate discharge into a suitable drainor soil pipe. The condensate outlet pipe must beconnected to the drain in accordance withbuilding regulations or other rules in force.
3A.11 INHIBITORSVokera recommend that a inhibitor – suitable foruse with aluminium heat exchangers – is usedto protect the boiler and system from the effectsof corrosion and/or electrolytic action. Theinhibitor must be administered in strictaccordance with the manufacturers* instructions.
*Fernox and Sentinel manufacture products thathave proved suitable for use with Vokeraappliances. Vokera Ltd. cannot comment on thesuitability of any other such product with ourappliances.
3A.12 DECLARATION OF CONFORMITYA Declaration of Conformity (as defined in I.S.813) must be provided on completion of theinstallation.A copy of the declaration must be given to theresponsible person and also to the gas supplierif required.
10
SECTION 4 INSTALLATION
4.1 DELIVERYDue to the weight of the appliance it may benecessary for two people to lift and attach theappliance to its mounting. The appliance iscontained within a heavy-duty cardboard carton.Lay the carton on the floor with the writing thecorrect way up.
4.2 CONTENTSContained within the carton is:● the boiler;● the wall bracket;● template;● an accessories pack containing appliance
service connections and washers;● the instruction pack containing the installation
& servicing instructions, user instructions,Benchmark logbook, guarantee registrationcard and a 3-amp fuse.
4.3 UNPACKINGAt the top of the carton pull both sides open – donot use a knife – unfold the rest of the carton fromaround the appliance, carefully remove allprotective packaging from the appliance, and laythe accessories etc. to one side. Protective glovesshould be used to lift the appliance, the applianceback-frame should be used for lifting points.
4.4 PREPARATION FOR MOUNTING THEAPPLIANCEThe appliance should be mounted on a smooth,vertical, non-combustible surface, which must becapable of supporting the full weight of theappliance. Care should be exercised whendetermining the position of the appliance withrespect to hidden obstructions such as pipes,cables, etc.When the position of the appliance has beendecided – using the template supplied – carefullymark the position of the wall- mounting bracket(fig. 6A) and flue-hole (if applicable).
4.5 FITTING THE FLUEThe top flue outlet permits both horizontal andvertical flue applications to be considered,alternatively, the Vokera twin flue system can beutilised if longer flue runs are required.
4.5.1 CONCENTRIC HORIZONTAL FLUE(For concentric vertical flue, see section 4.5.2).(For twin flue applications, see section 4.5.3).The appliance flue outlet elbow can be rotatedthrough 360º on its vertical axis. In addition theflue may be extended from the outlet elbow in thehorizontal plane (see section 2.9). A reductionmust also be made to the maximum length (seetable below) when additional bends are used.
Using the template provided (fig. 6A), mark anddrill a 125 mm hole for the passage of the fluepipe. The hole should have a 1º rise from theboiler to outside.The fixing holes for the wall-mounting bracketshould now be drilled and plugged, an appropriatetype and quantity of fixing should be used toensure that the bracket is mounted securely.Once the bracket has been secured to the wall,mount the appliance onto the bracket.
FITTING THE HORIZONTAL FLUE KITUsing a twisting motion, connect the boiler topadaptor – supplied with the flue terminal kit – tothe appliance flue outlet ensuring the male spigotof the adaptor is pushed fully into the flue outletspigot of the boiler (fig. 7). Carefully measure thedistance from the centre of the appliance flueoutlet to the edge of the finished outside wall(dimension X). Add 45 mm to dimension X togive you Dimension Y (fig 7A). Measuredimension Y from the terminal end of theconcentric flue pipe and cut off the excess. Passthe concentric flue pipe through the previouslydrilled hole. Fit the flue bend to the boiler top
Reduction for additional bends
Bend Reduction in maximum flue length for each bend
45° bend
90° bend
0.5 metre
1.0 metre
Horizontal flue terminals and accessories
Part No. Description Min-Max length
0225720
0225755
0225740
0225745
0225750
0225730
0225735
0225760
Horizontal flue kit for use withadd. bends & extensions
Telescopic extension
0.5 m extension
1.0 m extension
2.0 m extension
45° bend (pair)
90° bend
Wall bracket (5)
1000 mm
350 mm-500 mm
500 mm
1000 mm
2000 mm
N/A
N/A
N/A
Push-fitconnection
Horizontalterminal orextension
Boiler
Boiler topadaptor
Fig. 7
11
adaptor and insert the concentric flue pipe intothe flue bend ensuring the correct seal is made.
Using the clamp, gasket and screws supplied,secure the flue bend to the appliance flue spigot.
NOTEYou must ensure that the entire flue system isproperly supported and connected.
Seal the flue assembly to the wall using cementor a suitable alternative that will providesatisfactory weatherproofing. The interior andexterior trim can now be fitted.
4.5.1.1 EXTENDING THE FLUEConnect the bend – supplied with the terminal kit– to the top of the boiler using the boiler topadapter and clamp (supplied, fig. 7). The additionalbends & extensions have push-fit connections,care should be taken to ensure that the correctseal is made when assembling the flue system.Connect the required number of flue extensionsor bends (up to the maximum equivalent fluelength) to the flue terminal (fig. 7 & 7B).
Fig. 7A
NOTEWhen cutting an extension to the required length,you must ensure that the excess is cut from theplain end of the extension (fig. 7 & 7B). Removeany burrs, and check that all seals are locatedproperly.You must ensure that the entire flue system isproperly supported and connected.Seal the flue assembly to the wall using cementor a suitable alternative that will providesatisfactory weatherproofing. The interior andexterior trim can now be fitted.
4.5.2 CONCENTRIC VERTICAL FLUEThe vertical flue terminal can be connected directlyto the appliance flue outlet. Alternatively, anextension or bend can be connected to theappliance flue outlet if desired (see section 2.9),however if additional bends are fitted, a reductionmust be made to the maximum flue length (seetable below).
Reduction for bends
Bend Reduction in maximum flue length for each bend
45° bend
90° bend
0.5 metre
1.0 metre
Vertical flue terminal and accessories
Part No. Description Min-Max length
0225725
0225770
0225765
0225755
0225740
0225745
0225750
0225730
0225735
0225760
Vertical flue terminal
Pitched roof flashing plate
Flat roof flashing plate
350-500 telescopic extension
500 mm extension
1000 mm extension
2000 mm extension
45° bend (pair)
90° bend
Wall bracket (4)
1000 mm
N/A
N/A
350 mm-500 mm
500 mm
1000 mm
2000 mm
N/A
N/A
N/A
Fig. 8
520 mm
300 mm minimum
170mmFig. 7B
“Y” = “X” + 45 mm
Boiler
Extension pipe
Boiler top adaptor
Push-fit connection
Plain end
12
Using the dimensions given in fig. 8 as a reference,mark and cut a 105 mm hole in the ceiling and/orroof.IMPORTANTYou must ensure that the terminal is at least 300mm from any structure or surface (fig. 8).The vertical flue terminal is 1.0 metre in lengthand cannot be cut; therefore it may be necessaryto adjust the height of the appliance to suit or usea suitable extension. Ensure that any horizontalsections of the flue system have a 1º fall back tothe boiler (17 mm per 1000 mm).Fit the appropriate flashing plate to the roof andinsert the vertical flue terminal through the flashingplate from the outside, ensuring that the collar onthe flue terminal fits over the flashing.The fixing holes for the wall-mounting bracketshould now be drilled and plugged, an appropriatetype and quantity of fixing should be used toensure that the bracket is mounted securely.Once the bracket has been secured to the wall,mount the appliance onto the bracket.Secure the vertical flue terminal or intermediateflue component, to the appliance using the boilertop adaptor and 100 mm clamp supplied.NOTEWhen cutting an extension to the required length,you must ensure that the excess is cut from theplain end of the extension. Remove any burrs,and check that any seals are located properly.
4.5.3 TWIN FLUE SYSTEMThe Vokera twin flue system enables greater fluedistances to be achieved (see section 2.9) thanthat of the standard concentric flue system. It canbe used for horizontal or vertical applications,however the twin flue system must be convertedto the dedicated concentric flue kit for termination.It is essential that the installation of the twin fluesystem be carried out in strict accordance withthese instructions.GUIDANCE NOTES ON TWIN FLUEINSTALLATION● The flue must have a fall back of 1º back to the
appliance to allow any condensate that formsin the flue system to drain. Consideration mustalso be given to the fact that there is thepossibility of a small amount of condensatedripping from the terminal.
● Ensure that the entire flue system is adequatelysupported, use at least one bracket for eachextension.
● Extreme care must be taken to ensure that nodebris is allowed to enter the flue system atany time.
● As the exhaust outlet pipe can reach very hightemperatures it must be protected to preventpersons touching the hot surface.
MOUNTING THE BOILERThe fixing holes for the wall-mounting bracketshould now be drilled and plugged, anappropriate type and quantity of fixing should beused to ensure that the bracket is mountedsecurely. Once the bracket has been secured tothe wall, mount the appliance onto the bracket.
4.5.3.1 INSTALLATION OF TWIN ADAPTOR KIT (fig. 9)● Insert the exhaust connection manifold (B) onto
the appliance flue outlet and secure to the fluespigot using the screws provided.
● Remove the blanking plates (located to the leftof the appliance flue outlet) and – using thesame screws – install the air baffle (A).
4.5.3.2 HORIZONTAL TERMINATION (fig. 10)The twin flue system must be converted to thededicated concentric flue kit for termination.● The horizontal terminal is supplied with a built-
in converter box and cannot be shortened.● A 130 mm hole is required for the passage of
the concentric terminal through the wall.Depending on site conditions it may be preferableto install the terminal assembly prior to fitting thetwin flue pipes.Mark and drill a 130 mm hole for the passage ofthe horizontal flue terminal, ensuring that there isa 1° fall back to the boiler (17 mm per 1000 mm).Insert the terminal assembly into the flue hole.Push-fit the twin flue pipes onto the concentric totwin converter box ensuring that the exhaust pipe
Reduction in maximum flue length for each bend
Reduction for bends
Bend
45° bend
90° bend
1.0 metre
1.0 metre
Twin flue accessories
Part No. Description Length
0225805
0225810
359
0225770
0225765
0225815
0225820
0225825
0225830
0225835
0225840
0225845
0225850
0225855
Horizontal flue terminal
Vertical flue terminal
Twin adapter kit
Pitched roof flashing plate
Flat roof flashing plate
Condensate drain kit
0.25 m extension (pair)
0.5 m extension (pair)
1.0 m extension (pair)
2.0 m extension (pair)
45° bend (pair)
90° bend (pair)
Twin bracket (5)
Single bracket (5)
1000 mm
1000 mm
N/A
N/A
N/A
N/A
250 mm
500 mm
1000 mm
2000 mm
N/A
N/A
N/A
N/A
Fig. 9
BA
13
connects to the exhaust connection on theconcentric to twin converter.If necessary cut the plain ends (male) of the twinflue pipes to allow connection to the concentricto twin converter.NOTEBefore cutting twin flue pipes ensure allowanceshave been made for connection onto the previouspiece and onto the concentric to twin converter.The last twin flue pipes must be pushed 50 mmonto the male spigots of the concentric to twinconverter.
NOTEYou must ensure that the entire flue system isproperly supported and connected.When cutting an extension to the required length,you should ensure that the excess is cut fromthe plain end of the extension. Remove any burrsand check that both seals are located properly.Seal the flue terminal assembly to the wall usingcement or a suitable alternative that will providesatisfactory weatherproofing. The interior andexterior trim can now be fitted.
4.5.3.3 VERTICAL TERMINATION (fig. 11)The twin flue system must be converted to thededicated concentric flue kit for termination.● The vertical terminal is supplied with a built-in
converter box and cannot be shortened.● A 130 mm hole is required for the passage of
the concentric terminal through the ceiling and/or roof.
Depending on site conditions it may be preferableto install the terminal assembly prior to fitting thetwin flue pipes.Fit the appropriate flashing plate to the roof andinsert the vertical flue terminal through theflashing plate from the outside, ensuring that thecollar on the flue terminal fits over the flashing.Push-fit the twin flue pipes onto the concentric totwin converter ensuring that the exhaust pipeconnects to the exhaust connection on theconcentric to twin converter.If necessary cut the plain ends (male) of the twinflue pipes to allow connection to the concentricto twin converter.NOTE● Before cutting twin flue pipes ensure
allowances have been made for connectiononto the previous piece and onto the concentricto twin converter. The last twin flue pipes mustbe pushed 50 mm onto the male spigots of theconcentric to twin converter.
● You must ensure that the entire flue system isproperly supported and connected.
● Ensure that any horizontal sections of pipehave a 1° fall towards the appliance (17 mmper 1000mm).
convertor box
Fig. 11
convertor box
● The convertor box on the vertical terminal willhave to be temporarily removed when insertingthe terminal through the flashing.
4.6 CONNECTING THE GAS AND WATERCare must be taken to ensure that the applianceand/or its ancillary components are protectedfrom the use of a blowtorch or similar solderingequipment. The appliance is supplied withaccessories that include sealing washers andservice valves and connections.When connecting pipe work to the valves, tightenthe compression end first then insert the sealingwashers before tightening the valve to theappliance.NOTEIt will be necessary to hold the valve with onespanner whilst tightening with another.
4.6.1 GAS (fig. 6 & 6A)The appliance is supplied with a 15 mm servicevalve, connect the supply pipe to the inlet of thevalve and tighten the connecting nut.NOTEIt will be necessary to calculate the diameter ofthe gas supply pipe to ensure the appliance hasan adequate supply of gas.
4.6.2 FLOW & RETURN (fig. 6 & 6A)The appliance is supplied with 22 mm servicevalves for the flow and return connections, connecta 22 mm pipe to the inlet of each valve and tightenboth nuts.
4.6.3 SAFETY VALVEConnect the safety valve discharge pipe to thesafety valve outlet and tighten.The dischargepipe must have a continuous fall away from theappliance to outside and allow any water to drainaway thereby eliminating the possibility of freezing.The discharge pipe must terminate in a positionwhere any water - possibly boiling - dischargessafely without causing damage or injury, but isstill visible.
4.7 CONDENSATE OUTLET (fig. 6A)During normal operation the boiler producescondensate which is collected in a trap located inthe lower part of the boiler. A flexible pipe
Fig. 10
14
(condensate outlet pipe) is connected to theoutlet of the trap. The flexible pipe must beconnected to a plastic waste pipe only. Theplastic waste pipe must have a minimum of a 3ºfall towards the drain. Any external run of pipeshould be insulated to prevent the risk of freezing.
CONNECTING THE CONDENSATE OUTLETGently pull the condensate outlet pipe down fromits location inside the boiler until approximately250 mm protrudes from the underside of theboiler. Connect a suitable plastic (not copper)pipe (no less than 20 mm diameter) to the outletpipe and ensure it discharges in accordance withbuilding regulations or other rules in force.
4.8 AUTOMATIC AIR RELEASE VALVEMount the AAV as shown in fig. 12.
4.9 ELECTRICAL CONNECTIONSThe electrical supply must be as specified insection 3. A qualified electrician should connectthe electrical supply to the appliance. If controls– external to the appliance – are required, acompetent person must undertake the design ofany external electrical circuits, please refer tosection 8 for detailed instructions.ANY EXTERNAL CONTROL OR WIRING MUSTBE SERVED FROM THE SAME ISOLATOR ASTHAT OF THE APPLIANCE.The supply cable from the isolator to the appliancemust be 3-core flexible sized 0.75 mm to BS6500. Wiring to the appliance must be rated foroperation in contact with surfaces up to 90 ºC.
4.9.1 ELECTRICAL INPUT BOARDThe appliance electrical input board is locatedbehind the control fascia.To gain access to the appliance electricalconnections you must proceed as follows:● push to release front door panel and lower to
reveal controls. Loosen the 2 captive screwssecuring the front control panel to the lower partof the casing and lower to reveal inside of theboiler (fig. 13A);
● remove the 4 screws securing the input boardcover (fig. 13B).
NOTEThe appliance comes with a factory fitted link toallow basic operation of the boiler via the keypad.If it is anticipated that external controls will berequired please refer to the wiring diagrams insection 8 for more detailed information.
4.9.2 CONNECTING THE MAINS (230V) INPUT(fig. 14)Remove the electrical input board cover asdescribed in section 4.9.1. Pass the cable throughthe cable anchorage. Connect the supply cablewires (earth, live and neutral) to theircorresponding terminals on the electrical inputboard. Ensure that the EARTH wire is left slightlylonger that the others, this will prevent strain onthe EARTH wire should the cable become taut.Do not remove the link wire (between terminals 2& 3 on plug M7) unless additional external controlsare to be fitted (see section 8). Re-fit the electricalinput board cover.The securing screw on the cable anchorageshould now be tightened. This must be donebefore the control fascia is re-fitted in the uprightposition.
Fig. 13A
screws
Fig. 13B
Fig. 12
Fig. 14
15
Fig. 15
4.10 CASING REMOVALLower the front control panel as described insection 4.9.1.● Locate and remove the 2 screws that secure
the controls fascia to the appliance casing (fig.13A)
● locate and remove the 2 screws that secure thecasing to the back frame of the boiler (fig. 15)
● gently pull one side of the casing then the otherto disengage it from the retaining clips
● lift the casing upward to disengage it from thetop locating hooks and then remove
● store the casing and screws safely until required.Re-fit in the reverse order.
screwscrew
16
Parameter Description Range
1
2
3
4
N/A
N/A
Heating mode
Heating outlet temperature
N/A
N/A
00 = off01 = on03 = off
(pump on continuously)04 = on
(pump on continuously)
20 °C - 90 °C
5.1 GAS SUPPLY INSTALLATIONInspect the entire installation including the gasmeter, test for soundness and purge.
5.2 THE HEATING SYSTEMThe appliance contains components that maybecome damaged or rendered inoperable by oilsand/or debris that are residual from the installationof the system, consequently it is essential that thesystem be flushed in accordance with the followinginstructions.
5.3 INITIAL FILLING OF THE SYSTEM
5.3.1. Ensure both flow and return service valves areopen, identify the automatic air release valve (fig.12) and loosen the dust cap by turning the capanti-clockwise one full turn.
5.3.2. IMPORTANT, THERE ARE NO MANUAL AIRRELEASE VALVES LOCATED ON THEAPPLIANCE. Ensure all manual air release valveslocated on the heating system are closed.
5.3.3. Using the method of filling as described in fig. 5,slowly proceed to fill the system. As water entersthe system the pressure gauge will begin to rise.Once the gauge has reached 1 bar close thefilling valve and begin venting all manual airrelease valves, starting at the lowest first. It maybe necessary to go back and top-up the pressureuntil the entire system has been filled. Inspect thesystem for water soundness, rectifying any leaks.
5.4 INITIAL FLUSHING OF THE SYSTEMThe whole of the heating system must be flushedboth cold and hot as detailed in section 5.8. Openall radiator or heating valves and the applianceflow & return service valves. Drain the boiler andsystem from the lowest points. Open the drainvalve full bore to remove any installation debrisfrom the boiler prior to lighting. Refill the boilerand heating system as described in section 5.3.
5.5 PRE-OPERATION CHECKSBefore attempting the initial lighting of the appliance,the following checks must be carried out:● ensure all gas service valves from the meter to
the appliance are open and the supply pipe hasbeen properly purged;
● ensure the proper electrical checks have beencarried out, (see section 7.7) particularlycontinuity, polarity, and resistance to earth;
● ensure the 3 amp fuse – supplied with theappliance – has been fitted;
● ensure the system has been filled, vented, andthe pressure set to 1 bar;
● ensure the flue system has been fitted properlyand in accordance with the instructions;
● ensure all appliance service valves are open.
5.6 INITIAL LIGHTINGEnsure the electrical supply to the appliance isswitched on. Switch the time clock or programmerto an ‘on’ position and ensure all external controlsare also calling for heat.The appliance will operate in the central heatingmode as described in section 1.3. Should theappliance fail to ignite, refer to section 5.6 and/orsection 7 (faultfinding).
5.7 FINAL FLUSHING OF THE HEATING SYSTEMThe system shall be flushed in accordance withBS 7593. If a cleanser is to be used, it shall befrom a reputable manufacturer* and shall beadministered in strict accordance with themanufacturers instructions.*Both Sentinel and Fernox manufacture productsthat have proved suitable for use with Vokeraappliances. Vokera Ltd. cannot comment on thesuitability of any other such product with ourappliances.
5.8 INHIBITORSSee Section 3 “General Requirements”.
5.9 APPLIANCE OPERATING PARAMETERSThe appliance is supplied with pre-set operatingparameters. Parameters 3 & 4 can be adjusted atany time, however the remaining parameters (5 –42) can only be accessed after entering therelevant service code, and should only be adjustedby qualified service personnel.
5.10 PARAMETERS 3 & 4Parameters 3 & 4, are used to alter or adjust theoperating mode and flow temperature. Use thefollowing table and procedure to check or adjustthe relevant parameters:
● Press the mode button until “PARA” appearsin the display.
● Press the S button until the appropriate
parameter is shown in the left side of thedisplay.
● Use the + or - buttons to adjust the value
of the paramater as shown in the right side ofthe display.
● Press the M button to store the new setting.
● Press the reset button to return to thestand-by mode.
IMPORTANTUnder no circumstances should any parameters- other than those shown above - be changed oradjusted by non competent personnel.
5.11 INFORMATION MODEThe appliance keypad can be used to displaycertain information on the working status of theboiler. Information such as flow & returntemperature, and temperature rise can be viewedusing the following table and procedure:
SECTION 5 COMMISSIONING
17
● Press the mode button until “INFO” appearsin the display.
● Press the S button until the appropriate step
number is shown in the left side of the display.● The measured value of each step is shown on
the right side of the display.
● Press the mode button until “Stby” appears
in the display to return to the stand-by mode.5.12 SETTING THE SYSTEM DESIGN PRESSURE
The design pressure should be a minimum of 1bar and a maximum of 1,5 bar.The actual reading should ideally be 1 bar plusthe equivalent height in metres (0,1 bar = 1metre) to the highest point in the system abovethe base of the appliance (up to the maximumof 1,5 bar total).N.B. The safety valve is set to lift at 3 bar/30metres/45 psig.To lower the system pressure to the requiredvalue, pull lever on head of safety valve to releasewater until the required figure registers on thepressure gauge (fig. 1).
5.13 REGULATING THE CENTRAL HEATINGSYSTEMFully open all radiator and circuit valves and runthe appliance for both heating and hot water untilheated water is circulating. If conditions are warmremove any thermostatic heads. Adjust radiatorreturn valves and any branch circuit return valvesuntil the individual return temperatures are correctand are approximately equal.
5.14 CHECKING DYNAMIC GAS PRESSUREIsolate the appliance from the electrical supplyand remove the appliance casing as described insection 4.10. Unclip and remove the front airchamber cover.Attach a suitable manometer to the inlet testnipple of the gas valve.Restore the electrical supply to the boiler andgenerate a request for central heating via theroom thermostat and/or timer.
Press the mode and + buttons at the same
time, the boiler will now run at full power for 15minutes.The dynamic gas pressure will now be shown onthe manometer, and should be 20 mbar +/- 1 mbar.If the dynamic gas pressure is out-with thetolerance range, you should contact the gassupplier for advice.
Press the + and - buttons at the same
time to return to the normal operating mode.Isolate the appliance from the electrical supply,remove the manometer from the inlet test nipple,tighten the test nipple screw, and check forsoundness.Refit the air chamber cover and appliance casingin the reverse order.
5.15 FINAL CHECKS● ENSURE ALL TEST NIPPLES ON THE
APPLIANCE GAS VALVE ARE TIGHT ANDHAVE BEEN CHECKED FOR SOUNDNESS.
● ENSURE THE APPLIANCE FLUE SYSTEM ISFITTED CORRECTLY AND IS PROPERLYSECURED.
● ENSURE ALL PIPE WORK IS RE-CHECKEDFOR SOUNDNESS.
● RE-FIT APPLIANCE CASING.● COMPLETE APPLIANCE LOGBOOK.
Complete details of the boiler, controls, installationand commissioning in the logbook supplied withthe boiler. This is an important document, whichmust be correctly completed and handed to theuser. Failure to install and commission theappliance to the manufacturers instructions mayinvalidate the warranty.
5.16 INSTRUCTING THE USERHand over all documentation supplied with thisappliance – including these instructions – andexplain the importance of keeping them in a safeplace.Explain to the user how to isolate the appliancefrom the gas, water and electricity supplies, andthe locations of all drain points.Show the user how to operate the appliance andits associated controls correctly.Show the user the location of the filling valve andhow to top-up the system pressure correctly andshow the location of all manual air release points.Explain to the user how to turn off the appliancefor both long and short periods and advise on thenecessary precautions to prevent frost damage.
Step number Information displayed1234567
8
9A
Temperature at flow sensorTemperature at return sensorUnusedUnusedUnusedRequired temperature (as set at parameter 4)Temperature rise of flow sensor (measured in °C persecond)Temperature rise of return sensor (measured in °Cper second)UnusedUnused
18
SECTION 6 SERVICING INSTRUCTIONS
6.1 GENERALTo ensure the continued safe and efficientoperation of the appliance, it is recommendedthat it is checked and serviced at regular intervals.The frequency of servicing will depend upon theparticular installation conditions, but in general,once per year should be adequate.It is the law that any servicing work is carried outby competent person such as a Vokera engineer,an approved service agent, British Gas or otherCORGI registered personnel.The following instructions apply to the applianceand its controls, but it should be remembered thatthe central heating system will also requireattention from time to time.
6.2 ROUTINE ANNUAL SERVICING● Check the operation of the appliance and ensure
it functions as described in section 7.● Compare the performance of the appliance
with its design specification. The cause of anynoticeable deterioration should be identifiedand rectified without delay.
● Thoroughly inspect the appliance for signs ofdamage or deterioration especially the fluesystem and the electrical apparatus.
● Check and adjust – if necessary – the systemdesign pressure (see section 5.12).
● Ensure both the burner and heat exchanger areclean and free from any debris or obstruction.
● Carry out an analysis of the flue gases (seesection 7.4), and visually check the condition ofthe entire flue assembly.
● Compare the results with the appliance designspecification. Any deterioration in performancemust be identified and rectified without delay.
● Inspect all joints for signs of leakage and repairif necessary.
● Refer to the commissioning section and/orreplacement of parts section for detailedinstruction if required.
6.3 REPLACEMENT OF COMPONENTSAlthough it is anticipated that this appliance willgive years of reliable, trouble free service, the lifespan of components will be determined by factorssuch as operating conditions and usage. Shouldthe appliance develop a fault, the fault findingsection will assist in determining which componentis malfunctioning. Always use genuine Vokeraspare parts.
6.4 COMPONENT REMOVAL PROCEDURETo remove a component, access to the interior ofthe appliance is essential. Isolate the appliancefrom the electrical supply and remove the fuse.And when necessary, close all service valves onthe appliance, remove the appliance casing asdescribed in section 4.10. Drain the water contentfrom the appliance via the safety valve. Ensuresome water absorbent cloths are available tocatch any residual water that may drip from theappliance or removed component. Undertake acomplete commissioning check as detailed insection 5, after replacing any component.
ALWAYS TEST FOR GAS SOUNDNESS IFANY GAS CARRYING COMPONENTS HAVEBEEN REMOVED OR DISTURBED.
6.5 PUMP HEAD (fig. 1)Carry out component removal procedure asdescribed in section 6.4.Using a 4 mm Allen key or ‘T’ bar, unscrew andremove the four Allen screws that hold the pumpin position, pull firmly on the pump head to releaseit from the base. Disconnect the electrical leads.Replace in the reverse order.
6.6 SAFETY VALVE (fig. 16)Carry out component removal procedure asdescribed in section 6.4.Disconnect the outlet pipe from the safety valve.Remove safety valve locking screw from theunderside of the appliance manifold. Pull safetyvalve free from manifold.Replace in the reverse order.
6.7 AUTOMATIC AIR RELEASE VALVE (fig. 12)Carry out component removal procedure as de-scribed in section 6.4. Using a suitable pair ofpump pliers, unscrew the AAV from its position.Replace in the reverse order.
6.8 PRESSURE GAUGE (fig. 17)Carry out component removal procedure as de-scribed in section 6.4.Remove pressure gauge locking screw, locatedon manifold, and withdraw the pressure gaugepipe, locate the spring tabs on the pressuregauge body, push and hold tabs in, to enableextraction of the gauge from its location.Replace in the reverse order.
Fig. 16
Safety valve
Locking screw
Fig. 17
Pressure gaugeconnection
Locking screw
Manifold
19
6.9 NTC THERMISTORS (temperature sensors)Carry out component removal procedure as de-scribed in section 6.4.Flow & return sensors (fig. 1 & 18)Pull back protective boot and remove the 2 spadeconnectors. Slacken and remove the 2 securingscrews.Replace in the reverse order.
6.10 PRINTED CIRCUIT BOARD (PCB) (fig. 19)Carry out component removal procedure as de-scribed in section 6.4.● Locate and remove the 2 screws that secure
the PCB housing bracket to the underside ofthe air chamber.
● Remove the 4 screws that secure the housingcover to the housing.
● After carefully taking note of all wiringconnections, disconnect all wiring from thePCB.
● Locate and remove the 3 screws that securethe PCB to the housing.
Replace in the reverse order.
6.11 GAS VALVE (fig. 20)Carry out component removal procedure asdescribed in section 6.4.The gas valve must be changed as complete unit.Unclip and remove the air chamber cover.Disconnect the electrical plug from the gas valve.Disconnect silicone tube from gas valve regulator.Slacken and unscrew gas valve inlet and outletconnections. Please note, the sealing washersmust be discarded and replaced with new sealingwashers. The gas valve can now be removed.Replace in the reverse order. Refer to sectionseven for detailed instructions on how to set-upthe gas valve. WARNING, A GAS SOUNDNESSCHECK MUST BE CARRIED OUT.
6.12 FAN (fig. 20A)Carry out component removal procedure asdescribed in section 6.4.Unclip and remove the air chamber cover.Disconnect the electrical plug from the fan. Locateand remove the 4 bolts that secure the fan to thepre-mix manifold. Replace in the reverse order.
6.13 BURNER (fig. 21 & 23)Carry out component removal procedure as de-scribed in section 6.4.Unclip and remove the air chamber cover. Locateand remove the 8 nuts (10 mm) securing the pre-mix manifold/burner assembly.Disconnect thegas valve outlet pipe at its connection to the pre-mix manifold. Disconnect the silicone pipe fromthe pre-mix manifold. Gently pull away the fan/pre-mix manifold assembly from the heatexchanger. Remove the earth wire from the burnerearth tab and gently lift the burner from its location.Replace in the reverse order. Please note, ensureall seals are in good condition, taking care toensure they are replaced correctly.
Fig. 20
Fig. 19
Fig. 18
Screw
Screw
Securing nuts
Sparkelectrode
Gas valve outletconnection
Fig. 21
Fig. 20A
20
6.14 ELECTRODE (fig. 21 & 22)Carry out component removal procedure as de-scribed in section 6.4.Unclip and remove the air chamber cover.Remove the electrode lead. Remove the 2 screwsthat secure the electrode to the combustion cover,and gently withdraw the electrode.Replace in the reverse order ensuring that theelectrode seal is in good condition, and that thecombustion cover insulation board is undisturbed.
6.15 INJECTOR (fig. 23)Carry out component removal procedure as de-scribed in section 6.4.Unclip and remove the air chamber cover.Remove the fan as detailed in section 6.12 usinga 17 mm socket, locate and unscrew the injector.Replace in the reverse order.
6.16 AUTOMATIC BY-PASS ASSEMBLY (fig. 27)Carry out component removal procedure as de-scribed in 6.4.Disconnect and remove the flow pipe andexpansion pipe from the manifold assembly. Usinga suitably shaped screwdriver, lever out the auto
6.17 CONDENSE TRAP (see fig. 24)Carry out component removal procedure asdescribed in section 6.4. Disconnect the pressureswitch tube from the condense trap. Disconnectboth the inlet and outlet connections from thetrap. Carefully withdraw the trap, keeping it uprightto avoid spillage. Replace in the reverse order.
6.18 CONDENSE PRESSURE SWITCH (fig. 25)Carry out component removal procedure asdescribed in section 6.4.Unclip and remove the air chamber cover.Disconnect the electrical wiring and pressuretube from the pressure switch. Remove theretaining screws and/or clip.Replace in the reverse order.
6.19 COMBUSTION COVER (fig. 26)Carry out component removal procedure asdescribed in section 6.4.Unclip and remove the air chamber cover.Remove the gas valve as described in section6.11. Remove the condense pressure switch asdescribed in section 6.20. Disconnect the electricalconnection from the fan, disconnect the sparkelectrode lead and earth wire from the sparkelectrode. Locate and remove the twelve 10 mmsecuring nuts. Carefully remove the combustioncover from the locating studs. Remove thecombustion cover from the air chamber,withdrawing it at a slight angle from the right hand
All dimensions in mm.
Fig. 22
Injector
Fan
Burner plate
Fig. 23
Fig. 24
Inlet connectionPressure
switch connection
Outlet connection
Fig. 26
Fig. 25
Condensepressure switch
21
side. Replace in the reverse order, ensuring thatall seals and insulation panels are undamagedand in good condition.
6.20 EXPANSION VESSEL (fig. 1)Due to the compact design of this appliance,removal and/or replacement of the expansionvessel may require the appliance to be removedfrom the wall, if this is deemed impractical, anexternal expansion vessel may be fitted to thereturn pipe as close to the appliance as possible.
6.20.1 EXPANSION VESSEL (removal, fig. 28)Carry out component removal procedure asdescribed in section 6.4.Disconnect the flue from the appliance.Disconnect the expansion vessel from theexpansion pipe.Remove the flow sensor as shown in section 6.9.Locate and remove the 4 screws.Remove the rear frame.Slacken the flow pipe nut: the expansion vesselcan now be removed shifting the flow pipe on theleft side.Replace in the reverse order. Ensure all seals arein good condition, taking care to ensure they arereplaced correctly.
6.21 INPUT PCB & STATUS PCB (fig. 29)Carry out component removal procedure asdescribed in section 6.4.Refer to section 4.10 for details on how to removecasing.Remove the 5 screws securing the control boardcover. Carefully note the positions of allconnections relative to the PCB that is to beremoved. Remove the wiring and plugs from thePCB. Locate and remove the securing screws.Remove PCB.Replace in the reverse order, ensuring correctconfiguration of wiring.
Fig. 27
1 Hydraulic manifold2 Safety valve locking screw3 Pressure gauge locking screw4 Safety valve5 Expansion pipe6 Bleed/drain nipple7 Automatic bypass8 Expansion pipe locking screw
1
2
3
4
6
7
8
5
Fig. 28
screws
rearframe
Fig. 29input PCB status PCB
22
7.1 CHECKING APPLIANCE OPERATIONWhen carrying out any repairs or servicing to theappliance, the relevant commissioning and/orset-up procedure must be undertaken to ensurethe continued safe operation of the appliance.Particular attention should be made to ensuregas soundness, water soundness, and theelectrical integrity of the appliance.
7.2 APPLIANCE MODE OF OPERATION
7.2.1 START-UPWhen power is first supplied to the appliance itwill go through a self-purge procedure wherebythe pump and fan will be momentarily energised.The boiler will then operate in either one of thefollowing modes:● Stand-by● Heating mode
7.2.2 STAND-BYWhen there is no demand for heating or hotwater. And the appliance remains inactive for aperiod of 24 hours, the pump will be energised fora few moments to prevent it from seizing. Shouldthe flow temperature sensor fall below 7 °C thepump will be energised. If the flow sensortemperature falls to below 3 °C the burner will belit and the appliance will operate at the minimumoutput until the temperature of the flow sensorreaches 10 °C, whereupon the pump will continueto run in pump over-run mode.
7.2.3 CENTRAL HEATING MODEWhen there is a request for heat via the time clockand/or external controls the motorised valve andpump will go through a self-test function this is toensure correct operation and valve configuration.Once the self-test function is complete, the pumpand fan will be activated via the flow temperaturesensor. When the fan is sensed to be operatingcorrectly, the ignition sequence commences. Thespeed of the fan and therefore the output of theboiler is determined by the temperature of thewater sensed by the flow & return temperaturesensors, consequently a high temperature at theflow sensor results in a lower fan speed. As thewater temperature increases, the temperaturesensors – located on the flow and return pipes ofthe boiler – reduce the fan speed via the electroniccircuitry. Depending on the load, either the watertemperature will continue to rise until the set pointis achieved or the water temperature will fallwhereby fan speed will increase relative to theoutput required. When the boiler has reached theset point, the burner will switch off. The built-inanti-cycle device prevents the burner from re-lighting for an adjustable period of time (factorydefault is 92 seconds). When the temperature ofthe flow sensor falls below the set-point, theburner will re-light.
7.3 SERVICE PARAMETERS (5 – 42)
To check or adjust the service parameters, youmust first access the service mode.To access the service mode:
SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING
● press and hold the mode and S buttons
simultaneously for 2 seconds;● when “COdE” appears in the display, press
S again, “C” should now be shown on the left
side of the display, with a random number onthe right side of the display;
● using the + or - buttons, scroll until “05”
is shown in the right side of the display;
● press M to store the code;
● press to exit the sevice mode.
7.4 ADJUSTING THE GAS VALVEThe gas valve must be set-up or adjusted withthe aid of o properly calibrated flue gasanalyser.Isolate the appliance from the electrical supply andremove the appliance casing as described in section4.10. Unclip and remove the front air chamber cover.Set the flue gas analyser to read CO
2 and insert
the probe into the flue analysis test point (fig. 1).Restore the electrical supply to the boiler andgenerate a request for central heating via theroom thermostat and/or timer.
Press the mode and - buttons at the same
time, the boiler will now run at minimum power for15 minutes.
Consequently, by pressing the mode and +
buttons at the same time, the boiler will run onmaximum power for 15 minutes.
7.4.1 MINIMUM SETTINGWith the boiler operating at minimum output theCO
2 reading should be 9.8% (+/- 0.2%). If the CO
2reading is correct, proceed to section 7.4.2. If theCO
2 reading is incorrect, the minimum gas
pressure must be adjusted as follows:● Using a suitable screwdriver, very slowly turn
the minimum adjustment screw (fig. 30) –clockwise to increase, counter clockwise todecrease – until the correct value is displayedon the CO
2 analyser (allow time for the analyser
to stabilise).● Using the procedure detailed in section 7.4,
change the fan speed momentarily fromminimum to maximum, then back to minimum.
● Check that the correct value is still beingobtained. If not, repeat the above procedure.
7.4.2 MAXIMUM SETTINGThe maximum setting must only be checked and/or adjusted after the correct minimum setting hasbeen verified. Using the procedure detailed insection 7.4, change the power from minimum tomaximum.With the boiler operating at maximum output theCO2 reading should be 9.8% (+/- 0.2%). If the
CO2 reading is correct, press the + and -buttons at the same time to return to the normal
23
Service parameters must only be changed or adjusted by qualified service personnel
Parameter
56789
10111213
141516171819202122
23
2425262728293031
3233343536
373839404142
Description
Minimum setting for flow sensorUnusedUnusedUnusedUnusedUnusedUnusedUnused
Maximum fan speed for heating(hundreds)
Maximum fan speed (units)UnusedUnused
Minimum fan speed (hundreds)Minimum fan speed (units)
Ignition fan speedPump over-run
UnusedSet point drop before re-lighting
(heating)Set point overshoot before burner
off (heating)UnusedUnusedUnusedUnused
Heating anti-cycleUnusedUnused
Temperature differential requiredfor modulation
UnusedUnusedUnusedUnused
Temporary manual fan speedsetting (20 minutes)
UnusedUnusedUnusedUnusedUnused
Normal output/off/minimum output/off cycle
Range
5 °C - 60° C
10 - 55 (RPM x 100)
00 - 99 (RPM)
05 - 55 (RPM x 100)00 - 99
05 - 55 (RPM x 100)01 - 99 minutes
0 °C - 20 °C
0 °C - 10 °C
0 - 30 (1=10.2 secs.)
5 °C - 40 °C
0% - 100%
00 = OFF, 01 = ON
Factory settingPinnacle 26
20° C-1520-10
250020
55 (5500 RPM)
00 5500
17 (1700 RPM)00
44* (4400 RPM)10 minutes
15 °C
2 °C
-35
15-2
9 (91.8 secs.)03
25 °C
-1150000
-1 (= OFF)
240035102000
New settingFactory settingPinnacle 16
20 °C-1520-10
250020
40* (4000 RPM)
00 4000
13* (1300 RPM)00
55* (5500 RPM)10 minutes
15 °C
2 °C
-35
15-2
9 (91.8 secs.)03
25 °C
-1150000
-1 (= OFF)
240035102000
operating mode . If the CO2 reading is incorrect,
the maximum gas pressure must be adjusted asfollows:● Using a suitable screwdriver, very slowly turn
the maximum adjustment screw (fig. 30) –clockwise to increase, counter clockwise todecrease – until the correct value is displayedon the CO
2 analyser (allow time for the analyser
to stabilise).● Using the procedure detailed in section 7.4,
change the power momentarily from maximumto minimum, then back to maximum.
● Check that the correct value is still beingobtained. If not, repeat the above procedure.
● Press the + and - buttons at the same
time to return to the normal operating mode.Isolate the appliance from the electrical supplyand remove the analyser test probe from theanalysis test point and refit cap. Refit the airchamber cover. Refit appliance casing.NOTEYou should ensure that all radiators or heatemitters are fully open during the aboveprocedures. This will ensure that the fan speed(output) of the boiler is not compromised due to ahigh flow temperature.
*This is the setting for Natural Gas. On LPG versions, the factory setting is:
Parameter
13
1719
Description
Maximum fan speed for heating(hundreds)
Minimum fan speed (hundreds)Ignition fan speed
Range
10 - 55 (RPM x 100)
05 - 55 (RPM x 100)05 - 55 (RPM x 100)
Factory settingPinnacle 26
55 (5500 RPM)
17 (1700 RPM)30* (4400 RPM)
New settingFactory settingPinnacle 16
41* (4100 RPM)
14* (1400 RPM)39* (3900 RPM)
24
1st digitshows
123456
Right displayshows
Most recent fault codeAppliance status at time of fault
Flow sensor temperature at time of faultReturn sensor temperature at time of fault
N/AN/A
Code
b 18b 19b 24b 25b 26b 28b 29b 30b 65
Reason
Flow sensor above 95 °CReturn sensor above 95 °C
Temperature differential invertedExcessive temperature riseCondensate trap blocked
No signal from fanIncorrect signal from fan
Temperature differential exceededInsufficient fan speed for ignition
StatusStandbyPurge
IgnitionBurner on
Waiting for fanBuilt-in delay
Pump over-runTemporary fault
conditionCombustion test atmaximum output
Combustion test atminimum output
Anti seizing cycleManual operation of
fan
1st digit0123567
9/b
H
L
At
RightFlow temperatureFlow temperatureFlow temperatureFlow temperatureFlow temperatureFlow temperatureFlow temperature
Flow temp./temporary faultcode
Flow temperature
Flow temperature
Flow temperatureFlow temperature
Code
E 00E 02E 03E 04E 05E 06E 07E 11E 13E 14E 15E 16E 17E 18E 19E 25E 28E 29E 30E 31E 32E 36E 37E 44E 60E 65
Reason
False flameNo flame detectedInternal fault (PCB)
Appliance lockout and power failureInternal fault (PCB)Internal fault (PCB)Internal fault (PCB)Internal fault (PCB)Internal fault (PCB)Internal fault (PCB)Internal fault (PCB)Internal fault (PCB)Internal fault (PCB)
Flow sensor temperature exceededReturn sensor temperature exceeded
Excessive temperature riseNo signal from fan
Incorrect signal from fanTemperature differential exceeded
Short circuit on flow sensorShort circuit on return sensorOpen circuit on flow sensor
Open circuit on return sensor Internal fault (PCB)Parameter anomaly
Not enough fan driving force
7.8 DIAGNOSTIC RECALLIn addition to displaying a fault code, the appliancememorises the operating conditions at the time oflockout, this information can be recalled anddisplayed using the following procedure:
● access the appliance service mode as detailedin section 5.10
● press the mode button until “ERRO” appearsin the display
● press the S button to recall the information
as detailed below
● press the reset button to exit the applianceservice mode.
7.9 CHECKING THE EXPANSION VESSELCarry out the component removal procedure asdescribed in section 6.4. You must ensure thatthe boiler is completely drained of water.Using a suitable pressure gauge, remove dustcap on expansion vessel and check the chargepressure. The correct charge pressure should be1.0 bar ± 0.1 bar. If the charge pressure is less,use a suitable pump to increase the charge.Please note, you must ensure the safety valve isin the open position whilst re-charging takesplace. Replace the dust cap and carry out therelevant commissioning procedure.
7.5 1ST DIGIT STATUS CODEWhen the boiler is operating normally (withoutfault), the first digit of the display shows thecurrent status of the boiler whilst the right side willshow the relevant temperature.
7.6 TEMPORARY FAULT CODESThe built-in fault diagnostic system automaticallydisplays a unique fault code that can be used todetermine why the boiler has temporarily lockedout.
7.7 FINAL FAULT CODESWhen a volatile lockout condition occurs, or atemporary fault condition has not been corrected,the appliance will be permanently locked out anda manual reset will be required.
Fig. 30
Maximumscrew
Minimumscrew
25
7.10 EXTERNAL FAULTSBefore carrying out any fault-finding or componentreplacement, ensure the fault is not attributableto any aspect of the installation.For example, external wiring fault, service valvesclosed, gas supply turned off, etc. The tablebelow may assist in identifying some commoninstallation faults.
7.11 ELECTRICAL CHECKSAny electrical checks must be carried out by asuitably qualified person.
7.11.1 EARTH CONTINUITY TESTIsolate the appliance from the electrical supply,and using a suitable multi-meter carry out aresistance test. Connect test leads between anappliance earth point and the earth wire of theappliance supply cable. The resistance shouldbe less than 1 ohm. If the resistance is greaterthan 1 ohm check all earth wires and connectorsfor continuity and integrity.
7.11.2 SHORT CIRCUIT CHECKIsolate the appliance from the electrical supply,and using a suitable multi-meter, carry out a shortcircuit test between the Live & Neutral connectionsat the appliance input board (fig.14).Repeat above test on the Live & Earth connectionsat the appliance input board (fig.14).NOTEShould it be found that a fuse has failed but nofault is indicated, a detailed continuityCheck will be required to trace the fault. A visualinspection of components may also assist inlocating the fault.
7.11.3 POLARITY CHECKWith the appliance connected to the electricalsupply and using a suitable multi-meter, carry outthe following voltage tests:● connect test leads between the Live & Neutral
connections at the appliance input board (fig.14).The meter should read approximately 230V ac.If so proceed to next stage. If not, see section7.11.4.
● connect test leads between the Live & Earthconnections at the appliance input board (fig.14)the meter should read approximately 230V ac.If so proceed to next stage. If not, see section7.11.4.
● connect test leads between the Neutral & Earthconnections at the appliance input board (fig.14)the meter should read approximately 0 – 15Vac.If so polarity is correct. If not, see section7.11.4.
7.11.4 REVERSED POLARITY OR SUPPLY FAULTRepeat the above tests at the appliance isolator,if testing reveals correct polarity and/or supply at
the isolator, re-check wiring and connectionsbetween the isolator and the appliance.If tests on the isolator also reveal reversed polarityor a supply fault, consult the local electricitysupplier for advice.
7.11.5 RESISTANCE TO EARTH CHECKIsolate the appliance from the electrical supply,and using a suitable multi-meter carry out aresistance test. Connect test leads between theLive & Earth connections at the appliance inputboard (fig.14). If the meter reads other thaninfinity there is a fault that must be isolated, carryout a detailed continuity check to identify thelocation of the fault.IMPORTANTThese series of checks must be carried outbefore attempting any fault-finding procedureson the appliance. On completion of any task thatrequired the disconnection and re-connection ofany electrical wiring or component, these checksmust be repeated.
7.11.6 FUSESThe appliance is equipped with spare fuses.These fuses are located on the covers of the inputboard and main PCB respectively. If a fuse hasblown it is usually indicative of an external wiringfault or a faulty component such as the pump, fan,valve actuator, etc. Under no circumstancesshould a blown fuse be replaced with one of ahigher rating.
7.12 FAULT FINDINGBEFORE ATTEMPTING ANY FAULTDIAGNOSIS OR REPAIR THE FOLLOWINGPROCEDURE SHOULD BE CARRIED OUT:● carry out the relevant electrical checks as
detailed in section 7.11;● disconnect any external wiring from plug M7
(terminals 2 & 3) and replace with a solid linkwire;
● ensure the appliance is protected – externally –by a 3-amp fuse.
7.12.1 FAULT FINDING TESTSIf a lockout code is displayed on digits 3 & 4,please refer to section 7.6 for the cause of thelockout.
7.12.2 WIRING DIAGRAMSFigures 33 & 34 indicate the positions of all plugs,fuses and internal wiring configuration.
Fault codedisplayed
E 02
b/E 18
E 36
Possible cause
Gas turned offAir in gas pipeInsufficient gasPump seized
Flow/return service valve closedFlow sensor cable disconnected
FAULTNo display, boiler inactiveNo display, pump running
No display, pump running, fan speed alternatingNo display, boiler working OK
Pump failureFan fault
Ignition fault
GO TOTest 1
Test 1ATest 1ATest 1ATest 2Test 3Test 4
26
7.12.3 FAULT FINDING TEST ‘1’
M2
M3
27
7.12.4 FAULT FINDING TEST ‘1A’
28
7.12.5 FAULT FINDING TEST ‘2’
29
7.12.6 FAULT FINDING TEST ‘3’
30
7.12.7 FAULT FINDING TEST ‘4’
31
SECTION 8 WIRING DIAGRAMS
8.1 INSTALLATION OF VOKERA TIMECLOCK(part n° 201 or 202)The Vokera time clock (part no. 201 & 202) can beinstalled using the following procedure:• Isolate the appliance from the electrical supply
and remove the casing as described in 4.9.1.• Gain access to the electrical input board as
detailed in 4.9.2.• Remove the square blanking plate from the
clock aperture of the control panel.• Connect the wires to the clock as shown in fig.
31.• Mount the clock to the clock aperture using the
screws provided.• Remove the factory fitted link between
terminals 2 & 3 on plug M7.• Connect the clock wires to the electrical input
board as shown in fig. 31.• Replace the input board cover and appliance
casing once the clock installation has beencompleted.
8.2 EXTERNAL CONTROLS WIRINGIf additional or alternative controls are required,they must be connected to the boiler as shown inthe following diagrams.
NOTEGuidance on the recommended practice for theinstallation of external controls, can be foundin CHeSS – HC1/HC2 (www.energy-efficiency.gov.uk).
Fig. 31
Room thermostat contact rated at 230V
Fig. 32
“S” plan system
Roomthermostat
contact rated at230V
32
Fig. 32A
“Y” plan system
Roomthermostat
contact rated at230V
33
FUNCTIONAL DIAGRAM
NO
TE
. L-N
-E C
ON
NE
CT
ION
MU
ST
NO
T B
E IN
TE
RC
HA
NG
ED
KeyR.T. Room thermostatF FanP PumpS1 Flow thermistor (NTC)S2 Return thermistor (NTC)BE05 Connection boardMCBA Control boardL1 N/AL2 (V) Led OK
Fig. 33
L2 (R) Led alarmL3 N/AF1 Fuse 2 AFF3 Fuse 4 ATS/S.E. Spark/sense electrodeOPE Gas valve solenoidsP.S. Pressure switch (NC)
34
NO
TE
. L-N
-E C
ON
NE
CT
ION
MU
ST
NO
T B
E IN
TE
RC
HA
NG
ED
CO
NT
RO
L S
WIT
CH
ING
OF
TIM
E C
LO
CK
AN
D R
OO
M T
HE
RM
OS
TA
T R
AT
ED
AT
230
V.a
.c.
FUNCTIONAL DIAGRAM
Fig. 34
35
PCBDisplay PCBDisplay PCBDisplay PCB
PCBGas valve
FanCondense pressure switch
Flow sensorReturn sensor
PumpExternal transformer
24V connection for time clock orroom thermostat
Relay for actuatorStatus LED
PLUG or CONNECTIONOPE
FP.S.S1S2P
R.T.
RL3VL2
DESIGNATIONPlug X2 on main PCBPlug X2 on main PCBPlug X2 on main PCBPlug X3 on main PCBPlug X3 on main PCBPlug X1 on main PCB
Plug X10 on main PCBPlug M4 on input PCB (terminals 2 & 3)
Input PCB3-pins connector on display PCB
PLUG or CONNECTIONX7AX9
3-pins connector
DESIGNATIONConnection from main PCB
UnusedStatus LED connection
PCBInput PCBInput PCBInput PCBInput PCBInput PCBInput PCB
PLUG or CONNECTIONM2M3M4M5M7F1
DESIGNATIONIncoming 230V supply
230V supply to main PCB230V clock supply
Low voltage connector (to main PCB)Low voltage connector (heat request)
2AF fuse
PCBMain PCBMain PCB
Main PCBMain PCBMain PCBMain PCBMain PCBMain PCBMain PCB
PLUG or CONNECTIONX1X2
X3X7X8X10F1F2F3
DESIGNATIONIncoming 230V supply & pump connectionFan connection, condense pressure switch
connection, gas valve connectionSensor connections
Display board connectionUnused
External transformer connection2AF fuse2AF fuse4AT fuse
36
SECTION 9 EXPLODED DIAGRAMS
POS. DESCRIPTION 16 26
1 Frame 001005243 00100524312 Quick primer pressure gauge 1857 185713 Pin 10023044 1002304415 Cover 10023681 1002368116 2 A 5X20 inline fuse 8968 896817 3,15 A 5X20 inline fuse 8969 896918 Printed Circuit Board cover 10021849 1002184920 Printed Circuit Board 10023549 1002354921 Led Light Guide 10023892 1002389226 Instrumental panel 10023346 1002334631 Case 10023589 1002358939 Spring 1862 186240 Door panel 10023772 1002377243 Push-push cover 1864 186448 Green-red led 1858 185849 Plastic bezel 8654 8654
50 Pin 1867 186767 Printed circuit holding 10023476 1002347674 Bracket 10023571 1002357175 Display Printed Circuit Board 10023297 1002329780 Printed Circuit Board 10023763 1002376390 Fuse 3478 347899 Membrane keypad 10023891 10023891100 Cover 10023477 10023477101 Wired transformer 10023478 10023478226 Edge clip 5128 5128260 Nut 5230 5230261 O-ring 1869 1869300 Flat cable 10023586 10023586301 Cable 10024393 10024393
74
67
100
20
16
17
16
39
40
80
7521
2613
1249
99
50
43
18
15
260226
48
261
90
101
1
31
300
301
37
POS. DESCRIPTION 16 26
3 Pressure switch 10022556 100225567 Heating by-pass valve 1552 15529 Heating distributor manifold 10021821 1002182122 Safety valve 1806 180623 Pipe 10023065 1002306527 Heating cock 1789 178931 Venting plugs kit 01005137 0100513752 Bracket 10022671 10022671277 Screw 6903 6903353 Ogive 1824 1824
52
3
27
27
23
22
277
9
31
7
353
353
38
POS. DESCRIPTION 16 26
1 Expansion vessel 2573 25732 Flexible pipe 2164 21643 Pump 8876 88764 Pump cable 10023573 100235735 Brass nut 10022444 100224446 Pipe 10023574 100235748 Heat exchanger 8884 88849 Pipe 10023575 1002357510 Pipe 10023697 1002369712 Washer 9287 928716 Air vent bottle + cock assembly 9806 980625 Siphon 10024112 1002411226 Pipe 10023530 1002353027 Pipe 10023579 10023579
34 Connection for air vent bottle 8911 891136 Connection pipe 10023580 10023580200 Washer 5023 5023201 Washer 5026 5026253 Headless screw 5216 5216288 O-ring 6898 6898291 Washer 6897 6897310 NTC sensor 1194 1194316 Washer 1022 1022338 Connection for dom. exp. vessel 8873 8873369 Connection 10023493 10023493370 O-ring 10023533 10023533371 Clip 10023532 10023532398 Clip 10024336 10024336
200338
316 253
8
16
34
12
338
200
2
201
1
26
370
200
371
369
291
4
291
5
288
6
9
200
310
10
310
200
3
27
36
25
2
398
39
POS. DESCRIPTION 16 26
1 Roomsealed chamber 10023486 100234862 Upper panel for air box 8881 88813 Main burner jet support 1195 11954 Main burner 1196 11965 Spark electrode kit 01005242 0100524212 Gas pipe 10022442 1002244213 Gas valve 10022441 1002244114 Pipe 10023578 1002357815 Gas cock connection 1787 178716 Front panel for air box 1035 103517 Glass kit 01005234 0100523421 Washer 5905 5905
23 Main burner jet NG 8897 897023 Main burner jet LPG 10022453 929524 Washer 9299 929927 Air box hole cap 8084 808435 Air conveyor 10022450 888639 Gas pipe 10022443 1002244340 Washer 9285 928541 Spring 9296 9296200 Washer 5023 5023256 Screw 5221 5221295 Silicone tube 1457 1457351 Brass nut 1823 1823
40
4 40
35
23
24
3
256
200
12
200
13
200
39
295 41
17
5
2
27
1
21
200
15
14
1
351
16
40
POS. DESCRIPTION 16 26
2 Exchanger lower insulation panel 1193 11934 Exchanger upper insulation panel 1016 10165 Clip 10021115 100211156 Cover for heat exchanger 1033 103310 Fan 10024230 1002423011 Gas diaphragm 10022451 -13 Pressure connection 8915 891514 Pressure connection 8916 891620 Connection 8908 890822 Washer 8912 891223 Plug 8909 890940 Screw 1006 100641 Screw 9292 9292321 Fan gasket 8893 8893341 Screw 10021080 -
23
20
22
2
4
6
5
14
321
10
40
41
13
341
11
41
SECTION 10 L.P.G. INSTRUCTIONS
10.3 GAS SUPPLYThe gas supply must be connected to theappliance by a competent LPG installer and mustbe of sufficient size to supply the appliance at itsmaximum output.An existing supply must be checked to ensurethat it is of adequate size to deal with the maximumrated input of this and any other appliances thatit serves.
10.4 GAS SUPPLY INSTALLATIONThe entire installation including the meter, mustbe purged and checked for gas soundness.
10.5 ADJUSTING THE GAS VALVEThe gas valve must be set-up or adjusted withthe aid of a properly calibrated flue gasanalyser.Remove the appliance casing as detailed insection 4.10. Unclip and remove the air chambercover. Set the flue gas analyser to read CO
2 and
insert the probe into the flue analysis test point(see fig.1). Using the procedure as detailed insection 7, enter the appliance service mode andset the power to minimum.
10.5.1 MINIMUM SETTINGWith the boiler operating at minimum output theCO
2 reading should be 9.8% (+/- 0.2%). If the CO
2reading is correct, proceed to 10.5.2. If the CO
2reading is incorrect, the minimum gas pressuremust be adjusted as follows:● using a suitable screwdriver, very slowly turn the
minimum adjustment screw (fig. 30) – clockwiseto increase, counter clockwise to decrease – untilthe correct value is displayed on the CO
2 analyser
(allow time for the analyser to stabilise).● using the procedure as detailed in section 7,
change the power momentarily from minimumto maximum, then back to minimum.
For details of converting boilers to LPG please refer to the instructions supplied with the relevant conversion kit.
● check that the correct value is still beingobtained. If not, repeat the above procedure.
10.5.2 MAXIMUM SETTINGThe maximum setting must only be checked and/or adjusted after the correct minimum setting hasbeen verified. Using the procedure as detailed insection 7, change the power from minimum tomaximum.With the boiler operating at maximum output theCO
2 reading should be 9.8% (+/- 0.2%). If the CO
2
reading is correct, press the reset button toexit the appliance engineer mode. If the CO2reading is incorrect, the maximum gas pressuremust be adjusted as follows:● using a suitable screwdriver, very slowly turn
the maximum adjustment screw (fig. 33) –clockwise to increase, counter clockwise todecrease – until the correct value is displayedon the CO
2 analyser (allow time for the analyser
to stabilise).● using the procedure as detailed in section 7,
change the power momentarily from maximumto minimum, then back to maximum.
● check that the correct value is still beingobtained. If not, repeat the above procedure.
● press the reset button to exit the applianceservice mode.
Remove the analyser test probe from the analysistest point and refit cap. Refit the air chambercover. Refit appliance casing.NOTEYou should ensure that all radiators or heatemitters are fully open during the aboveprocedures. This will ensure that the power(output) of the boiler is not compromised due to ahigh flow temperature.
10.1 TECHNICAL DATA
10.2 RELATED DOCUMENTS
BS 6798BS 5449BS 5440BS 5482
PART 1PART 1PART 1
INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60 kWFORCED CIRCULATION HOT WATER SYSTEMSFLUESDOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS
Inlet pressureGas rate (max.)Gas rate (min.)
Injector sizeCO
2 level (cover off)
Maximum fan speed for heatingMinimum fan speed
Soft-lightNOx (max)NOx (min)CO (max)CO (min)
1637 mbar
2.49 l/per hr.0.72 l/per hr.
Single injector with six 1.6 mm holes9,80%
4.100RPM*1.400RPM*3.900RPM*
40 ppm20 ppm50 ppm50 ppm
2637 mbar
4.08 l/per hr.1.19 l/per hr.
Single injector with six 2.3 mm holes9,80%
5.500RPM*1.700RPM*3.000RPM*
30 ppm20 ppm50 ppm50 ppm
* set parameters: P. 13 (maximum), P. 17 (minimum), P. 19 (ignition) as shown in section 7.3.
Vokèra Ltd.4th Floor, Catherine House, Boundary Way, Hemel Hempstead, Herts, HP2 7RP
Email: [email protected] Web: www.vokera.co.ukSales, Technical Advice, General Enquiries - Tel: 0870 333 0520 Fax: 01442 281403
After Sales Service - Tel: 0870 333 0220
Vokèra IrelandWest Court, Callan, Co Kilkenny
Tel: 05677 55057 Fax: 05677 55060
Vokèra Ltd. reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected.
A Riello Group Company
energizing home heating
“Vokèra”supports Benchmark
COLLECTIVE MARK
Co
d. 1
0023
766
- 39
/03
- E
d. 2
