VOKERA Syntesi Installation & Servicing Instructions Manual
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VOKERA Syntesi Installation & Servicing Instructions Manual

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Supplied By www.heating spares.co Tel. 0161 620 6677
Installation
& Servicing
Instructions
THESE INSTRUCTIONS
TO BE RETAINED
BY USER

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  • Page 1 Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 2: Table Of Contents

    4.7.2 Appliance terminal block 10.1 Related documents 4.7.3 Connecting the mains (230V) input 10.2 Technical data 4.7.4 Connecting the Vokera time clock 10.3 Converting the appliance gas type Commissioning Page 10.4 Gas supply Gas supply installation 10.5 Gas supply installation The heating system 10.6...
  • Page 3 Vokera twin flue system. appliance – by design – incorporates electronic ignition, circulating pump, expansion vessel, safety valve, pressure The Syntesi range is approved for use with C12 & C32 gauge, and automatic by-pass. type flue applications.

  • Page 4: Design Principles And Operating Sequence Page

    OPTIONAL ACCESSORIES ture of the appliance fall to 7°C. The second The Syntesi is suitable for use with a range of stage becomes active when the temperature optional accessories that enable enhanced has dropped to 3°C.

  • Page 5: Technical Data Page

    SECTION 2 TECHNICAL DATA Syntesi 25 Syntesi 29 Syntesi 35 2.1 Central heating Heat input 25.0 kW 29.0 kW 35.0 kW Max heat output 60/80°C (return & flow temp.) 24.1 kW 28.0 kW 33.9 kW Max heat output 30/50°C (return & flow temp.) 25.9 kW...

  • Page 6: Pump Duty

    The graph is based on a 20°C temperature differ- ential. 1000 1100 1200 1300 Litres Per Hour Fig. 3 2.12 Emissions Appliance Syntesi 25 Syntesi 29 Syntesi 35 NOx max/min 160/140 180/120 160/110 CO max/min 70/20 100/60 90/80 CO2 max/min 6.5/4.8...

  • 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

    (25/29) or 10 litres (35) of expansion from 3A.11 INHIBITORS within the system, generally this is sufficient, Vokera recommend that a inhibitor – suitable for however if the system has an unusually high use with low water-content, copper heat water content, it may be necessary to provide 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) The twin flue system must be converted to the 4.5.3.3 VERTICAL TERMINATION (see fig. 13) dedicated concentric flue kit for termination. The twin flue system must be converted to the 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

    *Both Sentinel and Fernox manufacture products available flow rate, spare restrictors are included that have proved suitable for use with Vokera in the accessory pack. appliances. Vokera Ltd. cannot comment on the The spare flow rate restrictors can be fitted to...

  • 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 Page

    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 appliance, the relevant commissioning procedure Frost-protection: this function is only active 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 Page

    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 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 43 FUNCTIONAL DIAGRAM NOTE: L-N-E CONNECTION IS ADVISABLE CONTROL SWITCHING OF TIME CLOCK AND ROOM THERMOSTAT IS 230 V.a.c. Room thermostat or remote control jumper R.T. Room thermostat TS H Heat time switch Natural gas or L.P.G. selector G.V. Gas valve Timer on- off selector PT1 (S.B.) Selection of 0-reset / winter - summer...
  • Page 44 WIRING DIAGRAM Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 45: Exploded Diagrams Page

    SECTION 9 EXPLODED DIAGRAMS 16 17 POS. DESCRIPTION Frame R01005288 R01005289 R01005290 Quick primer pressure gauge R1857 R1857 R1857 2A fuse R8968 R8968 R8968 100 mA fuse R1947 R1947 R1947 Cover R10021849 R10021849 R10021849 Ignition module R10021848 R10021848 R10021848 Printed Circuit Board R10024390 R10024390 R10024390...
  • Page 46 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 47 POS. DESCRIPTION Domestic water heat exchanger R8036 R8037 R10024627 Connection R9807 R9807 R9807 Pressure switch R2044 R2044 R2044 Non return valve R2908 R2908 R2908 By-pass valve R2047 R2047 R1552 Heating manifold R10020439 R10020439 R10020439 Spring R6862 R6862 R6862 Three way valve overhault kit R01005127 R01005127 R01005127...
  • Page 48 SYNTESI 35 POS. DESCRIPTION Expansion vessel R2204 R2204 R2573 Flexible pipe R2164 R2164 R2164 Circulation pump R10020437 R10020437 R10020438 Pump cable R1845 R1845 R1845 Automatic air vent bottle R0439 R0439 R0439 Pipe R10023195 R10023202 R10023209 Pipe R10024312 R10024130 R10024519 Heat exchanger...
  • Page 49 SYNTESI 35 SYNTESI 35 POS. DESCRIPTION Air box bottom R10024449 R10024385 R10024516 Ambidx air box side R10024166 R10024166 R2059 Air box clip R0442 R0442 R0442 NG Burner R10023168 R10022980 R10023834 LPG burner R10023169 R10025053 R10024626 Spark electrode R10022027 R10022027 R10022027...
  • Page 50 POS. DESCRIPTION Combustion chamber assembly R6027 R6028 R10020514 Combustion chamber back panel R5270 R5316 R10020518 Combustion chamber lateral panel R5271 R5271 R5271 Combustion chamber front panel R5269 R5315 R10020517 Hood assembly R10024310 R10024125 R10024473 R10024035 R10024035 R10024035 Venturi and pressure tube kit R01005293 R01005293 R01005293...

  • Page 51: 10.1 Related Documents

    SECTION 10 LPG INSTRUCTIONS 10.1 RELATED DOCUMENTS BS 6798 INSTALLATION OF BOILERS OF RATED NOT EXCEEDING 60kW BS 5449 PART 1 FORCED CIRCULATION OF HOT WATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 5440 PART 1 FLUES BS 5482...
  • 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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