VOKERA Synergy 29 Installation & Servising Instruction
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VOKERA Synergy 29 Installation & Servising Instruction

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Installation
& Servicing
Instructions
THESE INSTRUCTIONS
TO BE RETAINED
BY USER

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Summary of Contents for VOKERA Synergy 29

  • Page 1 Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER...

  • Page 2: Table Of Contents

    3.A11 Declaration of conformity Wiring diagrams Page Installation Page External wiring Delivery Installation of Vokera twin channel programmer Contents Typical control applications Unpacking Vokera time clock Preparation for mounting the appliance Vokera room thermostat Fitting the flue “S” plan wiring 4.5.1...
  • Page 3 The Synergy output of 28kW. The appliance - by design - incorporates range can also be used with the Vokera twin flue system. electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge and automatic by-pass.

  • Page 4: Principle Components

    SECTION 1 DESIGN PRINCIPLE AND OPERATING SEQUENCE a high limit thermostat that over-rides the PRINCIPLE COMPONENTS temperature control circuit to prevent or A fully integrated electronic control board interrupt the operation of the burner. featuring electronic temperature control, anti- an analogue pressure switch (PAD) that cycle control, pump over-run, self-diagnostic checks the operation of the fan and flue thereby fault indicator, full air/gas modulation.

  • Page 5: Technical Data Page

    SECTION 2 TECHNICAL DATA 2.1 Central heating Synergy 29 Heat input 29.0 kW Max heat output 60/80°C (return & flow temp.) 28.1 kW Max heat output 30/50°C (return & flow temp.) 29.7 kW Min heat output 60/80°C (return & flow temp.) 9.5 kW...

  • Page 6: Pump Duty

    20°C temperature differ- ential. 1000 1100 1200 1300 Litres Per Hour Fig. 3 2.11 EMISSIONS Appliance Synergy 29 NOx max/min 180/120 CO max/min 100/60 CO2 max/min 6.60/4.15 CO/CO2 ratio max/min 0.00152 to 1/0.00145 to 1 Fig. 4 Location Minimum distance Below an opening (window, air-brik, etc.)

  • Page 7: General Requirements (Uk) Page

    SECTION 3 GENERAL REQUIREMENTS (UK) This appliance must be installed by a competent GAS SUPPLY person in accordance with the Gas Safety The gas meter - as supplied by the gas supplier - must be checked to ensure that it is of adequate (Installation &...

  • Page 8: Pipework

    3.10 INHIBITORS highest point in the system and at least 5 metres Vokera recommend that a inhibitor - suitable for above the boiler (see fig. 5). The cold feed from use with low water-content, copper heat the make-up vessel or tank must be fitted with...

  • Page 9: A1 Related Documents

    This appliance must be installed by a competent discoloration that may occur to building products person in accordance with and defined by, the located nearby. The terminal must not be located Standard Specification (Domestic Gas in a place where it is likely to cause a nuisance Installations) Declaration (I.S.

  • Page 10: A6.5 Expansion Vessel

    3A.6.5 EXPANSION VESSEL 3A.10 INHIBITORS The appliance has an integral expansion vessel Vokera recommend that a inhibitor - suitable for to accommodate the increased volume of water use with low water-content, copper heat when the system is heated. It can accept up to...

  • Page 11: Delivery

    CONCENTRIC HORIZONTAL FLUE Fig. 6 (For concentric vertical flue, see 4.5.2) (For twin flue applications, see 4.5.3) The appliance can be used with either the Vokera condensing 60/100mm concentric flue system or PREPARATION FOR MOUNTING THE the optional 80/125mm concentric flue system.
  • Page 12 NOTE Reduction for additional bends Fit the internal trim to the flue assembly prior to Bend Reduction in maximum flue length for each bend connecting the flue pipe to the bend. 45° bend 0.5 metre 90° bend 1.0 metre You must ensure that the entire flue system is properly supported and connected.

  • Page 13: Concentric Vertical Flue

    Fig. 8 4.5.2 CONCENTRIC VERTICAL FLUE The appliance can be used with either the Vokera condensing 60/100mm concentric flue system or the optional 80/125mm concentric flue system. NOTE These instructions relate only to the Vokera condensing 60/100mm concentric flue system.

  • Page 14: Twin Flue System

    4.5.3.1 INSTALLATION OF TWIN ADAPTOR KIT (see 4.5.3 TWIN FLUE SYSTEM fig. 10 & 11) The Vokera twin flue system enables greater flue Insert the exhaust connection manifold (A) distances to be achieved (see 4.4.2) than that of onto the appliance flue outlet.
  • Page 15 1-deg. = 17mm 1.0-metre Fig. 12 4.5.3.2 HORIZONTAL TERMINATION (see fig. 12) 4.5.3.3 VERTICAL TERMINATION (see fig. 13) The twin flue system must be converted to the The twin flue system must be converted to the dedicated concentric flue kit for termination. dedicated concentric flue kit for termination.

  • Page 16: Connecting The Gas And Water

    Control valve Control Temporary valve connection Flow pipe Double check valve Supply Fig. 14 4.6.1 GAS (see fig. 6A & 14) The appliance is supplied with a 15mm service valve, connect a 15mm pipe to the inlet of the valve and tighten both nuts. NOTE It will be necessary to calculate the diameter of the gas supply pipe to ensure the appliance has...

  • Page 17: Condense Pipe

    4.6.4 CONDENSE PIPE During normal operation the boiler produces condense which is collected in a trap located in the lower part of the boiler. A flexible pipe (condense outlet pipe) is connected to the outlet of the trap. The flexible pipe must be connected to a plastic waste pipe only.
  • Page 18 Fig. 16 Connect the supply cable wires (LIVE and NEUTRAL) to their corresponding terminals on the appliance terminal block. Connect the EARTH wire to the EARTH block (see fig. 16) ensuring that it’s left slightly longer that the others, this will prevent strain on the EARTH wire should the cable become taut.

  • Page 19: Gas Supply Installation

    *Both Sentinel and Fernox manufacture products the pressure set to 1 bar that have proved suitable for use with Vokera ensure the flue system has been fitted properly appliances. Vokera Ltd. cannot comment on the...

  • Page 20: Inhibtors

    5.8.1 INHIBITORS Show the user how to operate the appliance and See Section 3 “General requirements”. any associated controls correctly. Show the user the location of the filling valve and SETTING THE BOILER OPERATING TEM- how to top-up the system pressure correctly and PERATURE show the location of all manual air release points.

  • Page 21: General

    ALWAYS TEST FOR GAS component be replaced only with a genuine SOUNDNESS IF ANY GAS CARRYING Vokera spare part. The frequency of servicing will COMPONENTS HAVE BEEN REMOVED OR depend upon the particular installation conditions, DISTURBED.

  • Page 22: Automatic Air Release Valve

    AUTOMATIC AIR RELEASE VALVE (see fig. 18) (AAV) Carry out component removal procedure as described in 6.4. Using a suitable pair of pump pliers, unscrew the AAV from the rear of the pump assembly. Replace in the reverse order. WATER PRESSURE SWITCH (see fig. 20) Carry out component removal procedure as described in 6.4.

  • Page 23: Gas Valve

    6.14 INTEGRAL TIME SWITCH (if fitted) Carry out component removal procedure as described in 6.4. Locate and remove the terminal cover and securing screws (2), locate and remove the time clock retaining screws, remove time clock. Disconnect wiring after carefully taking note of all electrical connections.

  • Page 24: Flue Fan

    Fig. 27 6.16 FLUE FAN (see fig. 27 & 28) secure the analogue pressure switch assembly (4 & 5). Locate and remove the screws that secure Carry out component removal procedure as described in 6.4. the flue hood and air baffle, disconnect the flue clip (1) from the fan-flue elbow, and gently ease Fig.

  • Page 25: Main Heat Exchanger

    Fig. 29 6.17 MAIN HEAT EXCHANGER (see fig. 27 & 29) Carry out component removal procedure as described in 6.4. Fig. 27: unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging (2). Locate and remove the six screws that secure the front combustion cover, then remove the cover (3).

  • Page 26: Latent Heat Collector

    Carefully unclip the wires from the air chamber and withdraw the wiring & grommet from the air chamber. Disconnect the electrode lead and burner thermostat wires. Disconnect the outlet gas pipe, the flow & return pipes and the condense pipe from the air chamber. Locate and remove the 2-screws that secure the lower section of the air chamber.

  • Page 27: Checks, Adjustments And Fault Finding

    SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING maximum over a period of 8-seconds. During this CHECKING APPLIANCE OPERATION period the ignition electrode sparks continuously When carrying out any repairs or servicing to the even if the burner has ignited. appliance, the relevant commissioning procedure must be undertaken to ensure the continued safe NOTE operation of the appliance.

  • Page 28: Setting The Minimum Burner Pressure

    NOTE Always check and/or adjust the minimum and Protecting maximum gas pressures whilst the appliance is heating the radiators and HW cylinder. 7.3.2 SETTING THE MIMIMUM BURNER PRESSURE (see fig. 37) Once the maximum burner pressure has been checked and/or adjusted, remove one of the grey wires from the modulating coil.

  • Page 29: Electrical Checks

    ELECTRICAL CHECKS IMPORTANT Any electrical checks must be carried out by a These series of checks must be carried out before suitably qualified person. attempting any faultfinding procedures on the appliance. On completion of any task that 7.7.1 EARTH CONTINUITY TEST required the disconnection and re-connection of Isolate the appliance from the electrical supply, any electrical wiring or component, these checks...
  • Page 30 FAULT CODE 04 FAULT CODE 08 Fault code 04 appears if the pressure in the boiler is low. Fault code 08 appears if the burner thermostat has been activated. Check water pressure Check gas pressures Check water pressure switch Check burner thermostat Check water pressure gauge Check wiring continuity FAULT CODE 05...
  • Page 31 FAULT FINDING TEST ‘A’: turn the selector switch to the reset position START Status LED Status LED Status LED is blank is green is red Go to test "C" Does the Have the selector knob electrical rotate the checks as detailed in 7.7 switch on the been carried...
  • Page 35 FAULT FINDING TEST ‘E’: turn the selector to the “on” position START Is there 230V between terminals M14.1 & M14.2 Replace main Is there 230V between 4 & 5 on ignition PCB Check wiring & connections Is there 230V between 4 &...

  • Page 36: Wiring Diagrams

    For advice on controls that are not featured in this book, please contact Vokera technical on 0870 333 0520. INSTALLATION OF VOKERA TWIN CHANNEL PROGRAMMER (see fig. 39) Isolate the appliance from the electrical supply and remove the casing as described in 4.7.1...
  • Page 37 3 amp fuse orange grey brown Twin Channel Programmer blue green/yellow Heating orange grey brown Hot water blue green/yellow Motorised Valve (heating) Vokera Twin Channel Programmer Cylinder thermostat Appliance Common Terminal Strip Load Room thermostat 3 amp fuse Common Load Wiring Centre...
  • Page 38 230V supply @ 50Hz Load Heating Live Room thermostat Hot water Common Twin Channel Programmer Calling Satisafied Add if programmer has heating only position Cylinder thermostat Vokera Twin Channel Programmer Appliance Terminal Strip 3-Port mid-position valve orange grey white blue green/yellow Wiring Centre...
  • Page 39 NOTE: L-N-E CONNECTION IS ADVISABLE CONTROL SWITCHING OF TIME CLOCK AND ROOM THERMOSTAT IS 230 V.a.c. Fig. 44 B.C.B. PT1(S.B.) Selection of 0-reset / winter - summer (ACF02X) Burner control board R.T. Room thermostat Pump P.S. Water pressure switch DS1-DS2 Temperature / allarm display D.A.P.S.
  • Page 40 Fig. 45...

  • Page 41: Exploded Diagrams

    SECTION 9 EXPLODED DIAGRAMS 16 17 POS. DESCRIPTION Frame R01005294 Quick primer pressure gauge R1857 2A fuse R8960 100 mA fuse R1947 Cover R10021849 Ignition module R10021848 Printed Circuit Board R10024390 Instrumental panel R10023051 Case R1922 Printed Circuit Board R10020477 Spring R1862 Door panel...
  • Page 43 POS. DESCRIPTION Expansion vessel R2573 Flexible pipe R2164 Circulation pump R10020438 Wiring harness R1845 Automatic air vent bottle R0439 Pipe R10023202 Pipe R10024130 Heat exchanger R2378 Pipe R10021041 Pipe R10022859 Bracket R1642 Siphon R10023495 Siphon pipe R10023530 Pipe R10024132 Pump lock key R9263 Siphon plug R10023531...
  • Page 44 POS. DESCRIPTION Pressure switch R2044 By-pass valve R1552 Heating manifold R10021821 Safety valve R1806 Heating cock R1789 Venting plugs kit R01005137 Pipe R10023065 Screw R6903 R1824 Wiring harness R10024740...
  • Page 45 POS. DESCRIPTION Air box bottom R10024385 Ambidx air box side R10024166 Air box clip R0442 NG Burner R10022980 LPG burner R10023081 Spark electrode R10022027 NG plate R5172 Gas valve solenoid R10020838 Gas pipe R1839 Gas valve R10021021 Gas pipe R1840 Gas cock R1787 Air box cover...
  • Page 46 POS. DESCRIPTION Combustion chamber assembly R6028 Combustion chamber back panel R5316 Combustion chamber lateral panel R5271 Combustion chamber front panel R5315 Hood assembly R10024125 R10024035 Venturi and pressure tube kit R01005293 Clamp for tube R10024126 Fan flue connection R10024137 Block with combustion analysis check R8085 Brass cap R8086...

  • Page 47: Related Documents

    SECTION 10 LPG INSTRUCTIONS 10.1 RELATED DOCUMENTS BS 6798 INSTALLATION OF BOILERS OF RATED NOT EXCEEDING 60kW BS 5449 PART 1 FORCED CIRCULATION OF HOT WATER SYSTEMS BS 5440 PART 1 FLUES BS 5482 PART 1 DOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS 10.2 TECHNICAL DATA Gas Pressures...
  • Page 48 Vokèra Ltd. Floor, Catherine House, Boundary Way, Hemel Hempstead, Herts, HP2 7RP Email: enquiries@vokera.co.uk Web: www.vokera.co.uk Sales, Technical Advice, General Enquiries - Tel: 0870 333 0520 Fax: 01442 281460 After Sales Service - Tel: 0870 333 0220 Vokèra Ireland...

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