VOKERA ProCombi 85 HE Installation And Service Instructions Manual
VOKERA ProCombi 85 HE Installation And Service Instructions Manual

VOKERA ProCombi 85 HE Installation And Service Instructions Manual

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Installation & Servicing Instructions
THESE INSTRUCTIONS
TO BE RETAINED
BY USER
0694
Supplied By www.heating spares.co Tel. 0161 620 6677

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Summary of Contents for VOKERA ProCombi 85 HE

  • Page 1 Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER 0694 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 2: Table Of Contents

    Contents Servicing instructions Page Design principles and operating sequence Page General Principle components Routine annual servicing Mode of operation (at rest) Replacement of components Mode of operation (heating) Component removal procedure Mode of operation (DHW) Pump assembly Safety devices Safety valve Technical data Page Automatic air release valve...
  • Page 3: General Layout

    INTRODUCTION The PRO Combi HE range of appliances is comprised of powered flue outlet with an annular coaxial combustion air 2 models of high-efficiency combination boiler with inputs intake that can be rotated - horizontally - through 360 to heating & DHW of 25, 29 kW respectively. Each appli- degrees for various horizontal or vertical applications.
  • Page 4: Design Principles And Operating Sequence

    SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE PRINCIPLE COMPONENTS MODE OF OPERATION (Heating) A fully integrated electronic control board fea- When there is a request for heat via the time clock ● turing electronic temperature control, anti-cy- and/or any external control, the pump and fan are cle control, pump over-run, LED fault indicator, started, the fan will then prove the air pressure full gas modulation.
  • Page 5: Technical Data

    SECTION 2 TECHNICAL DATA 100 HE 85 HE 2.1 Central heating Heat input (kW) 25.00 29.00 Maximum heat output@ 80/60 °C (kW) 24.35 28.30 Minimum heat output@ 80/60 °C (kW) 14.25 14.28 Maximum heat output@ 50/30 °C (kW) 25.90 29.93 Minimum heat output@ 50/30 °C (kW) 14.85 14.75...
  • Page 6: Pump Duty

    2.11 PUMP DUTY Fig. 3 shows the flow rate available - after allowing for pressure loss through the appliance - for system requirements. When using this graph, apply only the pressure loss of the system. The graph is based on a 20 ºC temperature differential.
  • Page 7: Related Documents

    This appliance must be installed by a competent GAS SUPPLY person in accordance with the Gas Safety (Instal- The gas meter - as supplied by the gas supplier lation & Use) Regulations. - must be checked to ensure that it is of adequate size to deal with the maximum rated input of all RELATED DOCUMENTS the appliances that it serves.
  • Page 8: Pipework

    3.6.1 PIPEWORK 3.6.7 LOW PRESSURE SEALED SYSTEM It is recommended that copper tubing to BS 2871 An alternative method of filling the system would Part 1 is used in conjunction with soldered capil- be from an independent make-up vessel or tank lary joints.
  • Page 9: Mounting On A Combustible Surface

    MOUNTING ON A COMBUSTIBLE SURFACE If the appliance is to be fitted on a wall of combustible material, a sheet of fireproof mate- rial must protect the wall. 3.10 TIMBER FRAMED BUILDING If the appliance is to be fitted in a timber framed building, it should be fitted in accordance with the Institute of Gas Engineers publication (IGE/UP/ 7) ‘Guide for Gas Installations in Timber Frame...
  • Page 10: Installation

    SECTION 4 INSTALLATION DELIVERY Horizontal flue terminals and accessories Due to the weight of the appliance it may be necessary Part No. Description Min-Max Length for two people to lift and attach the appliance to its Telescopic flue terminal kit 350/500mm mounting.
  • Page 11: Concentric Vertical Flue

    an extension or bend can be connected to the appliance flue outlet if desired (see 4.4.2), how- ever 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 45º...
  • Page 12: Connecting The Gas And Water

    Fit the appropriate flashing plate to the roof and NOTE insert the vertical flue terminal through the flash- Depending on system requirements, it may nec- ing plate from the outside, ensuring that the collar essary to increase the size of the flow & return pipe on the flue terminal fits over the flashing.
  • Page 13: Electrical Connections

    ELECTRICAL CONNECTIONS The boiler is supplied with a 2-metre fly-lead. This lead can be used for connection to the electrical supply. Connect the fly-lead to a fused plug or fused isolator in the following way: brown wire to LIVE supply ●...
  • Page 14: Commissioning

    SECTION 5 COMMISSIONING GAS SUPPLY INSTALLATION INITIAL LIGHTING Inspect the entire installation including the gas Ensure the electrical supply to the appliance is meter, test for soundness and purge. Refer to BS switched on. Move the selector switch to the 6891 for specific instruction.
  • Page 15: Setting The Dhw Temperature

    5.9.1 SETTING THE DOMESTIC HOT WATER TEM- AND CHECKED FOR SOUNDNESS. PERATURE ENSURE THE APPLIANCE FLUE SYSTEM ● The DHW outlet temperature can be adjusted IS FITTED CORRECTLY AND IS PROPERLY between 40 ºC - 65 ºC via the Hot Water thermo- SECURED.
  • Page 16: Servicing Instructions

    SECTION 6 SERVICING INSTRUCTIONS GENERAL the appliance, remove the appliance casing as To ensure the continued safe and efficient opera- described in section 4.7.1 and drain the water tion of the appliance, it is recommended that it is content from the appliance via the drain valve checked and serviced at regular intervals.
  • Page 17: Safety Valve

    the flow pipe from the heat exchanger to facilitate this. Replace in the reverse order. 6.11 HIGH LIMIT THERMOSTAT fig. 18 Carry out component removal procedure as de- scribed in 6.4. Unclip and remove the air chamber cover. Fig. 16 SAFETY VALVE fig.
  • Page 18: Integral Time Switch

    CLK-1 CLK-4 Fig. 19a 6.15 ELECTRODE, BURNER & INJECTORS fig. 21 Carry out component removal procedure as de- scribed in 6.4. Unclip and remove the air chamber cover (2). Locate and remove the 6 screws securing the front combustion cover (3), pull the cover towards you before lifting and disengaging.
  • Page 19: Main Heat Exchanger

    Fig. 23 6.18 AIR PRESSURE SWITCH fig. 23 pull the cover towards you before lifting and Carry out component removal procedure as de- disengaging. Locate and remove the six screws scribed in 6.4. that secure the front combustion cover, then Unclip and remove the air chamber cover, gently remove the cover.
  • Page 20: Dhw Heat Exchanger

    Replace in the reverse order ensuring that the 6.21 DHW HEAT EXCHANGER fig. 16/16A seating cam inserts into the locating groove Carry out component removal procedure as correctly (see fig. 26a). Ensure all seals are in described in 6.4. good condition, taking care to ensure they are Before removing the DHW heat exchanger, it will replaced correctly.
  • Page 21: Expansion Vessel Removal (With Insufficient Clearance Above)

    can now be removed. Replace in the reverse order. 6.28.2 DISMANTLING THE LATENT HEAT COLLEC- Ensure all seals are in good condition, taking care to ensure they are replaced correctly. Apart from routine cleaning of the coil, the latent 6.27.2 EXPANSION VESSEL REMOVAL (with insuffi- heat collector is a non-serviceable component, cient clearance above) therefore, there is no requirement to disassemble...
  • Page 22: Checks, Adjustments And Fault Finding

    SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING CHECKING APPLIANCE OPERATION 7.2.4 APPLIANCE FUNCTIONS When carrying out any repairs or servicing to the Frost-protection: this function is only active ● ● ● ● ● appliance, the relevant commissioning proce- when there are no requests for heating or HW. dure must be undertaken to ensure the continued When the temperature of the primary thermis- safe operation of the appliance.
  • Page 23: Heating Mode

    of the fan causes the air pressure switch (APS) to deliver a signal voltage to the control PCB. A slow ignition sequence is enabled, whereby the current supplied to the gas valve modulating coil is pro- gressively increased from minimum to maximum over a period of 8-seconds.
  • Page 24: Checking & Adjusting Burner Pressure

    7.2.6.1 HEATING PARAMETERS 7.3.1 SETTING THE MAXIMUM BURNER PRESSURE fig. 39 RANGE MINIMUM MAXIMUM Light the boiler as described in 5.7 and compare the reading on the manometer with the value Temperature (°C) sector described in 2.3. If adjustment is required, re- move the protective cap from the gas valve AUTO sector sector...
  • Page 25: Checking The Expansion Vessel

    The boiler will now enter the combustion analy- GREEN LED ● sis mode (CO mode) for a period of 15 minutes, Frequency Faults/Status signified by the LED flashing Yellow. During ON every 6-secs At stand-by with no faults this time, the boiler will remain on full gas. Flashing 8-times a second AUTO function active Once the flue gas analysis has been made, turn...
  • Page 26: Reversed Polarity Or Supply Fault

    7.7.4 REVERSED POLARITY OR SUPPLY FAULT mode selector switch to the reset position (0) for Repeat the above tests at the appliance isolator, 2-minutes’ then back to the relevant mode of if testing reveals correct polarity and/or supply at operation. the isolator, re-check wiring and connections be- If the boiler does not reset, refer to the following tween the isolator and the appliance.
  • Page 27 7.10.1 FAULT FINDING TEST ‘A’: CHECKING OPERATION OF ELECTRONIC CONTROL BOARD AT START UP START SWITCH ON BOILER AND SELECT MODE TO WINTER C/H THERMOSTAT AT MAX. GREEN LED BLINKS MADE A LINK BETWEEN BLACK & BLACK WIRES AT BOILER TERMINAL STRIP AND CLOSE THE TIMER CONTACT PUMP...
  • Page 28 7.10.2 FAULT FINDING TEST ‘A’ SPARK AT ELECTRODE THERE 24 Vdc BETWEEN TERMINALS CN8.4 & CN8.5 ON PCB IGNITION THERE 230 Vac BETWEEN TERMINALS CN6.1 & CN6.2 ON PCB CHECK AND/OR REPLACE PCB LOCKOUT AFTER IGNITION THERE 24 Vdc BETWEEN TERMINALS CHECK CN8.4 &...
  • Page 29: Fault Finding

    7.10.3 FAULT FINDING TEST ‘A1’ RED LED BLINKS RED LED LIGHT REPLACE CONTROL BOARD YELLOW LIGHT SWITCH ON/OFF CHECK CH NTC YELLOW LED SELECTOR ON OFF SENSOR OR WIRING BLINKS POSITION AND CONNECTIONS CHIMNEY SWEEPER CYCLE. RESET AND RESTART TEST MAINS SWITCH ON/OFF PRESENT BETWEEN...
  • Page 30 7.10.4 FAULT FINDING TEST ‘B2’: CHECK CONTROL IN DHW MODE START SWITCH ON BOILER AND SELECT MODE TO SUMMER. DHW THERE 24 Vdc THERMOSTAT AT MAX. BETWEEN TERMINALS CN9.7 & CN9.8 ON PCB THERE A TURN ON TAP VOLTAGE >10 VDC CHECK BOILER BETWEEN TERMINALS STARTUP:...
  • Page 31 7.10.5 FAULT FINDING TEST ‘C’: CHECK CONTROL IN C/H MODE START SWITCH ON BOILER AND SELECT MODE TO WINTER C/H THERMOSTAT AT MAX. MADE A LINK BETWEEN BLACK & BLACK WIRES AT BOILER TERMINAL STRIP AND CLOSE THE TIMER CONTACT DOES BURNER LIGHT...
  • Page 32 7.10.6 TEST ‘C’ CONT’D WAIT WATER FLOW TEMPERATURE BURNER AND FAN >40 ûC SWITCH OFF SWITCH CH THERMOSTAT AT MAX. WATER FLOW TEMPERATURE >40 ûC REPLACE CONTROL BOARD BURNER AND FAN SWITCH ON TIMER JUMPER REMOVE JUMPER REPLACE WAIT 3 MIN. CONTROL BOARD RESTART THE TEST...
  • Page 33: Wiring Diagrams

    SECTION 8 WIRING DIAGRAMS EXTERNAL WIRING ROOM THERMOSTAT Should a room thermostat be required, it must be The appliance comes with a factory fitted clock to of the ‘voltage-free’ type, and should be con- allow basic operation of the boiler (fig. 38). If nected to the appliance as shown in fig.
  • Page 34: Functional Diagram

    FUNCTIONAL DIAGRAM NOTE: L-N-E CONNECTION IS ADVISABLE Fig. 40 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 35: L.p.g. Instructions

    SECTION 10 L.P.G. INSTRUCTIONS 10.1 RELATED DOCUMENTS BS 6798 INSTALLATION OF BOILERS OF RATED NOT EXCEEDING 60kW BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 5440 PART 1 FLUES BS 5482 PART 1...
  • Page 36 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...
  • Page 37: Service Interval Record

    SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
  • Page 38 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 39 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 40 Heating Services provides after-sales assistance and Technical advice for Procombi HE Boilers Service & Technical Helpline: 0870-264-1220 Heating Services, PO BOX 167, BRADFORD, BD19 4WL. COLLECTIVE MARK We reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected Supplied By www.heating spares.co Tel.

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