VOKERA Synergy 29, Installation & Servising Instruction

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

Page 2: ...heating system 17 5 8 1 Inhibtors 18 5 9 Setting the boiler operating temperature 18 5 10 Setting the system design pressure 18 5 11 Regulating the central heating system 18 5 12 Final checks 18 5 13 Instructing the user 18 Servicing instructions Page 6 1 General 19 6 2 Routine annual servicing 19 6 3 Replacement of components 19 6 4 Component removal procedure 19 6 5 Pump assembly 19 6 6 Safety v...

Page 3: ...iance is designed for use with a sealed system only consequently it is not intended for use on open vented systems Fig 1 Fig 1 General Layout 1 Safety Valve 2 Pressure Switch 3 Hydraulic manifold 4 Pump 5 Automatic Air Release Valve 6 Transformer 7 Main Burner 8 Electrode 9 Main Heat Exchanger 10 Latent Heat Collector 11 Condense Sensor 12 Flue Gas Analysis Test Point 13 Flue Outlet 14 Air Intake ...

Page 4: ...control PCB At this point an ignition sequence is enabled Ignition is sensed by the electronic circuitry to ensure flame stability at the burner Once successful ignition has been achieved the electronic circuitry increases the gas rate to 75 for a period of 15 minutes Thereafter the boiler s output will either be increase to maximum or modulate to suit the set requirement When the appliance reache...

Page 5: ...itres Maximum system volume 91 litres Pre charge pressure 1 0 bar 2 4 Dimensions Height 820mm Width 450mm Depth 350mm Dry weight kg 47 0 2 5 Clearances Sides 12mm Top 150mm from casing or 25mm above flue elbow whichever is applicable Bottom 150mm Front 600mm 2 6 Connections Flow return 22mm Hot cold water 15mm Gas 15mm Safety valve 15mm Condense 21mm 2 7 Electrical Voltage V Hz 230 50 Power consum...

Page 6: ...k etc 300 mm D Below gutter drain pipe etc 75 mm E Below eaves 200 mm F Below balcony car port roof etc 200 mm G To the side of a soil drain pipe etc 150 mm H From internal external corner or boundary 300 mm I Above ground roof or balcony level 300 mm J From a surface or boundary facing the terminal 600 mm K From a terminal facing a terminal 1200 mm L From an opening in the car port into the build...

Page 7: ...external installation 3 3 GAS SUPPLY The gas meter as supplied by the gas supplier must be checked to ensure that it is of adequate size to deal with the maximum rated input of all the appliances that it serves Installation pipes must be fitted in accordance with BS 6891 Pipe work from the meter to the appliance must be of adequate size Pipes of a smaller size than the appliance gas inlet connecti...

Page 8: ...ition at least 1 metre above the highest point in the system and at least 5 metres above the boiler see fig 5 The cold feed from the make up vessel or tank must be fitted with an approved non return valve and stopcock for isolation purposes The feed pipe should be connected to the return pipe as close to the boiler as possible 3 6 8 FREQUENT FILLING Frequent filling or venting of the system may be...

Page 9: ...maintained to each appliance when they are in use at the same time 3A 4 FLUE SYSTEM The terminal should be located where the dispersal of combustion products is not impeded and with due regard for the damage and SECTION 3A GENERAL REQUIREMENTS EIRE discoloration that may occur to building products located nearby The terminal must not be located in a place where it is likely to cause a nuisance see...

Page 10: ...z electrical supply it must be protected with a 3 amp fuse The method of connection to the mains electricity supply must allow for complete isolation from the supply The preferred method is by using a double pole switch with a contact separation of at least 3mm The switch must only supply the appliance and its corresponding controls i e time clock room thermostat etc 3A 8 MOUNTING ON A COMBUSTIBLE...

Page 11: ...e appliance Care should be exercised when determining the position of the appliance with respect to hidden obstructions such as pipes cables etc When the position of the appliance has been decided using the template supplied carefully mark the position of the wall mounting bracket see fig 6A and flue hole if applicable 4 5 FITTING THE FLUE The top flue outlet permits both horizontal and vertical f...

Page 12: ...flue pipe into the flue bend ensuring the correct seal is made Using the clamp gasket and screws supplied secure the flue bend to the appliance flue spigot The 60mm M F adaptor supplied with the flue kit should be discarded NOTE Fit the internal trim to the flue assembly prior to connecting the flue pipe to the bend You must ensure that the entire flue system is properly supported and connected Se...

Page 13: ...bracket 4 N A Reduction for bends Using the dimensions given in fig 9 as a reference mark and cut a 115mm hole in the ceiling and or roof Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside ensuring that the collar on the flue terminal fits over the flashing The fixing holes for the wall mounting bracket should now be dri...

Page 14: ...s provided The twin flue pipes extensions and accessories can now be installed by pushing together the plain end of each extension or bend should be pushed approximately 50mm into the female socket of the previous piece NOTE When cutting an extension to the required length you must ensure that the excess is cut from the plain end of the extension see fig 8 Remove any burrs and check that any seals...

Page 15: ... terminal assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing The interior and exterior trim can now be fitted Fig 12 4 5 3 3 VERTICAL TERMINATION see fig 13 The twin flue system must be converted to the dedicated concentric flue kit for termination The vertical terminal is supplied with a built in converter box and cannot be shortened A 130mm...

Page 16: ...of gas 4 6 2 FLOW RETURN see fig 6A 14 The appliance is supplied with 22mm service valves for the flow and return connections connect a 22mm pipe to the inlet of each valve and tighten both nuts NOTE Depending on system requirements it may necessary to increase the size of the flow return pipe work after the service valve connections 4 6 3 SAFETY VALVE see fig 6A 14 Connect the safety valve connec...

Page 17: ...ntrols cover catch locate and unscrew the 2 screws that secure the controls fascia to the appliance casing see fig 15 gently lower the control fascia until it rests remove the 2 screws located at the Left Right of the underside of the casing lift the casing upward to disengage it from the top locating hooks and then remove store the casing and screws safely until required Re fit in the reverse ord...

Page 18: ...to their corresponding terminals on the appliance terminal block Connect the EARTH wire to the EARTH block see fig 16 ensuring that it s left slightly longer that the others this will prevent strain on the EARTH wire should the cable become taut Fig 16 ...

Page 19: ...om the meter to the appliance are open and the supply pipe has been properly purged ensure the proper electrical checks have been carried out see 7 7 particularly continuity polarity and resistance to earth ensure the 3 amp fuse supplied with the appliance has been fitted ensure the system has been filled vented and the pressure set to 1 bar ensure the flue system has been fitted properly and in a...

Page 20: ...THE APPLIANCE GAS VALVE HAVE BEN TIGHTENED AND 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 COMPLETE APPLIANCE LOGBOOK Complete details of the boiler controls installation and commissioning in the logbook supplied with the boiler This is an important document which must be...

Page 21: ...enturis are clean and free from any debris or obstruction Ensure the burner main heat exchanger and latent heat collector are clean and free from any debris or obstruction 6 3 REPLACEMENT OF COMPONENTS Although it is anticipated that this appliance will give years of reliable trouble free service the life span of components will be determined by factors such as operating conditions and usage Shoul...

Page 22: ...ERMISTOR see fig 22 Carry out component removal procedure as described in 6 4 Unclip and remove the air chamber cover and remove the right side air baffle Disconnect thermistor electrical plug Using a 13mm spanner slacken and remove the thermistor and sealing washer 1 2 from the main heat exchanger Replace in the reverse order 6 11 HIGH LIMIT THERMOSTAT see fig 23 Carry out component removal proce...

Page 23: ...electrical connections Replace in the reverse order 6 15 ELECTRODE BURNER THERMOSTAT BURNER INJECTORS Fig 26 carry out component removal procedure as described 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 Disconnect the electrode lead and burner thermostat from their r...

Page 24: ... to the fan noting their positions Locate and remove the screws 6 that secure the analogue pressure switch assembly 4 5 Locate and remove the screws that secure the flue hood and air baffle disconnect the flue clip 1 from the fan flue elbow and gently ease the fan 3 flue hood assembly 2 from its location Locate and remove the four screws that secure the fan to the flue hood Remove the fan to flue ...

Page 25: ...sconnect and remove the flow pipe at the heating manifold 1 and at the connection to the air chamber Using a hooked piece of wire carefully withdraw the bypass cartridge 2 Ensure all seals are in good condition taking care to ensure they are replaced correctly Replace in the reverse order ensuring the cartridge is facing the correct way Fig 29 3 2 2 1 5 4 3 5 4 6 20 EXPANSION VESSEL fig 1 Should t...

Page 26: ... 6 16 Disconnect the condense sensor wire from the sensor Fig 32 disconnect and remove the inlet 1 outlet 3 and condense pipes 2 from the collector Fig 33 unscrew and remove the 3 screws 1 that secure the collector to the air chamber and disconnect the collector 2 from the flue connection Replace in the reverse order ensuring all seals are intact and located correctly Fig 34 8 9 6 4 2 3 5 7 1 2 1 ...

Page 27: ...ve The operation of the fan causes the analogue pressure switch PAD to deliver a signal voltage to the control PCB If the signal voltage is sufficient a slow ignition sequence is enabled whereby the current supplied to the gas valve modulating coil is progressively increased from minimum to maximum over a period of 8 seconds During this period the ignition electrode sparks continuously even if the...

Page 28: ...mode button once The boiler will now enter the combustion analysis mode CO mode for a period of 15 minutes During this time it will remain on full gas and CO will be displayed on the LED display Once the flue gas analysis has been made press the CO mode to resume normal operation 7 5 CHECKING THE EXPANSION VESSEL Carry out the component removal procedure as described in 6 4 You must ensure that th...

Page 29: ...e from the electrical supply and using a suitable multi meter carry out a resistance test Connect test leads between the Live Earth connections at the appliance terminal strip fig 16 If the meter reads other than infinity there is a fault that must be isolated carry out a detailed continuity check to identify the location of the fault FAULT CODE 01 Fault code 01 appears when the burner has failed ...

Page 30: ...mistor Check wiring continuity FAULT CODE 05 Fault code 05 appears if the appliance is connected to the optional remote control RC05 and there is a communica tion problem Check wiring between RC05 and appliance FAULT CODE 06 Fault code 06 appears if a problem exists with the jumper tags configuration of the PCB Check jumper tag configuration FAULT CODE d2 Fault code d2 appears if a problem exists ...

Page 31: ...7 7 been carried out Does the selector knob rotate the switch on the display PCB NO Replace selector knob NO Replace selector knob YES Is there 5vdc across terminals M9 1 M9 2 on main PCB YES Is there 5vdc across terminals M2 1 M2 2 on main PCB Go to test B YES Replace display PCB YES NO Replace main PCB NO Replace ribbon cable between main PCB display PCB FAULT FINDING TEST A turn the selector sw...

Page 32: ...ows 06 Display shows 07 RESET Ensure JP5 tag is on Check thermistor values and or replace Go to test C Replace main PCB Check wiring and continuity Display shows 08 Check gas pressure Check continuity and or replace thermostat Display shows 09 Replace main PCB Fault code showing d1 Check condensate level sensor Fault code showing d2 Check condensate sensor wiring continuity ...

Page 33: ...en terminals M3 10 M3 11 on PCB NO Checking wiring connections or analog air sensor NO YES Replace main PCB YES Check wiring connections check water pressure switch NO YES Checking wiring connections Is there a voltage 0 5VDC between pin M3 11 on main PCB and the gray wire on analog air sensor NO check flue gas tube check wiring connections check analog air sensor check fan Is there a voltage 0 5 ...

Page 34: ...S Is spark electrode ok YES YES NO Is there 230V between 1 2 of ignition PCB Is there 230V between gas valve YES YES Replace ignition PCB NO Check wiring connections Is gas valve ok NO NO YES Replace gas valve Check gas Is ionisation voltage ok NO YES Replace ignition PCB NO Replace spark electrode Replace spark electrode ...

Page 35: ...etween terminals M14 1 M14 2 NO NO Replace main PCB Check wiring connections YES Is there 230V between 4 5 on ignition PCB Is there 230V between 4 EARTH NO NO Replace ignition PCB YES YES Is spark electrode and spark gap ok NO YES Replace spark electorde Replace ignition transformer ...

Page 36: ...ers Twin channel programmers Single channel time clocks Programmable room thermostats In addition the appliance can be used in conjunction with a typical S Plan or Y Plan system 8 4 VOKERA TIME CLOCK see fig 40 Isolate the appliance from the electrical supply and remove the casing as described in 4 7 1 Remove the blanking plate from the clock aperture Remove the appliance PCB cover Remove the fact...

Page 37: ...p fuse N L E Heating Hot water Off On Off On orange grey brown blue green yellow orange grey brown blue green yellow N L E 4 5 6 7 8 9 10 L N Room thermostat Load Common 7 8 9 10 N L E 4 5 6 7 4 5 6 3 2 1 green yellow Motorised Valve hot water Motorised Valve heating blue brown orange grey green yellow blue brown orange grey Appliance Terminal Strip Wiring Centre N E 3 amp fuse L Cylinder thermost...

Page 38: ...alling Common Satisafied Add if programmer has heating only position 230V supply 50Hz white 10 9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1 Room thermostat grey orange blue green yellow Appliance Terminal Strip 3 Port mid position valve orange grey white blue green yellow 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 Vokera Twin Channel Programmer Cylinder thermostat Room thermostat Calling Common Satisafied Live Load Wi...

Page 39: ...rode OPE Gas valve solenoids B E B Boiler control board S B Secondary board JP8 Natural gas or L P G selector JP9 Timer on off selector JP5 Jumper C H only PT2 Central heating temperature control PT1 S B Selection of 0 reset winter summer F Fan P Pump DS1 DS2 Temperature allarm display TA1 Combustion test F1 Fuse 100 mA F on 24V circuit F2 Fuse 2 A F on 230 V circuit RL1 Ignition relay RL2 Pump re...

Page 40: ...38 Fig 45 ...

Page 41: ... Printed Circuit Board R10024390 26 Instrumental panel R10023051 31 Case R1922 38 Printed Circuit Board R10020477 39 Spring R1862 40 Door panel R10024508 43 Push push cover R1864 48 Led Light Guide R1858 49 Hole cap R8654 50 Pin R1867 51 Hole cover R1861 52 Selector knob kit R01005073 53 Control knob kit R01005072 90 3A fuse R3478 226 Edge clip R5128 326 O ring R1869 362 Transformer R10022659 400 ...

Page 42: ...40 2 1 2 201 26 370 370 371 372 289 50 388 45 393 47 394 395 396 200 200 277 394 398 3 4 290 28 200 288 8 202 288 285 200 9 287 48 200 6 10 200 11 25 40 7 49 27 400 5 500 ...

Page 43: ...g R10023531 45 Retarder R10024136 47 Sensor R10024140 48 Pipe R10024129 49 Pipe R10024131 50 Siphon plug R10024133 200 Washer 24 x 17 R5023 201 Washer 18 5 x 11 R5026 202 Washer R5041 277 Screw M4 R6903 285 Sensor R8484 287 Limit thermostat R2258 288 O Ring R6898 289 Clip R2223 290 Clip R2165 370 O Ring R10023533 371 Clip R10023532 372 Clip R2588 388 Washer Ø 60 R10021949 393 O Ring 4300 R10024141...

Page 44: ...S DESCRIPTION 29 3 Pressure switch R2044 7 By pass valve R1552 9 Heating manifold R10021821 22 Safety valve R1806 27 Heating cock R1789 31 Venting plugs kit R01005137 63 Pipe R10023065 277 Screw R6903 353 Nut R1824 400 Wiring harness R10024740 ...

Page 45: ...022980 4 LPG burner R10023081 5 Spark electrode R10022027 9 NG plate R5172 10 Gas valve solenoid R10020838 12 Gas pipe R1839 13 Gas valve R10021021 14 Gas pipe R1840 15 Gas cock R1787 16 Air box cover R10020217 17 Wascher R5072 18 Glass R3139 19 Glass flange R4007 21 Washer R5905 200 Washer R5023 332 Thermostat R2600 351 Nut R1823 400 Wiring harness R10021947 401 Wiring harness R10022112 ...

Page 46: ...ateral panel R5271 4 Combustion chamber front panel R5315 7 Hood assembly R10024125 10 Fan R10024035 13 Venturi and pressure tube kit R01005293 16 Clamp for tube R10024126 19 Fan flue connection R10024137 20 Block with combustion analysis check R8085 23 Brass cap R8086 25 Pressure differential switch R2677 295 Silicone tube R1457 300 Wiring harness R10024120 ...

Page 47: ...from the gas valve modulating coil assembly and turn the outer 10mm nut clockwise to increase or counter clockwise to decrease the burner pressure 10 6 2 SETTINGTHE MIMIMUM BURNER PRESSURE see fig 37 Once the maximum burner pressure has been checked and or adjusted remove one of the grey wires from the modulating coil Compare the reading on the manometer with the value described in 10 2 If adjustm...

Page 48: ...e General Enquiries Tel 0870 333 0520 Fax 01442 281460 After Sales Service Tel 0870 333 0220 Vokèra Ireland West Court Callan Co Kilkenny Tel 056 55057 Fax 056 55060 Vokèra Ltd reserve the right to change the specifications without prior notice Consumers statutory rights are not affected A Riello Group Company energizing home heating Vokèra supports Benchmark COLLECTIVE MARK ...