VOKERA Hydra Installation & Servicing Instructions Manual
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VOKERA Hydra Installation & Servicing Instructions Manual

VOKERA Hydra Installation & Servicing Instructions Manual

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Installation
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Instructions
THESE INSTRUCTIONS
TO BE RETAINED
BY USER

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Summary of Contents for VOKERA Hydra

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

  • Page 2: Table Of Contents

    Contents Design principles & operating sequence Page Servicing Page Principle components General Mode of operation (at rest) Routine annual servicing Domestic hot water mode Replacement of components Central heating mode Component removal procedure Safety devices Pump head Safety valve Automatic air valve Technical data Page Pressure gauge...
  • Page 3 360 degrees for various horizontal or vertical applications. pump, expansion vessel, safety valve, pressure gauge The Hydra can also be used with the Vokera twin flue and automatic bypass. system. The Hydra is produced as a room sealed, category C1,...

  • Page 4: Design Principles & Operating Sequence

    SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE PRINCIPLE COMPONENTS boiler is determined by the temperature of the water sensed by the flow & return temperature A fully integrated electronic control board sensors, consequently a high temperature at the featuring differential temperature control, flow sensor results in a lower fan speed.

  • Page 5: Technical Data Page

    SECTION 2 TECHNICAL DATA 2.1 Central heating Heat input (gross) 29.00 kW Maximum heat output 60/80°C (return & flow temperature) 25.3 kW Maximum heat output 30/50°C (return & flow temperature) 26.8 kW Minimum heat output 60/80°C (return & flow temperature) 7.3 kW Minimum heat output 30/50°C (return &...

  • Page 6: Adjusting Operating Parameters

    2.12 Adjustable operating parameters PARAMETER MINIMUM MAXIMUM FACTORY SETTING 40 °C 65 °C 55 °C P. 1 Hot water outlet temperature -5 °C 30 °C 15 °C P. 26 Pre-heat temperature drop 20 °C 90 °C 75 °C P. 4 Central heating flow temperature P.

  • Page 7: Related Documents

    This appliance must be installed by a competent Details of essential features of compartment/ person in accordance with the Gas Safety (Instal- cupboard design, including airing cupboard in- lation & Use) Regulations. stallations, are given in BS 6798. This appliance is not suitable for external installation.

  • Page 8: Air Supply

    AIR SUPPLY above the boiler (fig. 5). The cold feed from the make-up vessel or tank must be fitted with an The following notes are intended for general approved non-return valve and stopcock for iso- guidance only. lation purposes. The feed pipe should be con- This appliance is a room sealed, fan-flued boiler, nected to the return pipe as close to the boiler as consequently it does not require a permanent air...

  • Page 9: Condensate Disposal

    3.11 CONDENSATE DISPOSAL When choosing a location for the boiler, consideration should be given to the disposal of the condensate discharge into a suitable drain or soil pipe. The condensate outlet pipe must be connected to the drain in accordance with building regulations or other rules in force.

  • Page 10: General Requirements (Eire)

    SECTION 3A GENERAL REQUIREMENTS (EIRE) This appliance must be installed by a competent 3A.4 FLUE SYSTEM person in accordance with and defined by, the The terminal should be located where the dispersal Standard Specification (Domestic Gas of combustion products is not impeded and with Installations) Declaration (I.S.

  • Page 11: Electrical Supply

    3A.6.4 AIR RELEASE POINTS 3A.10 TIMBER FRAMED BUILDINGS These must be positioned at the highest points in If the appliance is to be fitted in a timber framed the system where air is likely to be trapped. They building, it should be fitted in accordance with I.S. should be used to expel trapped air and allow 813 and local Building Regulations.

  • Page 12: Installation

    Vokera twin flue system can be utilised if longer flue runs are required. FITTING THE HORIZONTAL FLUE KIT Using a twisting motion, connect the boiler top 4.5.1...
  • Page 13 the flue bend to the boiler top adaptor and insert NOTE the concentric flue pipe into the flue bend When cutting an extension to the required length, ensuring the correct seal is made. you must ensure that the excess is cut from the plain end of the extension (fig.
  • Page 14 4.5.3 TWIN FLUE SYSTEM Remove the blanking plates (located to the left The Vokera twin flue system enables greater flue of the appliance flue outlet) and – using the distances to be achieved (see section 2.9) than same screws – install the air baffle (A).

  • Page 15: Connecting The Gas & Water

    connects to the exhaust connection on the The convertor box on the vertical terminal will concentric to twin converter. have to be temporarily removed when inserting If necessary cut the plain ends (male) of the twin the terminal through the flashing. flue pipes to allow connection to the concentric to twin converter.

  • Page 16: Condensate Outlet

    4.6.5 HOT WATER OUTLET (fig. 6A & 6B) NOTE The appliance is supplied with a 15 mm female The appliance comes with a factory fitted link to connector. Connect a 15 mm pipe to the supplied allow basic operation of the boiler via the keypad. connector and tighten the nut.

  • Page 17: Casing Removal

    4.9.3 VOKERA TIME CLOCK The Vokera time clock (part no. 201 & 202) can be installed using the following procedure: Isolate the appliance from the electrical supply and remove the casing as described in 4.9.1 Gain access to the electrical input board as detailed in 4.9.2.

  • Page 18: Commissioning

    DO NOT OVERPRESSURISE. *Both Sentinel and Fernox manufacture products Once the desired pressure is achieved, turn the that have proved suitable for use with Vokera filling/inlet valve back to the closed position. appliances. Vokera Ltd. cannot comment on the...

  • Page 19: Parameters

    however the remaining parameters (5 – 42) can Press the mode button until “INFO” appears only be accessed after entering the relevant in the display. service code, and should only be adjusted by qualified service personnel. Press the button until the appropriate step 5.10 PARAMETERS 1 - 4 number is shown in the left side of the display.

  • Page 20: Final Checks

    5.15 FINAL CHECKS ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS VALVE ARE TIGHT AND HAVE BEEN CHECKED FOR SOUNDNESS. ENSURE THE APPLIANCE FLUE SYSTEM IS FITTED CORRECTLY AND IS PROPERLY SECURED. ENSURE ALL PIPE WORK IS RE-CHECKED FOR SOUNDNESS. RE-FIT APPLIANCE CASING.

  • Page 21: General

    It is the law that any servicing work is carried out remove the four Allen screws that hold the pump by competent person such as a Vokera engineer, in position, pull firmly on the pump head to release an approved service agent, British Gas or other it from the base.

  • Page 22: Ntc Thermistors (Temperature Sensors)

    NTC THERMISTORS (temperature sensors) 6.11 GAS VALVE (fig. 23) Carry out component removal procedure as de- Carry out component removal procedure as scribed in section 6.4. described in section 6.4. The gas valve must be changed as complete unit. Cold water inlet sensor (fig. 20) Unclip and remove the air chamber cover.

  • Page 23: Electrode

    6.16 DOMESTIC HOT WATER HEAT EXCHANGER Securing nuts (fig. 29) Carry out component removal procedure as described in section 6.4. Remove the PCB housing as described in section 6.10. Locate and remove both inlet and outlet securing screws. Gently ease from its location and rotate 180° clockwise the heat exchanger.

  • Page 24: Combustion Cover

    6.21 COMBUSTION COVER (fig. 30) Carry out component removal procedure as described in section 6.4. Unclip and remove the air chamber cover. Remove the gas valve as described in section 6.11. Remove the condense pressure switch as Condense described in section 6.20. Disconnect the electrical pressure switch connection from the fan, disconnect the spark electrode lead and earth wire from the spark...

  • Page 25: Input & Status Pcb

    6.22.1 EXPANSION VESSEL (removal, fig. 31) Carry out component removal procedure as described in section 6.4. Disconnect the flue from the appliance. Disconnect the expansion vessel from the expansion pipe. Remove the flow sensor as shown in section 6.9. Locate and remove the 4 screws. Remove the rear frame.

  • Page 26: Checks, Adjustments And Fault Finding

    SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING 7.2.4 DHW TEMPERATURE ADJUSTEMENT CHECKING APPLIANCE OPERATION The temperature of the hot water outlet can be When carrying out any repairs or servicing to the adjusted directly as shown in section 5.7.4 or via appliance, the relevant commissioning and/or the operating parameters (see section 5.10).

  • Page 27: Adjusting The Gas Valve

    Service parameters must only be changed or adjusted by qualified service personnel Parameter Description Range New setting Factory setting 5 °C - 60° C 20 °C Minimum setting for flow sensor -15 °C Minimum setting for external sensor -20°C - 10°C 20 °C Maximum setting for external sensor 15°C - 25°C...

  • Page 28: St Digit Status Code

    Using the procedure detailed in section 7.4, 1st digit Right Status change the fan speed momentarily from CH inlet temp. Standby minimum to maximum, then back to minimum. Flow temperature Purge Flow temperature Check that the correct value is still being Ignition Flow temperature obtained.

  • Page 29: Diagnostic Recall

    DIAGNOSTIC RECALL appliance supply cable. The resistance should In addition to displaying a fault code, the appliance be less than 1 ohm. If the resistance is greater than 1 ohm check all earth wires and connectors memorises the operating conditions at the time of for continuity and integrity.

  • Page 30: Fault Finding

    The appliance is equipped with spare fuses. These fuses are located on the covers of the input The Hydra boiler utilises 24V switching. Any external board and main PCB respectively. If a fuse has controls that are directly connected to the boiler must...
  • Page 31 7.12.4 FAULT FINDING TEST ‘1A’...
  • Page 32 7.12.5 FAULT FINDING TEST ‘2’...
  • Page 33 7.12.6 FAULT FINDING TEST ‘3’...
  • Page 34 7.12.7 FAULT FINDING TEST ‘4’...

  • Page 35: Wiring Diagrams

    SECTION 8 WIRING DIAGRAMS IMPORTANT The Hydra boiler utilises 24V switching. Any external controls that are directly connected 24V connections. to the boiler must be suitable for 24V Must be voltage free! applications and shall be voltage free. Under no circumstances should a 230V supply be connected to plug M7.
  • Page 36 FUNCTIONAL DIAGRAM Fig. 35 L2 (R) Led alarm R.T. Room thermostat Led CH mode Fuse 2 AF Pump Fuse 4 AT Flow thermistor (NTC) S/S.E. Spark/sense electrode Return thermistor (NTC) Gas valve solenoids DHW thermistor (NTC) 3 way valve BE04 Connection board RL3V 3 way relay...
  • Page 37 FUNCTIONAL DIAGRAM Fig. 36...
  • Page 38 PLUG or CONNECTION DESIGNATION Input PCB 3-port valve actuator Input PCB Incoming 230V supply Input PCB 230V supply to main PCB Input PCB 230V clock supply Input PCB Low voltage connector (to main PCB) Input PCB Low voltage connector (NTCs) Input PCB Low voltage connector (heat request) Input PCB...

  • Page 39: Exploded Diagrams

    SECTION 9 EXPLODED DIAGRAMS POS. DESCRIPTION CODE Plastic bezel 8654 Frame 01005243 1867 Quick primer pressure gauge 1857 Printed circuit holding 10023476 10023044 Bracket 10023571 Cover 10023681 Display Printed Circuit Board 10023297 2 A 5X20 inline fuse 8968 Printed Circuit Board 10023299 3.15 A 5X20 inline fuse 8969...
  • Page 40 POS. DESCRIPTION CODE Domestic water heat exchanger 10023482 Connection 8952 Heat exchanger-pipe connection 8432 Bracket 10022671 Pressure switch 10022556 Water supply stop cock 1749 Non return valve 2908 Non return valve 10023569 Heating bypass valve 2047 Filling cock 10023568 Heating distributor manifold 10020439 Pipe 10023643...
  • Page 41 316 253 POS. DESCRIPTION CODE Connection for air vent bottle 8911 Expansion vessel 2573 Connection pipe 10023580 Flexible pipe 2164 Washer 5023 Pump 8876 Washer 5026 Pump cable 10023573 Headless screw 5216 Brass nut 10022444 O ring 6898 Pipe 10023574 Clip 2223 Heat exchanger...
  • Page 42 POS. DESCRIPTION CODE Main burner jet 9295 Roomsealed chamber 10023486 Main burner jet LPG 8970 Upper panel for air box 8881 Washer 9299 Main burner jet support 1195 Air box hole cap 8084 Main burner 1196 Air conveyor 8886 Spark electrode kit 01005242 Gas pipe 10022443...
  • Page 43 POS. DESCRIPTION CODE Exchanger lower insulation panel 1193 Exchanger upper insulation panel 1016 Clip 10021115 Cover for heat exchanger 1033 10022853 Pressure connection 8915 Pressure connection 8916 Connection 8908 Washer 8912 Plug 8909 Screw 1006 Screw 9292 Fan gasket 8893...

  • Page 44: Instructions

    SECTION 10 L.P.G. INSTRUCTIONS For details of converting boilers to LPG please refer to the instructions supplied with the relevant conversion kit. 10.1 TECHNICAL DATA Maximum Minimum Inlet pressure 37 mbar 37 mbar Gas rate 4.09 l/per hr. 1.90 l/per hr. Injector size Single injector with six 2.3 mm holes Single injector with six 2.3 mm holes...
  • Page 45 Notes...
  • Page 48 Vokèra Ltd. Floor, Catherine House, Boundary Way, Hemel Hempstead, Herts, HP2 7RP Email: enquiries@vokera.co.uk Web: www.vokera.co.uk General Enquiries - Tel: 01442 281400 Fax: 01442 281460 Technical Advice - Tel: 0141 945 6810 Spare Parts - Tel: 0141 945 6820 After Sales Service - Tel: 0870 333 0220 Vokèra Ireland...

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