VOKERA CONDEXA PRO 100 M Installation & Servicing Instructions Manual
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VOKERA CONDEXA PRO 100 M Installation & Servicing Instructions Manual

VOKERA CONDEXA PRO 100 M Installation & Servicing Instructions Manual

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CondexaPRO
Light commercial boiler
Installation
& Servicing
Instructions
THESE INSTRUCTIONS
TO BE RETAINED
BY USER
Vokèra is a licensed member of the Benchmark scheme
which aims to improve the standards of installation and
commissioning of domestic hot water systems in the UK.

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  • Page 1 CondexaPRO Light commercial boiler Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER Vokèra is a licensed member of the Benchmark scheme which aims to improve the standards of installation and commissioning of domestic hot water systems in the UK.
  • Page 2 CONFORMITY The Vokera CONDEXA PRO boilers comply with: • Gas Appliances Directive 90/396/EEC • Boiler Efficiency Directive 92/42/EEC • Electromagnetic Compatibility Directive 89/336/EEC • Low Voltage Directive 73/23/EEC. • EN 677 standard on condensing boilers. 0085 RANGE MODEL FUEL CODE...
  • Page 3 3 months from date of purchase which ever soo- ner providing it has been commissioned by Vokera or a qualified engineer and a copy of the com- missioning certificate has been returned and filled with Vokera Ltd.

  • Page 4: Table Of Contents

    CONTENTS GENERAL General warnings page 5 Fundamental safety rules “ Description of the appliance “ Safety devices “ Identification “ Structure “ Technical specifications “ Accessories “ Water circuit “ Positioning the probes “ Pumps “ Wiring diagrams “ Control panels “...

  • Page 5: General Warnings

    1.5 bar and less than not the case, contact Vokera Ltd. the maximum limit specified for the appliance. If this is not the case, contact Vokera Ltd or other profes- The CONDEXA PRO Boiler must be installed by sionally qualified personnel.

  • Page 6: Description Of The Appliance

    90°C, shutting down the bur- potentially dangerous malfunction on the boiler; ner. immediately contact Vokera Ltd or other professio- Diagnosis in the water circuit, the minimum flow-rate of nally qualified personnel. the heat exchange fluid in each heating unit is controlled...

  • Page 7: Identification

    IDENTIFICATION The boilers can be identified by the: - Packaging label This shows the code, the serial number and the barcode. - Rating plate This shows the technical and performance speci- Models 50 M - 100 M fications. - Gas label This is applied on the side of the frame, and describes the type of fuel used by the boiler, and Models...

  • Page 8: Structure

    STRUCTURE CONDEXA PRO 50 M CONDEXA PRO 100 M - 100 S 12 16 12 15 1 - Fan 13 - Central heating return inlet 2 - Combustion air intake fitting 14 - Central heating flow outlet 3 - Gas valve 15 - Main switch 4 - Flue gas outlet fitting 16 - Safety valve connection pipe...

  • Page 9: Technical Specifications

    TECHNICAL SPECIFICATIONS CONDEXA PRO DESCRIPTION 50 M 100 M 100 S Fuel G20 - G30 - G31 Appliance category II2H3+ Type of appliance B23 - C63 Heat input ref. HHV (min - max) 16,3 - 50 16,3 - 100 16,3 - 100 Heat input ref.

  • Page 10: Water Circuit

    WATER CIRCUIT 1 - Fan 2 - Gas valve 3 - Automatic vent valve 4 - Burner 5 - Heat exchanger 6 - Condensate drain trap 7 - Drain cock 8 - Water differential pressure switch 9 - Safety valve (6 bar) - Air intake - Flue gas outlet SC1 - Safety valve drain...

  • Page 11: Positioning The Probes

    POSITIONING THE PROBES The following probes/thermostats are installed for each heating unit: CENTRAL HEATING OUTLET PROBE SAFETY THERMOSTAT FLUE GAS PROBE CENTRAL HEATING RETURN PROBE PUMPS CONDEXA PRO Boiler does not come with a pump, which must be installed in the system. When choosing the pump, refer to the following system diagrams.
  • Page 12 Configuration with injection pumps PB - DHW pump Boiler discharge head: 6 mWC PZ1 - Pump in zone 1 Boiler flow-rate: 2 m /h for each pump. (high temperature) Recommended pump TYPE A for each heating unit. PZ2 - Pump in zone 2 (low temperature) - Injection pump (accessory)
  • Page 13 Pump TYPE A Flow-rate (m /h) Pump TYPE B 1100 1000 Flow-rate (m /h) Pump TYPE C 1200 1100 1000 Flow-rate (m /h) CONDEXA PRO...

  • Page 14: Wiring Diagrams

    WIRING DIAGRAMS The control panel on CONDEXA PRO models 50 M and 100 M contains one master board and one or two slave boards, depending on the output of the boiler. Model 100 S contain just two slave boards. If connecting a series of boilers in casca- ding, the master board on the CONDEXA PRO 50 M or 100 M manages all the boards on the CONDEXA PRO 100 S boi- lers via BUS.
  • Page 15 The pumps should be connected by installing suitable contactors with manual emergency operation. part 2 to main earth pole to main earth pole EA/ER EA/ER Earth Earth Earth Fuse 4A Earth Line Line Neutral Neutral Gas valve Safety thermostat Diff. pressure switch SLAVE 1 SLAVE 2 Blower (+)
  • Page 16 CONDEXA PRO 100 S part 1 Main earth pole 230V~50Hz Earth Neutral Line Joint with sheath to main earth pole EA/ER Earth Earth Fuse 4A Earth Line Neutral Gas valve Safety thermostat Diff. pressure switch SLAVE 1 Blower (+) Hall sensor imput Hall sensor power Hall sensor common Blower (-)
  • Page 17 part 2 - Gas valve - Safety thermostat - Water differential pressure switch - Outlet probe - Return probe - Flue gas probe EA/ER - Ignition/detection electrode - Cable for connection to two-way valve or injection pump (accessories) - Main boiler switch - FIRST heating unit switch - SECOND heating unit switch J10/J17 - Microswitches for setting the address (see page 54)

  • Page 18: Control Panels

    CONTROL PANELS CONDEXA PRO 50 M 11 12 13 1 - FIRST heating unit switch CONDEXA PRO 100 M 2 - Button for selecting the operating mode 3 - Reset button (Master) 4 - Boiler lockout signal 5 - Button for selecting the parameters 6 - Display 7 - Save button...

  • Page 19: User Interface

    Functional notes The control panel on the CONDEXA PRO Boiler models 50 M and 100 M manages: - The domestic hot water priority function whereby when - The dispersion function: the pumps in the high and low there is demand for domestic hot water, the master temperature circuits remain on for 5 minutes after the board can also serve the high or low temperature cir- last burner has shut down.

  • Page 20: Display Mode

    DISPLAY MODE The red LED (see ref. 4 on page 18) comes on in the event of faults that cause the permanent lockout of a heating unit (normal operation is reset only by pressing the Master or Slave reset button). The 3 digits with seven segments display the status of the system: Status of the system Display...

  • Page 21: Setting The User Parameters

    Value displayed Display Operating status of the mixing valve E.g.: closing, opening, standby Operating status of the main pump E.g.: pump not working, pump working Operating status of the DHW pump E.g.: pump not working, pump working Operating status of the secondary pump E.g.: pump not working, pump working To exit the display of the values, press the "MEMO"...

  • Page 22: Monitor Mode

    Procedure Display Press “MODE” Press “ ” to change the set point to the desired value. E.g.: 40°C. Press “MEMO” to save the new value After 3 seconds Display mode resumes, with the new value set. If after having pressed “MODE” no change is made for 10 seconds (because the desired value is already set), the ope- ration of the board returns to Display mode.

  • Page 23: Installer Programming Mode

    Value Display Fan PWM signal (%). If PWM = 100%, this corresponds to 99 on the display. E.g.: 66 % Flow switch contact open/closed (not active) E.g.: contact open Pump or motorised valve on the individual unit on/off E.g.: Pump ON E.g.: Pump OFF Maximum ionisation current (range from 0 to 99) at first attempt E.g.: maximum ionisation current 80...

  • Page 24: Test Mode

    TEST MODE In Test mode, a high temperature heating demand can be generated corresponding to maximum output and minimum output. All the system fans must be on. If the installer switches off some of the Slaves, the others, connected to the Master, must continue operating.

  • Page 25: Receiving The Product Pag

    RECEIVING THE PRODUCT The Vokera CONDEXA PRO Boiler is supplied in a sin- gle package protected by a cardboard box. The following material is supplied with the boiler: - Installation and operation manual - Warranty certificate - Water pressure test certificate...

  • Page 26: Handling

    ROOM WHERE THE BOILER IS INSTALLED The Vokera CONDEXA PRO boiler must be installed in rooms used exclusively for this purpose, provided with ade- quately sized ventilation openings, in compliance with any current standards and low applicable. If the combustion air is taken from outside (accessories code 5037685135067 and 5037685135074) the room where the boiler is installed, CONDEXA PRO operates as a room-sealed appliance (type C).

  • Page 27: Installation In Old Systems Or Systems To Be Upgraded

    INSTALLATION IN OLD SYSTEMS OR SYSTEMS TO BE UPGRADED Where Vokera CONDEXA PRO Boilers are installed in old systems or systems to be upgraded, check that: - The flue is suitable for the temperature of the products of combustion with condensing operation, calculated...

  • Page 28: Installing The Boiler

    INSTALLING THE BOILER The Vokera CONDEXA PRO Boiler must be secured to a solid brick wall using the bracket (1). For installation: - Position the bracket (1) on the wall at a height of around 200 cm from the ground, using a spirit level to...
  • Page 29 Repeat the operation until the system is clean. WATER CONNECTION KIT code 5037685135012 For additional information on the type and the use of the additives, contact Vokera Ltd or a suitable additives manufacture. Water connection kits To assist the construction of the water circuit, two acces-...

  • Page 30: Fuel Connections

    FUEL CONNECTIONS The Vokera CONDEXA PRO Boiler must be connected to the natural gas or LPG supply in compliance with the When installation is completed, check that the joints are relevant standards in force. all tight, as required by the installation standards.
  • Page 31 MAXIMUM LENGTH OF THE PIPES model 50 M The maximum equivalent length of the sum of the 50 mm intake pipes and flues is 30 metres, with a pressure drop of 2 metres for each 90° bend. Installation of a single boiler with flue passing inside a compartment (open flue operation).
  • Page 32 PREPARING THE CONDENSATE DRAIN The condensate produced by the boiler during normal operation must be drained at atmospheric pressure and must conform to any current standards and law applica- ble. - install a neutraliser where required by law. i ≥ 3° Specific pipes for condensing boilers must be used.

  • Page 33: Electrical Connections

    ELECTRICAL CONNECTIONS The CONDEXA PRO 50 M and 100 M boilers leave the factory completely wired, with the power cable already connec- ted, and only require the connection of the room thermostats, the outside probe and the pumps used, to the correspon- ding terminals.
  • Page 34 - Identify the terminal block (5) and make the connec- tions, as in the diagram shown below. TERMINAL BLOCK INSIDE THE MASTER CONTROL PANEL Probe in zone 1, PB (*) high temperature DHW pump PZ1 (*) Storage heater probe High Temperature system pump PZ2 (*) Loop pump or...

  • Page 35: Installing The Outside Probe

    INSTALLING THE OUTSIDE PROBE The correct positioning of the outside probe is fundamental for the correct operation of the climate control function. The probe must be installed outside of the building being heated, at a height of around 2/3 of the wall facing NORTH or NORTH-WEST, and away from flues, doors, windows and areas exposed to direct sunlight.

  • Page 36: Filling And Emptying The Systems

    FILLING AND EMPTYING THE SYSTEMS The Vokera CONDEXA PRO Boiler is not fitted with an automatic filling valve, which must be installed on the system return. FILLING - Open the valves (1) installed on the boiler water fittings; - Open the caps on the automatic vent valve/valves (2) two or three turns;...
  • Page 37 EMPTYING Before starting to empty the system, disconnect the power supply by moving the main system switch to "off". Emptying the BOILER - Close the valves (1) installed on the boiler water fit- tings; - Connect a plastic hose to the drain cock (4), on each heating unit, and open the cock;...

  • Page 38: Preparing For First Start-Up

    PREPARING FOR FIRST START-UP Before starting the system and running the functional tests on the Vokera CONDEXA PRO Boiler, check that: - The fuel valve and valves in the central heating system are open; - The type of gas and the supply pressure are correct for the boiler;...

  • Page 39: Starting For The First Time Pag

    STARTING FOR THE FIRST TIME - Move the main system switch to "on"; - Move the main switch (1) on the boiler and the switches (2) on each heating unit to "on". The green SLAVE power supply signal (3) flashes. The boiler performs a self-diagnosis cycle, after which it will enter DISPLAY mode.
  • Page 40 (see the paragraph "Setting the temperature controller"). These settings must only be performed by Vokera Ltd or a suitably qualified person. If the boiler is connected to a storage heater, set parameter 6 (pre-set to 0=no DHW service).

  • Page 41: Checks During And After First Start-Up

    When the boiler is in Standby, the display on the Master unit is in Readout mode and the three digits show the number "1", followed by the value of the outlet tempe- rature. The green LED (ref. 11 on page 18) flashes. See the paragraph on "DISPLAY MODE", page 20, for details on the various information displayed by the system.
  • Page 42 After a few minutes of continuous operation controlled by the room thermostat, the adhesives and the processing residues will have evaporated, and the following checks can be completed: - check the gas supply pressure; - check combustion, CHECKING THE GAS SUPPLY PRESSURE - Move the main system switch to "off";...
  • Page 43 In TEST mode, a high temperature heating demand at maximum output can be generated. To do this: - Press the “MODE” and “+” buttons together for 5 seconds; - Start the boiler by adjusting the room thermostat. The boiler will operate at maximum output showing "H" on the display, followed by the outlet temperature (chimney sweep function);...
  • Page 44 - Combustion can be checked by unscrewing the cap (4) and inserting the analyser probe in the available position; - Once having completed the check, stop the chimney sweep function by pressing “MEMO”; - Adjust the thermostat so as to stop the boiler; - Remove the analyser probe and carefully retighten the cap (4);...

  • Page 45: Setting The Functional Parameters

    SETTING THE FUNCTIONAL PARAMETERS The functions of the central heating high temperature and low temperature circuits and the DHW circuits can be set based on the system requirements, by setting the functional parameters. The first three parameters are accessible at a user level, while the remaining parameters require the password to be entered ("22", see page 23).
  • Page 46 2 Setpoint_T_CH_Low Set point in the low temperature circuit (parameter 3) If the operating mode is set to "fixed set point" (par. 22=CH_type_low=0), this is the objective temperature. If the operating mode is set to "climate control" (par. 22=1), this is the maximum objective temperature for the mini- mum outside temperature (T_out_min=par.

  • Page 47: Setting The Domestic Hot Water Parameters

    SETTING THE DOMESTIC HOT WATER PARAMETERS The following functions can be set for the domestic hot water circuit: 1 Setpoint_DHW Domestic hot water set point (parameter 2) This is the temperature value for the production of domestic hot water. The maximum limit is set by par. 8 (T_DHW_limit, pre-set to 60°C). Pre-set to 50°C.

  • Page 48: Setting The Temperature Controller

    SETTING THE TEMPERATURE CONTROLLER 1 Attenuation_High Attenuation function for the HIGH TEMPERATURE circuit (parameter 21) Two cases are possible: - Operation with fixed set point, Par. 14=0 - Operation with climate control Par. 14=1. OPERATION WITH FIXED SET POINT, PAR. 14=0 With attenuation in the high temperature circuit disabled, Par21=0, when the thermostat in the high temperature cir- cuit closes, the heating demand is signalled.
  • Page 49 2 Attenuation_Low Attenuation function for the LOW TEMPERATURE circuit (parameter 25). This paragraph is similar to the previous one, however in this case referred to the low temperature circuit. Two cases are possible: - Operation with fixed set point, Par. 22=0 - Operation with climate control Par.
  • Page 50 3 T_out_correct Outside temperature correction (parameter 39) Normally the value displayed is the value read by the micro-controller, plus or minus a correction value (T displayed = T read by the probe +/- correction). The outside temperature value read can be corrected by changing the value of parameter 39, (the limit allowed for the correction is +/- 30 °C).
  • Page 51 Disconnect the power supply from the system, unplug the BUS and connect the PC interface. The output of the burners can be sent directly to the Slave boards using the PC. In the event of faults, contact Vokera Ltd or a suitably qualified person. CONDEXA PRO...
  • Page 52 Managing the heating demand in the high temperature circuit by analogue input (Par. 14=2 or 3) The room thermostat in the high temperature circuit is ignored for the heating demand, and the input signal is used to calculate the output or the system set point. There is just one analogue input (see terminals 13-14 on the wiring diagram on page 34) on the Master board and this can also be used for the low temperature circuit (Par.22).
  • Page 53 MANAGEMENT OF THE MIXING VALVE The mixing valve is controlled by the following parameters: Mix_valve_step_open_time: Par.28 pre-set to 5s Mix_valve_step_close_time: Par.29 pre-set to 7s Mix_valve_interval_time: Par.30 pre-set to 5s Mix_valve_p_hyst: Par.31 pre-set to 2°C Mix_valve_still_hyst: Par.32 pre-set to 2°C Before opening or closing, the valve waits the time set for Par.30.

  • Page 54: Setting The Addresses For Cascading Configurations

    SETTING THE ADDRESSES FOR CASCADING CONFIGURATIONS The microswitches on the slave boards are factory-set so as to interface a master boiler (50 M or 100 M) to a slave boi- ler (100 S). If other slave boilers need to be connected, the microswitches must be set again. Accessing the slave boards - Move the main system switch to "off"...
  • Page 55 Example configuration of a set of 7 burners in cascading If installing a set of seven slave generators, there are two blocks: the first made up of four generators, and the second of three. Therefore, two blocks need to be configured, with address 1 and 2 respectively, and the generators belonging to the first block must have address 1, 2, 3 and 4, and those belonging to the second block address 1, 2 and 3.

  • Page 56: Fault Codes

    FAULT CODES ERRORS ON THE MASTER BOARD The following tables provide a description of the errors that may occur on the Master board. The errors can be divided into two groups: - Type A errors, which can only be deactivated by pressing RESET (see ref. 3 on page 18). - Type E errors, which are deactivated when the causes are no longer present.
  • Page 57 ERRORS ON THE SLAVE BOARD List of slave errors: manual reset (see ref. 3 on page 18) If slave errors with manual reset occur, the Slave reset button can be used (see ref. 13 on page 18). Error A 01 5 failed attempts at ignition A 02 Too many failed ignitions...

  • Page 58: List Of Parameters

    LIST OF PARAMETERS No. Name lower upper default Description limit limit setting User parameters SetPoint_ch_high Par. 17 °C If Par14=0 this is the high temperature circuit set point If Par14=1 this is the maximum temperature in the high temperature circuit SetPoint_DHW Par.
  • Page 59 No. Name lower upper default Description limit limit settinglimit limit setting 26 CH_low_hyst_on °C Start hysteresis in low circuit calculated on the mixer outlet temp 27 CH_low_hyst_off °C Stop hysteresis in low circuit calculated on the mixer outlet temp 28 Mix_valve_step_ open_time 0 For each step the valve opens 1/2 of the set value 29 Mix_valve_step_close_time 0...
  • Page 60 CONVERSION FROM ONE TYPE OF GAS TO THE OTHER The Vokera CONDEXA PRO Boiler is supplied for ope- The conversion must only be carried out by Vokera ration on G20 (natural gas). However, it can be conver- Ltd or personnel authorised by Vokera, even when ted for operation on G30-G31 (LPG), using the special the boiler is already installed.
  • Page 61 - Replace the calibrated diaphragm fitted on the gas valve with the diaphragm (4) supplied inside the kit, 6.75 marked “6.5”. Only if the boiler is supplied by a mixture of gases that causes ignition problems, use the other diaphragm (5) marked “6.75”.
  • Page 62 ADJUSTMENTS The adjustments at maximum and minimum out- The Vokera CONDEXA PRO Boiler is supplied for ope- put must be carried out in the sequence descri- ration on G20 (natural gas), as indicated on the rating bed, and only by Vokera Ltd or personnel autho- plate, and has already been adjusted in the factory by rised by Vokera.
  • Page 63 TEMPORARY SHUTDOWN In the event of temporary absence over the weekend, The frost protection function has two levels: brief trips, etc. proceed as follows: - the first starts the pump if the manifold temperature ≥ 5°C, or alternatively, when - Set the room thermostats to around 10°C CH_type=1 and the outside probe is connected;...
  • Page 64 It ensures reduced consumption and pollu- ting emissions and maintains the reliability of the pro- duct over time. The appliance can be serviced Vokera Ltd or personnel authorised by Vokera. Analysis of combustion, performed before starting servi- cing, provides useful information on the operations to be performed.
  • Page 65 Removing the front panel, accessing the control panel and the inside of the boiler - Unscrew the fastening screws (1) on the front panel (2) - Pull the base of the panel (2) outwards and then upwards to release it from the frame and then remove - Turn the control panel (3) 90°C and take out the four screws (4) so as to remove the rear cover.
  • Page 66 Dismantling the Master and Slave boards - Remove the panel front and access the inside of the control panel (see the steps described on the previous page). - Remove the screws (V) and then the cover from the Master board. - Repeat the same operation to remove the cover (7) from the first Slave board and (8) any second Slave board.
  • Page 67 Dismantling and cleaning the burner and the exchanger - Remove the front and top panel of the boiler (see the operations described on page 65). - Remove the wiring (5) from the fan (6) - Unscrew the two screws (8) that fasten the fan (6) to the air conveyor (9) - Unscrew the four screws (10) that fasten the fan assembly (6) to the exchanger, using a 10 mm socket...
  • Page 68 Cleaning the drain trap and condensate drain - Remove the front and top panel of the boiler (see the operations described on page 65) and identify the condensate drain trap (14) - Remove the safety pin (15), remove the corrugated condensate drain pipe, remove the drain trap and dismantle it, using the two screw caps (16).
  • Page 69 TROUBLESHOOTING CAUSE SOLUTION PROBLEM Check the tightness of the joints Smell of gas Gas supply circuit and that the pressure test points are closed Check: Smell of unburned gas Flue gas circuit - The tightness of the joints - The absence of obstructions - The quality of combustion Irregular combustion Burner gas pressure...
  • Page 70 CAUSE SOLUTION PROBLEM Check: The boiler doesn’t start No power supply - electrical connections (the display is blank) - fuse The boiler does not reach Boiler body dirty Clean combustion chamber the operating temperature Insufficient burner flow-rate Check burner adjustment Boiler controller Check correct operation Check set temperature...
  • Page 71 CAUSE SOLUTION PROBLEM Reset the pump The pump doesn’t start Pump fault Replace the pump Check the electrical connections to the pump Frequent activation of System safety valve Check calibration or efficiency the system safety valve Pressure in heating system circuit Check charge pressure Check pressure reducer System expansion vessel...
  • Page 72 CONDEXA PRO...
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  • Page 76 Registered address: Vokèra Ltd Borderlake House Unit 7 Riverside Industrial Estate London Colney Herts AL2 1HG enquiries@vokera.co.uk www.vokera.co.uk www.vokera.ie Sales, General Enquires T 0844 391 099 F 0844 391 0998 Vokèra Ireland West Court, Callan Co Kilkenny T 056 7755057 F 056 7755060 Vokèra Limited reserve the right to change...

This manual is also suitable for:

Condexapro100 mCondexapro 100 sCondexa pro 100 s

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