VOKERA syntesi e series Installation & Servicing Instructions Manual
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VOKERA syntesi e series Installation & Servicing Instructions Manual

VOKERA syntesi e series Installation & Servicing Instructions Manual

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Installation
& Servicing
Instructions
THESE INSTRUCTIONS
TO BE RETAINED
BY USER

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Summary of Contents for VOKERA syntesi e series

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

  • Page 2: Table Of Contents

    Electrical connections Other controls 4.7.1 Casing removal Exploded diagrams Page 4.7.2 Appliance terminal block Table 1 - 5 43 - 48 4.7.3 Connecting the mains (230V) input 4.7.4 Connecting the Vokera time clock Commissioning Page Gas supply installation The heating system...
  • Page 3 The Syntesi e appliance is a high-efficiency combination various horizontal or vertical applications. The Syntesi e boiler with outputs to heating & DHW. appliance can also be used with the Vokera twin flue The appliance – by design – incorporates electronic system.

  • Page 4: Principle Components

    successful ignition has been achieved, the PRINCIPLE COMPONENTS electronic circuitry increases the gas rate to A fully integrated electronic control board maximum or will modulate output to stabilise the featuring electronic temperature control, anti- temperature. In the event of the appliance cycle control, pump over-run, self-diagnostic exceeding the desired temperature the burner will fault indicator, full air/gas modulation.

  • Page 5: 2.1 Central Heating

    Syntesi 25 e 2.1 Central heating Heat input 25.0 kW Max heat output 60/80°C (return & flow temp.) 24.7 kW Max heat output 30/50°C (return & flow temp.) 26.6 kW Min heat output 60/80°C (return & flow temp.) 7.28 kW Min heat output 30/50°C (return &...

  • Page 6: Pump Duty

    SECTION 2 TECHNICAL DATA 2.11 PUMP DUTY Fig. 3 shows the flow-rate available – af- ter 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°C temperature differ- ential.

  • 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: Water Circulation

    WATER CIRCULATION The cold feed from the make-up vessel or tank Detailed recommendations are given in BS 5449 must be fitted with an approved non-return valve Part 1 and BS 6798. The following notes are for and stopcock for isolation purposes. The feed pipe general guidance only.

  • Page 9: Timber Framed Building

    Institute of Gas Engineers publication (IGE/UP/ 7) ‘Guide for Gas Installations in Timber Frame *Fernox and Sentinel manufacture products that Buildings’. have proved suitable for use with Vokera appli- ances. Vokera Ltd. cannot comment on the suit- 3.11 INHIBITORS ability of any other such product with our Vokera recommend that a inhibitor –...

  • Page 10: A6 Water Circulation

    3A.11 INHIBITORS generally this is sufficient, however if the system Vokera recommend that a inhibitor – suitable for has an unusually high water content, it may be u s e w i t h l o w w a t e r - c o n t e n t , c o p p e r h e a t necessary to provide additional expansion exchangers –...

  • Page 11: Delivery

    4.5.1 CONCENTRIC HORIZONTAL FLUE (For concentric vertical flue, see 4.5.2) (For twin flue applications, see 4.5.3) The appliance can be used with either the Vokera condensing 60/100mm concentric flue system or the optional 80/125mm concentric flue system. Fig. 6 NOTE These instructions relate only to the Vokera condensing 60/100mm 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

    Hot water Outlet Cold water Inlet Stopcock/filling valve C/H flow valve Filling Loop Cock C/H return Safety valve Fig. 14 valve outlet 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.

  • Page 17: Condense Pipe

    Connect a discharge pipe to the fixing jig connection and tighten. The discharge pipe must have a continuous fall away from the appliance to outside and allow any water to drain away thereby eliminating the possibility of freezing. The discharge pipe must terminate in a position where any water –...

  • Page 18: Connecting The Vokera Time Clock

    The clock connector plug is for use with the clock harness that is included in the accessory pack and facilitates an easy connection to the optional Vokera time clock. Fig. 17 To fit the Vokera time clock:...

  • Page 19: Gas Supply Installation

    SECTION 5 COMMISSIONING GAS SUPPLY INSTALLATION valve full bore to remove any installation debris Inspect the entire installation including the gas from the boiler prior to lighting. Refill the boiler meter, test for soundness and purge. Refer to and heating system as described in 5.3. BS 6891 for specific instruction.

  • Page 20: Final Flushing Of The Heating System

    5.11.1 CHANGING THE FLOW RESTRICTOR *Both Sentinel and Fernox manufacture products Refer to 6.19 for detailed instruction on changing that have proved suitable for use with Vokera the flow restrictor. appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our 5.11.2 REGULATING THE CENTRAL HEATING...

  • Page 21: Instructing The User

    It is the law that any servicing work is carried out Should the appliance develop a fault, the fault by competent person such as a Vokera engineer, finding section will assist in determining which an approved service agent, British Gas, or other component is malfunctioning.

  • Page 22: Safety Valve

    Fig. 20 Fig. 22 SAFETY VALVE (see fig. 21) Carry out component removal procedure as described in 6.4. PRESSURE GAUGE (see fig. 23) Disconnect the outlet pipe from the safety valve, Carry out component removal procedure as remove safety valve locking screw (1) from the described in 6.4.

  • Page 23: High Limit Thermostat

    Fig. 24 Fig. 26 6.11 HIGH LIMIT THERMOSTAT (see fig. 25) NOTE Carry out component removal procedure as Ensure that any replacement PCB has the correct described in 6.4. ‘Jumper Tag’ configuration (see section 8). Unclip and remove the air chamber cover. Pull off electrical connections from the high limit 6.13 GAS VALVE (see fig.

  • Page 24: Integral Time Switch

    6.14 INTEGRAL TIME SWITCH (if fitted) removed, the electrode retaining screw can be Carry out component removal procedure as can be removed. Locate the burner injectors (2) described in 6.4. and remove (if necessary). Replace in the reverse Locate and remove the terminal cover and order.

  • Page 25: Flue Fan

    6.16 FLUE FAN (see fig. 28 & 30) secure the analogue pressure switch assembly Carry out component removal procedure as (4&5). Locate and remove the screws that secure described in 6.4. the flue hood and air baffle, disconnect the flue Fig.

  • Page 26: Air Pressure Switch

    6.18 AIR PRESSURE SWITCH (see fig. 30) inserted into the DHW manifolds. Ensure all seals Carry out component removal procedure as are in good condition, taking care to ensure they described in 6.4. are replaced correctly. Fig. 28: unclip and remove the air chamber cover, If necessary remove the condense trap as gently pull the cover towards you before lifting described in 6.29.

  • Page 27: Secondary Thermistor

    6.24 SECONDARY THERMISTOR (see fig. 36) Carry out component removal procedure as described i 6.4. Pull back the protective cover from the thermistor and disconnect the electrical plug. Using a 13mm spanner slacken and remove the thermistor and sealing washer from the DHW heat exchanger manifold.

  • Page 28: Latent Heat Collector

    6.28 LATENT HEAT COLLECTOR fig’s. 40 & 41 Carry out component removal procedure as described in 6.4. Remove the flue hood and fan assembly as detailed in 6.16. Disconnect the condense sensor wire from the sensor. Fig. 40: disconnect and remove the inlet (1), outlet (3) and condense pipes (2) from the collector.

  • Page 29: Checks, Adjustments And Fault Finding

    SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING Thereafter the pump and fan will over-run for CHECKING APPLIANCE OPERATION 10-seconds. When carrying out any repairs or servicing to the Frost-protection: this function is only active appliance, the relevant commissioning procedure must be undertaken to ensure the continued safe when there are no requests for heating or HW.

  • Page 30: Dhw Mode

    the temperature at the primary thermistor has described in 2.3. If adjustment is required, remove dropped 6°C below the set-point. the protective cap from the gas valve modulating coil assembly and turn the outer (10mm) nut NOTES clockwise to increase, or counter-clockwise to The timer delay can be de-activated by the decrease the burner pressure.

  • Page 31: Checking The Expansion Vessel

    Light the boiler as described in 5.7 and press Fault code Possible causes the ‘CO mode’ button once. Gas supply problem The boiler will now enter the combustion Gas line requires purging analysis mode (CO mode) for a period of 15 Reversed polarity minutes.

  • Page 32: Resistance To Earth Check

    (DHW) thermistor. Check thermistor NOTE Check wiring continuity If the Vokera remote-control (RC05) is connected to the appliance, it should be disconnected during FAULT CODE 07 any faultfinding checks. Fault code 07 appears if a problem exists with the primary Restore the electrical supply to the boiler and thermistor.
  • Page 33 VOKERA START LINEA PLUS AG Rev. 1 08/03/2000 TEST A : CHECKING OPERATION OF ELECTRONIC SWITCH ON/OFF CONTROL BOARD AT START UP SELECTOR TO DHW POSITION IS THE 3 WAY VALVE IN DHW POSITION? GREEN LED MAINS ALIGHT ON 3 WAY...
  • Page 34 THERE 24 Vdc BETWEEN TERMINALS M5.3 AND M3.3 ON PCB REPLACE THE CONTROL BOARD THERE 24 Vdc BETWEEN TERMINALS M5.3 ON PCB & WHITE WIRE ON HIGH LIMIT THERMOSTAT CHECK WIRING CONNECTIONS THERE 24 Vdc BETWEEN TERMINALS M5.3 ON PCB & RED WIRE ON HIGH LIMIT THERMOSTAT RESET THE...
  • Page 35 5 Vdc BETWEEN TERMINALS M2.1 & M2.2 ON DISPLAY BOARD REPLACE DIGITS RED LED BOARD FLASHING 5 Vdc BETWEEN FAULT TERMINALS CODE M9.1 & M9.2 ON SHOWING CONTROL BOARD CHECK AND/OR REPLACE WIRING OR CONNECTIONS WITH DISPLAY BOARD MAINS BICOULORED PRESENT BETWEEN LED ASSEMBLY M16.L &...
  • Page 36 VOKERA START LINEA PLUS AG Rev. 1 08/03/2000 TEST B : CHECK CONTROL TURN MODE IN DHW MODE SELECTOR SWITCH TO DHW. DHW STAT AT MAX. TURN ON TAP DOES BURNER LIGHT CHECK BOILER STARTUP: TEST A THERE A VOLTAGE >4 Vdc BETWEEN TERMINALS M3.10 &...
  • Page 37 VOKERA START LINEA PLUS AG Rev. 1 08/03/2000 SWITCH ON BOILER TEST C: CHECK CONTROL AND SELECT MODE IN C/H MODE TO WINTER C/H THERMOSTAT AT MAX. MAKE A LINK BETWEEN PIN M16.TA AND M16.TA ON CONTROL BOARD IS THE...
  • Page 38 SPARK AT ELECTRODE THERE MAIN BETWEEN TERMINALS M14.1 & M14.2 IGNITION ON PCB THERE MAIN BETWEEN TERMINALS L & N ON LOCKOUT IGNITION AFTER CONTROL IGNITION CHECK WIRING CHECK SENSING CONNECTIONS ELECTRODE AND LEAD CHECK SPARK ELECTRODE AND SENSING LEAD OR REPLACE ELECTRODE IGNITION AND LEAD...
  • Page 39 DOES THE FLOW SWITCH PIN FAULT CODE OPERATE SHOWING 03 CHECK AND/OR REPLACE THE DIAPHRAGM. CHECK THE CORRECT WATER DP CHECK THE WATER CIRCUIT. FAULT CODE CHECK IF THE PUMP IS ON 3a SPEED SHOWING 04 REPLACE CONTROL BOARD THE BOILER FLOW SWITCH OPERATE FAULT CODE...
  • Page 40 BURNER AND FAN SWITCH ON TIMER JUMPER WAIT 3 MIN. REPLACE REMOVE CONTROL JUMPER BOARD BURNER AND FAN RESTART THE SWITCH ON TEST WAIT WATER FLOW TEMPERATURE THERE A < 80 ˚C VOLTAGE < 1 Vdc BETWEEN TERMINALS WATER FLOW M3.10 &...

  • Page 41: Wiring Diagrams

    RC05. VOKERA ROOM THERMOSTAT Connect the Vokera room thermostat to the appliance as detailed in fig. 48 The Vokera room thermostat can be used with the Vokera time clock or any other voltage-free time clock. Fig. 47...
  • Page 42 Fig. 49...
  • Page 43 FUNCTIONAL DIAGRAM NOTE: L-N-E CONNECTION IS ADVISABLE CONTROL SWITCHING OF TIME CLOCK AND ROOM THERMOSTAT IS 230 V.a.c. R.T. Room thermostat Room thermostat or remote control jumper TS H Heat time switch Natural gas selector Timer on- off selector G.V. Gas valve C.S.
  • Page 44 WIRING DIAGRAM...

  • Page 45: Exploded Diagrams

    SECTION 9 EXPLODED DIAGRAMS 16 17 POS. DESCRIPTION Frame R01005288 Quick primer pressure gauge R1857 2A fuse R8968 100 mA fuse R1947 Cover R10021849 Ignition module R10021848 Printed Circuit Board R10025911 Instrumental panel R10021951 Case R1880 Printed Circuit Board R10024558 Spring R1862 Door panel...
  • Page 47 POS. DESCRIPTION Domestic water heat exchanger R8036 Connection R9807 Pressure switch R2044 Non return valve R2908 By-pass valve R2047 Heating manifold R10020439 Spring R6862 Three way valve overhault kit R01005127 Three way valve cover R2904 Fixing fork wrench R2906 O ring connection R6919 Motorized valve R2905...
  • Page 48 POS. DESCRIPTION Expansion vessel R2204 Flexible pipe R10023603 Circulation pump R10020437 Pump cable R1845 Automatic air vent bottle R0439 Pipe R10023195 Pipe R10024312 Heat exchanger R10024578 Pipe R10021041 Pipe R10023198 Bracket R2940 Siphon R10023495 Siphon pipe R10023530 Pipe R10024440 Pump lock key R9263 Siphon plug R10023531...
  • Page 49 POS. DESCRIPTION Air box bottom R10024449 Ambidx air box side R10024166 Air box clip R0442 NG Burner R10023168 Spark electrode R10022027 NG plate R5172 Gas valve solenoid R10020838 Gas pipe R1839 Gas valve R10025074 Gas pipe R1840 Gas cock R1787 Air box cover R10020216 Washer...
  • Page 50 POS. DESCRIPTION Combustion chamber assembly R10025935 Combustion chamber back panel R5270 Combustion chamber lateral panel R5271 Combustion chamber front panel R5269 Hood assembly R10025934 R10025938 Clamp for tube R10024126 Fan flue connection R10024137 Block with combustion analysis check R8085 Brass cap R8086 Pressure differential switch R2677...
  • Page 52 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 281403 After Sales Service - Tel: 0870 333 0220 Vokèra Ireland...

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