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VOKERA EXCELL 80SP Installation And Servicing Instruction
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VOKERA EXCELL 80SP Installation And Servicing Instruction

VOKERA EXCELL 80SP Installation And Servicing Instruction

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9Vokéra
DOMESTIC
HEATING
APPLIANCES
EXCELL
80SP
Installation
and Servicing
Instructions
Tested
and Certified
63 AP 0640 (N/G)
63 AQ 0640 (LPG)
British
Gas Service
G.C. No.47 094 17
WRc
No. 9502032
HAND
THESE
INSTRUCTIONS
TO THE
USER
Listed

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  • Page 1 9Vokéra DOMESTIC HEATING APPLIANCES EXCELL 80SP Installation and Servicing Instructions Tested and Certified 63 AP 0640 (N/G) 63 AQ 0640 (LPG) British Gas Service Listed G.C. No.47 094 17 No. 9502032 HAND THESE INSTRUCTIONS TO THE USER...
  • Page 3 SECTIONI INTRODUCTION The Vokera EXCELL 80SP is a combined The appliance is designed for use with a central heating and domestic hot water sealed heating system only and is not appliance. By design it incorporates a intendedfor use on an open ventedsystem.
  • Page 4 Flue Outl Intake Fig. 2 Notes Differential pressure unit. Senses water flow rate through the pump & main heat exchanger and operates the flow switch .(26) Differential pressure unit. Senses domestic hot water flow which operates the single microswitch and fulcrum arm operating the 3 port valve. Note 2 Note I RETURN...
  • Page 5 SECTION TECHNICAL DATA Units Dimensions and values are given in the CONCENTRIC FLUE: preferred Sl Units with Imperial units in REDUCTION IN FLUE brackets where applicable. BEND LENGTH FOR EACH BEND Dimensions and Contents Height 790mm (31.1 in) appliance only. 982mm (38.7in) inc.horizontal flue.
  • Page 6 Water pressure mbar Water 1 ooo 1250 Fig. 3 Pump pressure Residual Pressure Boiler pressure loss Hot Water System Heating System Working Pressures 6.0bar/90psig I .5bar/15m.wg/50ft Maximum 0.6bar/7psig 0.5bar/5m.wg/16ft Minimum 3bar/30m/102ft Safety valve setting Flow Rates Min. water flow (dhw) 2.8 litres/min (0.6 gal/min) Min.
  • Page 7 SECTION4 GENERAL REQUIREMENTS General Requirements A compartment used to enclose the boiler must be designed and constructed specifi- This appliance must be installed by a compe- cally for this purpose. An existing cupboard tent person in accordance with the Gas or compartment may be used provided that it Safety (Installation &...
  • Page 8 The following notes are given for general 4.6.1 A suitable guard is available from guidance. G.R.Claudio (Vokera) Ltd. Part No 018, 4.6.2 Pipework G.C. No. 301 Copper tubing to BS 2871: 1:1971 is recom- This guard must be fitted centrally over the mended for water pipe.
  • Page 9 Shower bath basin sink drain poine drain tap Cold inlet (from mains or cistern) (at lowest potnt(s) •uppiy Fig 5 Schematic layout 2 pipe central heating Radiator mean temperature depends on water flow rate through radiator boiler CODD ions •bov• NOTE! ngures (e.g.
  • Page 10 A method is shown in fig. 7 using the Vokera filling loop which is acceptable in most areas. In the event that this method is not suitable in a particular area, contact the local authority for preferred methods.
  • Page 11 SECTION INSTALLATION Delivery (fig. 8) The appliance is delivered in a heavy duty cardboard carton. Lay the carton on the floor with the writing the correct way up. Unpacking (fig.9) Pull both sides of the carton open. Do not Fig. 8 use a knife.
  • Page 12 Mounting the Appliance (Fig. 13) ø105 5.4.1 Place the template on a smooth, vertical incombustible surface use it to locate the upper bracket, bottom fixing and flue pipe holes. (If the appliance is to be fitted on a wall of combustible material, the wall Fig.13...
  • Page 13 5.5.10 | 0drop away from the appliance and ad- equately supported. Use at least one bracket foreach extension. (Conventional adjustable strap supports, Part No. 03, G.C. No. 301 105, suffice, Vokera stockist can supply if necessary) 5.5.11 Assemble the second small maintenance clip on the end of the inner flue tube.
  • Page 14 Measure carefully the distance between the 5.5.24 Fig. 17 Scrcw centre of the flue bend on the boiler to the centre of the hole through the wall (dimen- Sion X fig. 18). NOTE: Extension kits part No. 026 (G.C. No. 370 346) will be required if the distance measured is greater than 780mm Subtract 230mm from the measured dimen-...
  • Page 15 VERTICAL FLUE INSTRUCTIONS The Vokera Room sealed vertical flue terminal If a pair of 90 Degree bends are used a maximum of assembly is intended for use where a horizontal flue one 850mm extension may be used vertically before outlet is not possible or desired.
  • Page 16 Fig. D Fixed Offset Short to Short Long to Short Long to Long Measure W. Then W+Xmm (see table) = Proceed with installation as detailed distance from ceiling for appliance hanging section 5 of the main installation bracket. servicing Instructions, ignoring all refer- ences to the flue...
  • Page 17 Any shortening of extension tubes must be carried out on the end which does not have the screw retaining the inner and outer tubes together. Dimensions in mm Remove the screw retaining the inner and outer tubes together. Measure the distance between the inner tubes and cut the inner tube to this length.
  • Page 18 INSTRUCTIONS Installation of Twin Flue Svstem The Vokera room sealed twin flue system is intended for use where either the concentric horizontal or vertical Assembly of Twin Flue Connection kit. flue length would normally be exceeded. It can be used...
  • Page 19 Concentric Teminal Concentric to twin converter Exhaust Connection Fig. 3 3.9 x 9.5mm Self Tapping Screws Silicone Fig. 2 Seal Air Inlet 3.9 x 9.5mm Self Tapping Screws Concentric to Twin or Twin to Concentric Converter inlet pipe 7.5mm Fig. 4 Exhaust Concentric outlet...
  • Page 20 Depending on flue configuration remove either Concentric Termination. the left or right hand cover from the top of the combustion chamber, using these Follow the instructions detailed on page 10, figs. screws install the air bane. 14 & 15 for horizontal or page 13 for vertical flue (termination only).
  • Page 21 Connecting the Gas and Water 5.6.1 Figs. 12 and 16 show the locations of the fittings. 5.6.2 Do not over tighten nuts and use another spanner to apply counter force to avoid damaging the appliance 5.6.3 Gas Supply Connecting the gas supply. Fig.
  • Page 22 Pass the cable through the cord anchorage 5.7.4 and connect the wires Brown to L Blue to N and GreenNellow to* , arrange the cable so that should the cable slip the anchorage the currentcarryingconductorsbecometaut before the earthing conductor. No other terminals on this plug should be NOTE: used for any electrical connections.
  • Page 23 SECTION COMMISSIONING Where the text bears identifying numbers in 6.3.4 Setting the System Design Pressure brackets, refer to figs. 1 and 2 unless 6.3.4.1 The design pressure must be a minimum of otherwise instructed. Close control panel, 1 bar and maximum 1.5 bar.
  • Page 24 Reduce the domestic water flow rate to 6.7.6 Lighting the Boiler approx. 3-4 litres/min, turn the domestic Ensure flow and return valves are open 6.6.1 control knob slowly to minimum the boiler (Cl 6.3.3.2) output will reduce to the minimum setting. If low flame cannot be established in this way, If external controls are fitted (e.g Timeclock...
  • Page 25 11 44 Input Fig.23 100030 10.26 ".7 '3.18 14.65 16.1 17.6 tø 23.4 26.4 24.9 27.9 29.3 30.8 32.24 33.7 Checking the Flue System Open all drain taps and quickly drain the system whilst still hot to remove offending 6.8.1 The flue system should be visually checked substances.
  • Page 26 Hinge up the control fascia. 6.14.2 It is best to set for the lowest acceptable temperature since the user can gain higher Refixing the Front Cover fig. 24 6.15 temperatures by restricting flow at the tap. Offer up the front casing to the back frame in 6.15.1 N.B.
  • Page 27 SECTION INSTRUCTING USER Hand over the copy of the Users Instruc- tions supplied with the appliance, together with these instructions, and explain how to operate the boiler correctly and explain how to use the timeclock and room thermostat fitted. Show the user how to switch off the appli- ance quickly and indicate the position of the electric supply isolator.
  • Page 28 SECTION SERVICING INSTRUCTIONS 5. Turn off mains electricity and turn off gas General service tap on the appliance. To ensure the continued safe and efficient 6. Gain general access as described below operation of the appliance, it is recom- in clause 8.4.
  • Page 29 To Gain General Access/Assembly To remove components access to the interior is essential. Refer to fig. 25. Ensure electricity supply is isolated before carrying out any servicing. To remove front casing. 8.4.1 Release 4 retaining screws fig. 25. Pull bottom of case slightly forward and push case upwards to disengage from top support hooks and withdraw the case from the appliance.
  • Page 30 8.7.6 Remove main burner. To remove/replace electrode, thermocouple and pilot burner. Reassemble in reverse order. Refer to fig. 28 Main Burner Injectors Gain general access as 8.4 8.6.1 Gain general access as 8.4 8.8.1 Remove room sealed front cover 8.6.2 Remove room sealed front cover plate and 8.8.2 To remove pilot burner assembly...
  • Page 31 Main Heat Exchanger Part No. 5351 Refer to Fig. 29 & 30 8.9.1 Gain general access as 8.4 8.9.2 Remove roomsealedfront cover plate (8.5). 8.9.3 Remove front of combustion chamber (8.6.3). Pressure Maintenance clip differential 8.9.4 Remove two air baffle plates. 1 screw secur- switch ing each.
  • Page 32 Modulator Coil 8.13.3 Pull off tab connectors and remove pres- 8.11.4 Part No. 6901 sure switch, disconnecting the air pressure Pull off electrical leads from tab connectors. pipes in process. 8.13.4 Reassemble in reverse order. Release the modulator coil retaining clip. 8.11.5 8.13.5 Seefig.
  • Page 33 8.13.15 Replace in reverse order using a new gasket. 8.15.11 Reassemble in reverse order. Reconnecting electrical leads Brown to L, 8.13.16 See fig. 39 for electrical connections. Blue to N and Green to E. 8.13.17 Check burner pressures as clause 6.7 8.16 Removal of Hydraulic group Gas Control Valve (complete)
  • Page 34 Remove fulcrum arm 8.17 8.20.3 Fulcrum 8.17 Remove flow microswitch by unscrewing 8.20.4 Gain general access as 8.4 8.17.1 retaining screw on bracket. Remove screw from pivot point of arm 8.17.2 Remove manifold front cover by removing (accessto screwis fromunderside of arm) 8.20.5 the five cover retaining screws.
  • Page 35 8.21.4 Close heating flow and return valves fig. 1, 8.22 Safety Valve 23 and 24) by turning % turn until indicating Part No. 8433 Refer to fig. 32 & 33 lines are horizontal. 8.22.1 Gain General Access 8.4. Drain appliance via safety valve by % turn of 8.21.5 8.22.2 Close heating flow and return valves fig.
  • Page 36 Slow fan speed resistor 8.23.24 Removal of Electrical Components 8.23 Part no. 4028 Ensure electricity is switched off at main 8.23.1 Unplugthe inlineconnectorbelowfan resis- 8.23.25 isolatorand gain generalaccess (8.4) tor. Flow Micro Switch 8.23.2 Remove2 retaining screws from resistor. 8.23.26 Part No 0811 (Fig.
  • Page 37 Refer to the commissioning rate recorded by the commissioning engineer on the boiler badge. 8.28 End of Servicing Run through the general commissioning as described in Section 6 as far as they apply. Refit casing and clean up. EXCELL 80SP...
  • Page 38 SECTION 9 OPERATIONAL C HECKS ANDWIRING DIAGRAMS Conversely a fall intemperatureofthe On completionof any service/faultfinding primarywaterwill increasethe lowvoltage task which has requiredthe breakingand to the modulator coil and this inturn in- remakingof electricalconnections,the creases the gas rate accordingly. checks Earth Continuity, polarity and Constantmonitoringof the temperatureof Resistance to Earth must be repeated.
  • Page 39 To ensure that external controls (if fitted) do not interfere with fault finding, disconnect the wires from terminals 1 & 3 (labelling them in the process to ensure correct reconnection) and provide a solid link between 1 & 3. EXCELL 80SP...
  • Page 40 START TURN SWITCH Tt—OSTAT CONTROL TO MAX. —w PRESENT BETWEEN TEwdAL 16 & NEUTRAL FAN RI.WNING AT MIN. 230V AC PRESENT BETWEEN TERMNAL TURN ON HOT TAP 9 & NEUTRAL REPLACE CIRCUIT BOARD PUMP RUNNING 230V AC RESENT BETWEEN ERMNAL 10 &...
  • Page 41 ES GAS VALV ENERGISE AC PRESENT BETWEEN TERMINAL 11 & NEUTRAL CHECK WIRING CONNECTIONS PRESSURE DIFFERENTIAL SWITCH IS 230V AC PRESENT ACROSS TERMINALS 1B & 20 REPLACE PRINTED TURN CIRCUIT BOARD POTENTIOMETER TO MAX. IS 230V AC PRESENT SOLENOID CHECK AND/OR REPLACE WIRING...
  • Page 42 230V PRESENT BETWEEN TERMINAL RECHECK SUPPLY FUSE & CONNECTIONS BOILER TERMINALS CHECK FUSE ON CIRCUIT BOARD 230V AC REPLACE CIRCUIT PRESENT FUSE REPLACE FUSE BOARD BETWEENTERMINAL 7 & NEUTRAL CHECK WIRING AND 230V AC CONNECTIONS PRESENT BETWEEN BOILER FLOW TERMINAL SWITCH &...
  • Page 43 START SWITCH ON BOILER SELECT SUMMER MODE. TURN POTENTIOMETER TO MIN. TURN ON TAP DOES BURNER LIGHT IS 230V AC PRESENT BETWEEN TERMINAL OLTAGE ACROSS 24 & NEUTRAL TERMINALS MODULATOR COIL IS THERE > 10 VDC A VOLTAGE >IOVDC BETWEEN CHECK BOILER TERMINALS...
  • Page 44 START SWITCH ON BOILER AND SELECT WINTER MODE TURN IS 230V POTENTIOMETER AC PRESENT MIN. BETWEEN TERMINAL 2 & NEUTRAL ROTATE RANGE IS 230V RATING ADJUSTER AC PRESENT TO MAX (SEE DIA) BETWEEN TERMINAL 1 & NEUTRAL TURN ROOM THERMOSTAT REPLACE CIRCUIT CHECK BOILER...
  • Page 45 IS VOLTAGE ACROSS TERMINALS If timer jumper (plug) is OF MODULATOR COIL fitted here remove discard WAIT UNTIL Control knobs BURNER SWITCHES DOES BURNER SWITCH IS NTC & WIRE OR CONNECTIONS TURN cn-* POTENTIOMETER REPLACE REPLACE CIRCUIT AND/OR WIRE OR BOARD CONNECTIONS DOES BURNER...
  • Page 46 START OPEN MAN GAS COCK CHECK CHECK SUPPLY OF AVAILABLE GAS TO APPLIANCE REPEATEDLY PRESS PIEZO IGNITOR BUTTON CHECK ELECTRODE CAN SPARK UNDAMAGED. CHECK BE OBSERVED AT LEAD & CONNECTIONS. ELECTRODE? REPLACE PEZO IGNITOR PRESS & HOLD DOWN GAS CONTROL VALVE KNOB REPEATEDLY.
  • Page 47 (Part No. 05 G.C. No. 301 109) (B Wiring to external Time Switches, Room Thermostats and Frost Thermostat. Installation of the Vokera time switches (24 Hr and 7Day) Remove the clock aperture blanking plate (1) fig. 1 by removing the securing screws and pulling the plate out.
  • Page 48 MUST BE AT EITHER ROOM THERMOSTAT APPLIANCE EXTERNAL TERMINAL TIME SWITCH BLOCK Remove link (ii) ACL Time Switch and Vokera Room Thermostat ACL Lifestyle LP 111 Do not link L & 1 L 12 VOKERA ROOM STAT APPLIANCE TERMINAL LINK 1 &...
  • Page 49 Wiring Plan Installations. APPLIANCE TERMINAL BLOCKS ROOM CYLINDER THERMOSTAT THERMOSTAT REMOVE SATISFIED • CALLING LINK LIVE COMMON REMOTE JUNCTION 3 Amp Fuse MAINS SUPPLY 2 PORT ZONE VALVE 230v 50Hz GREY BROWN BLUE GREENNEL BLUE DOUBLE CHANNEL 2 PORT ZONE VALVE PROGRAMMER Wiring...
  • Page 50 EXPLODED DIAGRAMS Fig. 36 4174 Fig. 36C 4028 Fig. 36G Fig. 36D Fig. 361 Fig. 36J Fig. 36B Fig. 36L Fig. 36K Fig. 36E Fig. 36F Fig. 36A Outer Casing 5093 7212 5256 5093 7211 7212 EXCELL80SP...
  • Page 51 Fig. 36B Gas Assembly Fig. 36C Main Frame & Expansion Vessel 5172 N.G. 7095 L.P.G. 7206 5180 5079 5280 7204 5079 5176 4961 N.G. 4891 L.P.G. 4893 7304 7201 7311 5472 5128 8031 5371 5171 7094 5176 Circulafion Pump Fig. 36E Fig.
  • Page 52 Fig. 36F Hydraulic Assembly 5188 7139 7131 7130 8431 5041 Ice. 8436 6888 6865 5183 5183 5214 5184 6866 8445 5184 5042 5185 4612 8442 6887 6874 6870 8441 8437 7134 8468 5041 5197 Fig. 36H Expansion Vessel Kit (Optional) Fig.
  • Page 53 Fig. 361 Combustion Chamber 5917 5916 5151 5081 4807 5176 7618 5079 5912 5128 5079 5165 5067 5271 5079 5270 5351 5924 5079 6027 5949 5093 Fig. 36J Sealed Case Fig. 36K Cover 5180 5079 5079 7701 5905 5128 7701 5080 Kepa 5082...
  • Page 54 Fig. 36L Front Panel 5133 5133 5128 5212 5132 71 1 6160 7157 5275 EXCELL80SP...
  • Page 55 SHORT SPARE PARTS LIST REFER TO FIG. Code G.C. Description 0402 333837 Gas Valve Solenoid 4039 333879 Pilot Tube Seal To Combustion Chamber 333 722 4254 Auto Vent 4640 333 888 Gas Valve Complete 4961 333 902 Thermocouple 5280 Pilot Assembly 5351 301 085 Main Heat Exchanger...
  • Page 56 FUNCTIONAL FLOW DIAGRAM General Layout Fig. 37 0.1. N.G./L.P.G. TIMER ON-OFF R.T. D.P.S. Fuse Mode Selector Switch (Off Position) Mode Selector Switch Position) Mode Selector Switch JIMPosition) Frost Thermostat Time Clock Room Thermostat R.T. Pump Domestic Microswitch Slow Fan Speed Resistor R=560Q Flow Switch...
  • Page 57 GENERAL LAYOUT OF WIRING FROM PRINTED CIRCUIT BOARD Fig. 38 ROOM THERMOSTAT 230v TIME CLOCK FROST 501--lz THERMOSTAT BOILER D.H.w. FLOW FLOW SWITCH SWITCH DIFFERENTIAL SWITCH RESISTOR 5600hm b ro•n THERMISTOR FUSE 24 9 1011121314 16171 TWER N.G/L.P.G. RATING D.H.w. ON/OFF MODE TEMP.
  • Page 58 ILLUSTRATED WIRING DIAGRAM Pressure Differential Switch Fig. 39 Brown Blue/Black Red/Black Blue White Microswitch Black White Pump Flow Switch Resistor Valve Brown Blue Brown A - Black B - White C - Purple D - Grey E - Blue F - Brown G - Red Electronic H - White...
  • Page 59 PRELIMINARY ELECTRICAL SYSTEM CHECKS A. EARTH CONTINUITY CHECK - appliance must RESISTANCE TO EARTH CHECK be electrically disconnected - meter set on Q (ohms) Appliance must be disconnected from mains supply x 1 scale and adjust zero if necessary. and meter set on Q (ohms) x 100 scale. All switches, including stats, ON - Test leads from L to E - if meter a) Test leads from any appliance earth point to earth reads other than infinity...
  • Page 60 SECTION 11 L.P.G. INSTRUCTIONS 11.1 Gas Rates (LPG) 80SP 1.68 litres/h Min. Rate 4.12 litres/h Max. Rate 11.2 Burner Details (LPG) 80SP Polidoro NP12 Main Bumer Main Burner Injectors 36.0 mbar Burner Pressure Max. Rate Burner Pressure Min. Rate 5.5 mbar CIH &...
  • Page 61 11.6.6 Reduce the domestic water flow rate to Setting the Maximum Rate for Central 11.7 approximately 3-4 litres/min, turn the domes- Heating (Range Rating) tic control knob slowly to minimum the boiler Refer to fig. 40 to determine the pressure for output will reduce to the minimum setting.
  • Page 64 1.02 3/97 Vokéra Head Office and Accounts: Clarisham House, Morson Road, Enfield, Middlesex EN34NQ Tel. 0181-804 7202 Fax. 0181804 8163 Northern Region: Stubs Beck Lane, West 26 Business Park, Whitehall Road, Cleckheaton, west Yorkshire BD19 41TTel.01274 865556 Fax. 01274 865557 Scottish Region: Shuna sreet, Mayhill, Glasgow G209NW Tel.