VOKERA Compact HE Installation & Servicing Instructions Manual
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VOKERA Compact HE Installation & Servicing Instructions Manual

High efficiency combi boiler compact he series
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Compact HE
High efficiency combi boiler
Supplied By www.heating spares.co Tel. 0161 620 6677
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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Summary of Contents for VOKERA Compact HE

  • Page 1 Compact HE High efficiency combi 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: Table Of Contents

    Wiring diagrams Page 4.6.2 Flow and return External wiring 4.6.3 Cold water inlet Typical control applications 4.6.4 Hot water outlet Vokera remote control 4.6.5 Safety valve Room thermostat 4.6.6 Condense pipe Other controls Electrical connections Functional diagram 4.7.1 Casing removal...

  • Page 3: General Layout

    & DHW of 25, 29 & 35kW respectively. Each degrees for various horizontal or vertical applications. appliance - by design - incorporates electronic ignition, The Compact HE range can also be used with the Vokera circulating pump, expansion vessel, safety valve, pres- twin flue system.

  • Page 4: Design Principles And Operating Sequence

    SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE PRINCIPLE COMPONENTS MODE OF OPERATION (Heating) A fully integrated electronic control board fea- When there is a request for heat via the time clock ● turing electronic temperature control, anti-cy- and/or any external control, the pump and fan are cle control, pump over-run, LED fault indicator, started, the fan will then prove the air pressure full gas modulation.

  • Page 5: Technical Data

    SECTION 2 TECHNICAL DATA 2.1 Central heating Heat input (kW) 25.0 29.0 34.8 Maximum heat output@ 80/60 °C (kW) 24.3 28.1 33.8 Minimum heat output@ 80/60 °C (kW) 14.2 14.2 13.9 Maximum heat output@ 50/30 °C (kW) 25.9 30.2 36.1 Minimum heat output@ 50/30 °C (kW) 14.9 14.8...

  • Page 6: Pump Duty

    2.11 PUMP DUTY Fig. 3 shows the flow rate available - after 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 ºC temperature differential.

  • Page 7: Related Documents

    This appliance must be installed by a competent GAS SUPPLY person in accordance with the Gas Safety (Instal- The gas meter – as supplied by the gas supplier lation & Use) Regulations. – must be checked to ensure that it is of adequate size to deal with the maximum rated input of all RELATED DOCUMENTS the appliances that it serves.

  • Page 8: Pipework

    3.6.1 PIPEWORK 3.6.7 LOW PRESSURE SEALED SYSTEM It is recommended that copper tubing to BS 2871 An alternative method of filling the system would Part 1 is used in conjunction with soldered capil- be from an independent make-up vessel or tank lary joints.

  • Page 9: Mounting On A Combustible Surface

    7) ‘Guide for Gas Installations in Timber Frame Buildings’. 3.11 INHIBITORS Vokera recommend that an inhibitor - suitable for use with copper and aluminium heat exchangers - is used to protect the boiler and system from the effects of corrosion and/or electrolytic action.

  • Page 10: General Requirements (Eire)

    SECTION 3A GENERAL REQUIREMENTS (EIRE) This appliance must be installed by a competent The terminal must not be located in a place where person in accordance with and defined by, the it is likely to cause a nuisance (refer to I.S. 813 for Standard Specification (Domestic Gas Installa- guidance on permitted locations and minimum tions) Declaration (I.S.

  • Page 11: A6.6 Filling Point

    Frame Buildings’ gives specific advice on this type of installation. 3A.11 INHIBITORS Vokera recommend that an inhibitor - suitable for use with copper and aluminium heat exchangers - is used to protect the boiler and system from the Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 12: Installation

    (For twin flue applications, see section 4.5.3). hole. Fit the flue bend to the boiler flue outlet and The appliance can be used with either the Vokera insert the concentric flue pipe into the flue bend condensing 60/100mm concentric flue system or ensuring the correct seal is made.

  • Page 13: Concentric Vertical Flue

    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 con- Fig.

  • Page 14: Twin Flue System

    4.5.3 TWIN FLUE SYSTEM Less than 7.0 metre 40mm diameter The Vokera twin flue system enables greater flue Less than 13.5 metres 45mm diameter distances to be achieved (see 4.4.2) than that of Less than 19.5 metres not required a concentric flue system. It can be used for...
  • Page 15 Total flue length Restrictor required Less than 5.0 metres 50mm diameter Less than 10.0 metres not required 4.5.3.1 INSTALLATION OF TWIN ADAPTOR KIT (fig. 10 & 11) Insert the exhaust connection manifold (A) ● onto the appliance flue outlet. Remove the blanking plate (located to the right ●...

  • Page 16: Connecting The Gas And Water

    Depending on site conditions it may be prefer- NOTE able to install the terminal assembly prior to fit- Depending on system requirements, it may nec- ting the twin flue pipes. essary to increase the size of the flow & return Fit the appropriate flashing plate to the roof and pipe work after the service valve connections.

  • Page 17: Casing Removal

    FROM THE SAME ISOLATOR AS THAT OF The securing screw on the cable anchorage THE APPLIANCE. The supply cable from the should now be tightened. This must be done isolator to the appliance must be 3-core flexible before the control fascia is re-fitted in the upright sized 0.75mm to BS 6500 or equivalent.

  • Page 18: Commissioning

    SECTION 5 COMMISSIONING GAS SUPPLY INSTALLATION INITIAL LIGHTING Inspect the entire installation including the gas Ensure the electrical supply to the appliance is meter, test for soundness and purge. Refer to BS switched on. Move the selector switch to the 6891 for specific instruction.

  • Page 19: Setting The Dhw Temperature

    5.9.1 SETTING THE DOMESTIC HOT WATER TEM- 5.12 FINAL CHECKS PERATURE ENSURE ALL TEST NIPPLES ON THE AP- ● The DHW outlet temperature can be adjusted PLIANCE GAS VALVE HAVE BEN TIGHT- between 40ºC - 65ºC via the Hot Water thermo- ENED AND CHECKED FOR SOUNDNESS.

  • Page 20: Servicing Instructions

    SOUNDNESS IF ANY GAS CARRYING COM- It is the law that any servicing work is carried out PONENTS HAVE BEEN REMOVED OR DIS- by competent person such as a Vokera engineer, TURBED. an approved service agent, British Gas, CORGI PUMP ASSEMBLY fig. 19...

  • Page 21: Automatic Air Release Valve

    6.11 HIGH LIMIT THERMOSTAT fig. 22 Carry out component removal procedure as de- scribed in 6.4. Unclip and remove the air chamber cover. Pull off electrical connections from the high limit thermostat (2), slacken and remove retaining screws (3). Replace in reverse order. Fig.

  • Page 22: Integral Time Switch

    CLK-1 CLK-4 Fig. 23 Fig. 23a 6.15 ELECTRODE, BURNER THERMOSTAT, BURNER & INJECTORS fig. 25 Carry out component removal procedure as de- scribed in 6.4. Unclip and remove the air chamber cover (2). Locate and remove the 6 screws securing the front combustion cover (3), pull the cover towards you before lifting and disengaging.

  • Page 23: Flue Fan

    Fig. 27 6.16 FLUE FAN fig. 27 panels if necessary by unscrewing the securing Carry out component removal procedure as de- screws. Disconnect the flow and return connec- scribed in 6.4. tions (4,5, fig. 28) on the heat exchanger. The Unclip and remove the air chamber cover, gently heat exchanger can now be withdrawn from the pull the cover towards you before lifting and...

  • Page 24: Dhw Flow Switch

    6.20 DHW FLOW SWITCH fig. 29 assembly. The cartridge assembly is a non- Carry out component removal procedure as de- serviceable item and therefore needs to be re- scribed in 6.4. placed if it’s suspected as being damaged or Disconnect the cold water inlet pipe (A) from the worn.

  • Page 25: Expansion Vessel Removal (With Insufficient Clearance Above)

    Disconnect the flexible expansion pipe from the the collector from the flue connection. Replace in vessel. Locate and remove the four screws (A) the reverse order ensuring all seals are intact and that secure the vessel top holding plate (B), located correctly.

  • Page 26: Condense Trap Removal

    6.29 CONDENSE TRAP REMOVAL fig. 36 Carry out component removal procedure as de- scribed in 6.4. Disconnect the flexible condense pipe (1) from the condense trap. Locate and remove the con- dense pipe locking pin and disconnect the con- dense pipe (2) from the condense trap. Locate and disconnect the condense pressure switch pipe from the condense trap (3).

  • Page 27: Heating Mode

    signal voltage to the control PCB. A slow ignition tion of the fan causes the air pressure switch to sequence is enabled, whereby the current sup- deliver a signal voltage to the control PCB. A slow plied to the gas valve modulating coil is progres- ignition sequence is enabled, whereby the cur- sively increased from minimum to maximum over rent supplied to the gas valve modulating coil is...

  • Page 28: Checking & Adjusting Burner Pressure

    7.2.6.1 HEATING PARAMETERS 7.3.1 SETTING THE MAXIMUM BURNER PRES- SURE fig. 40 RANGE MINIMUM MAXIMUM Light the boiler as described in 5.7 and compare the reading on the manometer with the value Temperature (°C) sector described in 2.3. If adjustment is required, re- move the protective cap from the gas valve SARA sector sector...

  • Page 29: Checking The Expansion Vessel

    The boiler will now enter the combustion analy- GREEN LED ● sis mode (CO mode) for a period of 15 minutes, Frequency Faults/Status signified by the LED flashing Yellow. During ON every 6-secs At stand-by with no faults this time, the boiler will remain on full gas. Flashing 8-times a second SARA function active Once the flue gas analysis has been made, turn...

  • Page 30: Reversed Polarity Or Supply Fault

    (boiler modulates at set point and remains on minimum power, even if the set point is exceeded). NOTE If the Vokera remote-control (RC05) is connected to the appliance, it should be disconnected during any faultfinding checks. Restore the electrical supply to the boiler and turn the selector switch to the on position.
  • Page 31 7.10.1 FAULT FINDING TEST ‘A’: CHECKING OPERATION OF ELECTRONIC CONTROL BOARD AT START UP START SWITCH ON BOILER AND SELECT MODE TO WINTER C/H THERMOSTAT AT MAX. GREEN LED BLINKS MADE A LINK BETWEEN BLACK & BLACK WIRES AT BOILER TERMINAL STRIP AND CLOSE THE TIMER CONTACT PUMP...
  • Page 32 7.10.2 FAULT FINDING TEST ‘A’ SPARK AT ELECTRODE THERE 24 Vdc BETWEEN TERMINALS CN8.4 & CN8.5 ON PCB IGNITION THERE 230 Vac BETWEEN TERMINALS CN6.1 & CN6.2 ON PCB CHECK AND/OR REPLACE PCB LOCKOUT AFTER IGNITION THERE 24 Vdc BETWEEN TERMINALS CHECK CN8.4 &...

  • Page 33: Fault Finding

    7.10.3 FAULT FINDING TEST ‘A1’ RED LED BLINKS RED LED LIGHT REPLACE CONTROL BOARD YELLOW LIGHT SWITCH ON/OFF CHECK CH NTC YELLOW LED SELECTOR ON OFF SENSOR OR WIRING BLINKS POSITION AND CONNECTIONS CHIMNEY SWEEPER CYCLE. RESET AND RESTART TEST MAINS SWITCH ON/OFF PRESENT BETWEEN...
  • Page 34 7.10.4 FAULT FINDING TEST ‘B2’: CHECK CONTROL IN DHW MODE START SWITCH ON BOILER AND SELECT MODE TO CHECK OR REPLACE THE SUMMER. DHW THERE 24 Vdc ELECTRICAL 3 WAY THERMOSTAT AT MAX. BETWEEN TERMINALS MIXING VALVE, CN9.7 & CN9.8 CABLES AND ON PCB CONNECTIONS...
  • Page 35 7.10.5 FAULT FINDING TEST ‘C’: CHECK CONTROL IN C/H MODE START SWITCH ON BOILER AND SELECT MODE TO WINTER C/H THERMOSTAT AT MAX. MADE A LINK BETWEEN BLACK & BLACK WIRES AT BOILER TERMINAL STRIP AND CLOSE THE TIMER CONTACT DOES BURNER LIGHT...
  • Page 36 7.10.6 TEST ‘C’ CONT’D WAIT WATER FLOW TEMPERATURE BURNER AND FAN >40 C SWITCH OFF SWITCH CH THERMOSTAT AT MAX. WATER FLOW TEMPERATURE >40 C REPLACE CONTROL BOARD BURNER AND FAN SWITCH ON TIMER JUMPER REMOVE JUMPER REPLACE WAIT 3 MIN. CONTROL BOARD RESTART THE TEST...

  • Page 37: Wiring Diagrams

    45. TYPICAL CONTROL APPLICATIONS The appliance can be used with the following controls: Vokera RC05 remote control (part no. 405) and ● Compact interface (part no. 409) Vokera external sensor (must be used in con- ●...

  • Page 38: Functional Diagram

    FUNCTIONAL DIAGRAM NOTE: L-N-E CONNECTION IS ADVISABLE Fig. 46 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 39: Exploded Diagrams

    SECTION 9 EXPLODED DIAGRAMS POS. DESCRIPTION 25 HE 29 HE Frame assembly 01005403 01005406 Pressure gauge 10024019 10024019 Cover assembly 10026475 10026475 Printed Circuit Board 10025340 10025340 Led light guide 10023816 10023816 Instrumental panel 10027547 10027547 Control knob 10023937 10023937 Selection knob 10023936 10023936...
  • Page 40 POS. DESCRIPTION 25 HE 29 HE Domestic water heat exchanger 8036 8037 Connection 10024640 10024640 Pressure switch 2044 2044 Non return valve 10025056 10025056 By-pass casing 10024641 10024641 By-pass valve 2047 2047 Heating manifold and cartridge 10026508 10026508 3 way valve cartridge 10025305 10025305 Motorized valve...
  • Page 41 POS. DESCRIPTION 25 HE 29 HE Expansion vessel 2204 2573 Flexible pipe 10025188 10025188 Circulation pump 10027571 10027571 Automatic air vent bottle 10025485 10025485 Pipe 10027541 10027566 Pipe 10024312 10024130 Heat exchanger 2381 2378 Pipe 10021041 10021041 Pipe 10027542 10027567 Siphon 10027546 10027546...
  • Page 42 POS. DESCRIPTION 25 HE 29 HE Air box bottom 10027533 10027562 Ambidx air box side 10024166 10024166 Clip 0442 0442 Burner assembly 10027536 10027564 Spark electrode 10025985 10025985 Burner plate 5172 5172 Gas pipe 10027537 10027537 Gas valve 10025074 10025074 Gas pipe 10026703 10026703...
  • Page 43 POS. DESCRIPTION 25 HE 29 HE Combustion chamber assembly 10025935 10026406 Combustion chamber back panel 5270 5316 Combustion chamber lateral panel 5271 5271 Combustion chamber front panel 5269 5315 Hood assembly 10024310 10024125 10024035 10024035 Venturi and pressure tube kit 01005405 01005405 Clamp for tube...

  • Page 44: L.p.g. Instructions

    SECTION 10 L.P.G. INSTRUCTIONS 10.1 RELATED DOCUMENTS BS 6798 INSTALLATION OF BOILERS OF RATED NOT EXCEEDING 60kW BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 5440 PART 1 FLUES BS 5482 PART 1...
  • Page 45 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...

  • Page 46: Service Interval Record

    SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
  • Page 47 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 48 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...

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Compact 25 heCompact 29 heCompact 35 he

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