VOKERA Linea Max Installation & Servicing Instructions Manual
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VOKERA Linea Max Installation & Servicing Instructions Manual

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See also: Instructions for Using
Room Sealed, Fanned Flue, Combination Boiler
Installation
& Servicing
Instructions
BRITISH GAS SERVICE LISTED
G.C. No 47 094 30
THESE INSTRUCTIONS
TO BE RETAINED
BY USER
Supplied By www.heating spares.co Tel. 0161 620 6677

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Summary of Contents for VOKERA Linea Max

  • Page 1 Room Sealed, Fanned Flue, Combination Boiler Installation & Servicing Instructions BRITISH GAS SERVICE LISTED G.C. No 47 094 30 THESE INSTRUCTIONS TO BE RETAINED BY USER Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 2 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 3: Table Of Contents

    Range Rating C/H Checking The Flue System Checking The Heating Thermistor Regulating The C/H System Final Flushing The C/H System Filling & Testing H/W System Final Checks For Operation Concluding Operations Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 4 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 5: Introduction

    SECTION 1 INTRODUCTION The Vokèra Linea Max is a com- This appliance is designed for use with a bined central heating and domestic hot sealed heating system only and is not water appliance. By design it incorporates intended for use on an open vented system.

  • Page 6: Central Heating Mode

    40°C. KEY: Fig. 2 This drawing is indicative only and does Hot Water Outlet not accurately represent pipe positioning. Cold Water Inlet Central Heating Flow Central Heating Return Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 7: Technical Data

    Minimum 0.6 bar/7psig 45° 425 mm Offset 850 mm For LPG instructions see page 62 Twin Flue Reduction in flue lenght Bend for each bend 90° 850 mm 45° 850 mm Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 8: Central Heating Pump Duty

    3.10 Central Heating Pump Duty Water pressure mbar X 100 Water flow Fig. 3 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 9: General Requirements

    The effect of such ‘steaming’ must be considered. Where the installation of the boiler will be in an unusual location special procedures may be necessary and BS 6798:1987 gives detailed guidance on this aspect. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 10: Air Supply

    BS 2879:1980. Where installed in a cupboard or compart- ment ventilation is required for cooling. The table following gives the recommended minimum effective areas of such air vents. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 11: Air Release Points

    UP/7) ‘Guide for Gas Installations in Timber Frame Buildings’. C/H Return Valve C/H Flow Valve Hot Water Outlet Safety Valve Base Tray Outlet Cold Water Inlet Stopcock/ filling valve Cock Fig. 5 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 12: Installation

    Safety valve outlet pipe (1) Filling loop hose (1) Various washers Base plate screws (2) Spare front panel door tool (1) Restrictor ring (1) Flue kit supplied in separate carton. Fig. 8 Fig. 9 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 13: Siting The Appliance

    If the hot water system does not include a tap below the hot water outlet connection, provide a suitable drain tap to permit draining of the appliance hot water side during servicing. Fig. 12 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 14 See fig.11. and gently slide into position. Tighten the nuts from the valves on the base plate to the corresponding inlet/outlet connec- tions on the appliance using the fibre washers supplied. Fig. 14 Fig. 13 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 15: Fitting The Flue (Horizontal)

    ‘Y’. Cut vertical flue applications to be considered, only the outer flue pipe at this mark. alternatively, the Vokera twin flue system can be utilised if longer flue runs are required. Mark dimension ‘Y’ on the inner flue pipe then add 10mm and cut at the new mark.
  • Page 16 If the vertical flue requires extension/s or addi- tional bend/s, connect the required number of flue extensions or bends (up to the maximum equivalent flue length) between the boiler top adapter and vertical flue assembly. Fig.16 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 17 – using the same screws – install the air baffle. 5.5.3 Twin flue system The Vokera twin flue system enables greater flue distances to be achieved (see 3.4.4) than that of the standard concentric flue system, however the twin flue system must be con- verted to the dedicated concentric flue kit for termination.
  • Page 18 When cutting an extension to the required length, you should ensure that the excess is cut from the plain end of the extension. Re- move any burrs, and check that both seals are located properly. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 19: Electrical Connections

    0.75mm² (24 x 0.2mm) to table 15-16, BS6500. Wiring to the appliance should be rated for operation in contact with surfaces up to 90°C. Locating hook Locating hook Fig. 19 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 20 Incoming Gas slip the anchorage the current carrying Pressure Test Fig. 20 conductors become taut before the earthing Point conductor. Closed Position Normal Filling Operating Position Position Fig. 21 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 21: Commissioning

    The pump only will run for approximately 1 6.3.2.7 Inspect the system for water soundness and minute, the appliance will then go through remedy any leaks discovered. an ignition sequence and the burner will light. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 22: Checking Burner Pressures

    Adjust hot water control knob to it's maximum setting. Main burner test point Gas Valve U Gauge Tube Fig. 22 Manometer Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 23: Checking The Flue System

    6.10. 6.12.3 Check the appearance of the gas flame to 6.11.2 Open a domestic hot water tap (Preferably assess adequacy of combustion air supply. the bath tap). Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 24: Concluding Operations

    OFF the mains for yellowing of flame tip, flame lift off or electricity supply and disconnect the plug at sooting. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 25: Replacement Of Parts

    To do this, disconnection from hot and cold services is necessary. Reconnect only after thorough flushing with clean water. Fig. 24 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 26: Main Burner Injectors

    Remove room sealed front cover plate (8.5). 8.8.3 Remove front of combustion chamber (8.6.3). 8.8.4 Remove two air baffle plates, 1 screw Fig. 26 securing each (fig.27). 8.8.5 Remove both side panels, 2 screws each (fig.26) Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 27: Flue Fan

    8.11.4 To remove rear board, gently prise upwards and pull out. 8.11.5 Fourth panel (front) is replaced complete with combustion chamber front panel. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 28: Ignition Control Box

    8.13.11 Check burner pressures. As 6.6 If incorrect adjust as instructed in 8.23. Gas Valve Regulator Silicon Pipe Connection Point Pipe Securing Clip Pump Securing Bracket Modulator Coil Fig. 29 Fig. 28 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 29: Pump

    & Ignition Control Water Flow Switch Motorised Valve Safety Valve Cold Water Domestic Diverter Valve Heating flow Heat Inlet Stopcock/ & Flow Switch and return valves Exchanger Fig. 30 filling valve Assembly Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 30: Diverter Valve

    Alternatively, a new vessel can be fitted in the return to the appliance, and the old vessel isolated in situ. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 31: Safety Valve

    (see fig.36 for electrical connections) Flow Switch Diaphragm Diverter Valve and Flow Switch Manifold Safety Valve Diverter Valve Bobbin Diverter Valve Cover Fig.31 Motorised Valve Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 32: 8.21.13 Printed Circuit Board

    8.21.33a PRIMARY Turn the 3 butterfly primary store isolation valves to the closed position (handle across Safety Thermostat valve body) this isolates the primary store thus preventing unnecessary draining. Fig. 32 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 33: Setting Gas Pressures

    0.13 mbar. 8.23.5 Maximum Rate in Central Heating Mode. Replace the grey wire back onto the modula- After initial ingnition (8.23.4), the Linea Max tor coil together with the protective cover. range does not require any adjustment to 8.23.3...

  • Page 34: Fig. 33

    Gas pressure adjustment protective cover Fig. 33 Maximum pressure Minimum pressure ad- adjustment screw (a) justment screw (b) Minimum Adjustment Button Minimum Adjustment Potentiometer Fig. 34 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 35: Sequence Of Functions

    Once the flow switch has activated the fan starts which results in a changeover of the pressure differential switch. Once these actions have Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 36: Diagnostic Error Codes

    To ensure that internal/external controls (if fitted) do not interfere with fault finding, disconnect the wires from terminals 2 & 3 (labelling them in the process to ensure correct reconnection) and provide a solid link between 2 & 3. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 37: Linea Max

    VOKERA Linea Max Start Test A: Checking operation of electronic control board at start up Switch on/off Selector to DHW position Is the 3 way valve in the DHW position Green 230 V alight on 3 way valve between terminals M11.1 &...

  • Page 38: Linea Max

    Check the fan and /or flue gas tube Check wiring Replace the and connections control board Green led alight Check wiring and connections, high limit thermostat or Restart the test Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 39: Linea Max

    Restart the test Ignition Green box OK led alight Replace the Restart the control board test Check wiring and Replace Ignition connections high limit thermostat and control board Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 40: Linea Max

    VOKERA Start Linea Max Test B: Check control in DHW mode Switch on boiler and select mode to summer. DHW thermostat to max Turn on tap there a voltage >10 VDC between terminals Does M4.1 & M4.2 on the burner...

  • Page 41: Linea Max

    VOKERA Start Linea Max Test C: Check control in C/H mode Switch on boiler and select mode to winter. C/H thermostat to max Make a link between 2 & 3 at boiler terminal strip 0 VAC present Is the 3 between pin M16.TA...

  • Page 42: Linea Max

    OK connections Replace ingition box Pressure switch OK valve OK Check Water Replace Check Gas Gas valve there 24 VDC between terminals M3.5 & M5.4 on Replace ingition box Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 43: Linea Max

    Digital display showing 05 Digital display showing 06 Check DHW NTC sensor or connection Digital display showing 07 Check Flow NTC sensor or connection Replace control board Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 44: Linea Max

    Is DHW NTC OK Replace DHW pressure switch water flow Replace Replace temperature DHW NTC control board <78°C Does the fan switch Is DHW NTC OK Replace Replace DHW control board Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 45: Linea Max

    LOCK OUT Is flow state NTC OK Does the pump Replace switch OFF control board Replace Replace flow NTC Switch OFF control boiler. Wait board about 10 secs. then restart test Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 46: Linea Max

    >40°C Switch C/H thermostat to Replace control board Do the burner and fan switch ON timer jumper Remove Wait 3 min. jumper Replace control board Restart the test Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 47: Appendix

    Remove the loop between terminals 2 & 3 and con- nect room thermostat between 1 & 2 (as fig. 7) Vokera room thermostat Link 1 & 4 in r/stat Live Load Neutral Fig. 3 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 48: Internal Time Clock Installation

    Should the room thermostat require a neutral or earth, connect neutral to the terminals marked N, and the earth to the earth terminal. Internal Note: Room thermostat contact rated at time clock 230v. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 49 103E 103E7 Do not link terminals 3 & 6 in time switch Room Thermostat LOAD COMMON Appliance Terminal Block 1 2 3 4 5 Remove link between 2 & 3 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 50: Linea Max

    ADD THIS WIRE IF PROGRAMMER HAS A HEATING ONLY POSITION. DOUBLE CHANNEL PROGRAMMER NOTE: WHEN USING A 'Y' PLAN INSTALLATION THE MODE SELECTOR SWITCH WILL BE OVERRIDEN BY THE CONTROL CIRCUIT. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 51: Linea Max

    Fig.35a Gas Assembly R5317 R5317 R1931 R7721 R102929 R102411 R100068 R102866 R102930 R102397 R102868 R102291 R102934 R102392 R102936 R102937 R102399 R102938 77085 R102935 77086 R102847 48897 R100057 R102254 R102405 Fig.35b Front Panel Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 52: Linea Max

    Fig.35c cover R2374 R1920 R2374 R5072 R3139 Fig.35d Inlet Assembly R101954 R101319 R103317 R102330 R102956 R102955 R102947 R103318 R103319 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 53: Linea Max

    Fig.35e Expansion Vessel R102957 R103320 R100035 Fig.35f Circulating pump and pipes R100035 R103321 R102960 R102962 R102964 R102961 R100035 R102961 R100035 R102963 R100035 R102924 R100035 R100035 R102931 R102927 R100035 R100035 R102961 Fig.35g Pipes Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 54: Linea Max

    Fig.35i Thermal store & insulation R102921 R102991 R102923 R102804 R102906 R103322 R102928 Fig.35j Base tray Complete Kit : Part No 48945 R102950 R103327 R103317 R103319 R103323 R103326 R103324 R102946 R102947 R103325 R103318 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 55: Exploded Diagrams

    Fig.35m Hydraulic Manifold (Exploded Diagram) R2909 R4611 R6872 R6867 R6888 R6853 R5184 R6865 R6860 R5041 R5042 R1806 R4612 R2904 R6862 R6895 R5184 R2910 R6919 R6887 R2905 R2913 R2906 R8444 R5041 R7134 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 56: Linea Max

    Fig.35n Outer casing R102796 R100939 R100940 R101821 R102768 R102914 R102915 R102785 R102848 R102919 R102918 Fig.35o Sealed Case R5922 R5964 R2073 R8085 R8086 R5923 R9805 R9232 R100953 R5927 R1835 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 57: Linea Max

    Fig.35p Combustion chamber R8083 R5916 R5917 R7948 R6985 R7280 R6492 R1912 R5907 R5316 R1914 R6028 R5271 R5315 R5909 Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 58: Short Spare Parts List

    Jumpers JP1, JP2, JP3, JP5 and JP7 also exist on the printed circuit board DO NOT under any circumstances add or remove jumpers at these points. Spare jumpers are available from Vokera stockists. Part no. 7232. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 59: Illustrated Wiring Diagram

    C/H Temperature Control R1 ,2 & 3 Relay D/H/W Temperature Control CO10 Time Clock Connector Pump Mode Selector Switch High Limit Thermostat Digital Display Motorised Valve Combustion Switch Solenoid Operators Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 60: Preliminary Electrical System Checks

    ELECTRICITY AUTHORITY. The customer should be warned not to use the appliance until this examination has been carried out. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 61: Linea Max

    SECTION 11 L.P.G. INSTRUCTIONS 11.1 Gas Rates (LPG) Linea Max 1.63 litres/h Min. Gas Rate Max. Gas Rate 4.85 litres/h 11.2 Burner Details (LPG) Main Burner Polidoro NP14 Main Burner Injectors 14 x 0.77 Burner Pressure Max. Rate 36.0 mbar 5.5 mbar...

  • Page 62: Linea Max

    & anti-clockwise to decrease the gas pressure. When all is adjusted, press the minimum ad- justment button once (the appliance will return to normal operation). Turn the appliance off. Linea Max Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 63 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 64 P U T T I N G T H E A C C E N T O N Q U A L I T Y Vokèra Ltd. Web: www.vokera.co.uk Southern Region: Morson Road, Enfield, Middlesex EN3 4NQ. Sales: 020 8216 6300. Fax: 020 8805 6320.

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