VOKERA Compact 25 HE, Installation & Servicing Instructions Manual

Page 1: ...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 Compact HE High efficiency combi boiler ...

Page 2: ...etting the system design pressure 17 5 11 Regulating the hot water 17 5 11 1 Changing the flow restrictor 17 5 11 2 Regulating the central heating system 17 5 12 Final checks 17 5 13 Instructing the user 17 Servicinginstructions Page 6 1 General 18 6 2 Routineannualservicing 18 6 3 Replacementofcomponents 18 6 4 Componentremovalprocedure 18 6 5 Pump assembly 18 6 6 Safety valve 18 6 7 Automatic ai...

Page 3: ...ed 33 CH temperature selector 34 Timeclock The Compact HE range of appliances is comprised of 2 models of high efficiency combination boiler with inputs to heating DHW of 25 29 35kW respectively Each appliance by design incorporates electronic ignition circulating pump expansion vessel safety valve pres sure gauge and automatic by pass The Compact HE range is produced as room sealed category II2H3...

Page 4: ...t down and the boiler will perform a three minute anti cycle timer de lay When the request for heat has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appli ance 1 4 MODE OF OPERATION DHW When there is a request for DHW via a hot water outletortap thepumpandfanarestarted thefan will then prove the air pressure switch At this point an ign...

Page 5: ...m3 h 3 07 1 59 m3 h 3 68 1 59 m3 h Injectors size 12 x 1 35 mm 14 x 1 35 mm 16 x 1 35 mm 2 4Expansionvessel Capacity 8 litres 10 litres 10 litres Maximum system volume 76 litres 76 litres 76 litres Pre chargepressure 1 0 bar 1 0 bar 1 0 bar 2 5Dimensions Height 780 mm 780 mm 780 mm Width 400 mm 450 mm 500 mm Depth 332 mm 332 mm 332 mm Dry weight 40 kg 44 kg 48 kg 2 6Clearances Sides 12 mm 12 mm 12...

Page 6: ... 300 mm D Below gutter drain pipe etc 75 mm E Below eaves 200 mm F Below balcony car port roof etc 1200 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 1200 mm K From a terminal facing a terminal 1200 mm L From an opening in the car port into the building...

Page 7: ...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 connection must not be used The installation must be ...

Page 8: ...air is carried naturally to air release points and that water flows naturally to drain cocks Except where providing useful heat pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing Particular atten tion should be paid to pipes passing through ventilated areas such as under floors loft space and void areas 3 6 2 AUTOMATIC BY PASS The appliance has a bu...

Page 9: ...ion IGE UP 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 The inhibitor must be administered in strict ac cordance with the manufacturers instructions Water treatment of the complete ...

Page 10: ... at the same time 3A 4 FLUE SYSTEM The terminal should be located where the disper sal of combustion products is not impeded and with due regard for the damage and discoloration thatmayoccurtobuildingproductslocatednearby The terminal must not be located in a place where it is likely to cause a nuisance refer to I S 813 for guidance on permitted locations and minimum distances of flue terminals Wa...

Page 11: ...ains electricity supply must allow for com plete 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 corre sponding controls i e time clock room thermo stat etc 3A 8 SHOWERS If the appliance is intended for use with a shower the shower must be thermostatically controlled and be s...

Page 12: ...the instruc tions supplied with the 80 125mm terminal The appliance flue outlet elbow can be rotated through 360º on its vertical axis In addition the flue may be extended from the outlet elbow in the horizontal plane see 2 9 A reduction must also be made to the maximum length see table below when additional bends are used Bend Reduction in maximum flue length for each bend 45º bend 0 5 metre 90º ...

Page 13: ...lue system please refer to the instruc tions supplied with the 80 125mm terminal The vertical flue terminal can be connected di rectly to the appliance flue outlet Alternatively an extension or bend can be connected to the appliance flue outlet if desired see 4 4 2 how ever if additional bends are fitted a reduction must be made to the maximum flue length see table below Fig 8 Part No Description ...

Page 14: ...ate dripping from the terminal Ensurethattheentirefluesystemisadequately supported use at least one bracket for each extension The entire flue system must be adequately insulated to maintain heat within the flue sys tem thereby reducing the possibility of conden sate production As the exhaust outlet pipe can reach very high temperatures it must be protected to prevent persons touching the hot surf...

Page 15: ... the hole in the exhaust connection mani fold as a guide drill a 3mm hole in the appliance flue spigot and secure the exhaust manifold connection to the flue spigot using the screw provided C Using the two holes in the air inlet plate as a guide drill a 3mm hole in each and secure the air inlet pipe bend using the screws provided The twin flue pipes extensions and accessories can now be installed ...

Page 16: ...e is supplied with a 15mm stopcock connect a 15mm pipe to the inlet of the stopcock and tighten both nuts 4 6 4 HOT WATER OUTLET fig 6 14 The appliance is supplied with a 15mm outlet connection connect a 15mm pipe to the outlet connection and tighten both nuts 4 6 5 SAFETY VALVE fig 6 14 Connect the safety valve connection pipe to the safety valve outlet and tighten The discharge pipe must have a ...

Page 17: ...at secures the terminal block cover NOTE The appliance comes with a factory fitted clock to allow basic operation of the boiler If it is antici pated that additional controls such as a room thermostat will be required please refer to the wiring diagrams in section 8 for more detailed information 4 7 3 CONNECTINGTHE MAINS 230V INPUT see fig 16 Lift the terminal block cover as described in 4 7 2 Pas...

Page 18: ...ll gas service valves from 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 ...

Page 19: ...g Ifconditionsarewarm remove any thermostatic heads Adjust radiator return valves and any branch circuit return valves until the individual return temperatures are cor rect and are approximately equal 5 12 FINAL CHECKS ENSURE ALL TEST NIPPLES ON THE AP PLIANCE GAS VALVE HAVE BEN TIGHT ENED AND CHECKED FOR SOUNDNESS ENSURE THE APPLIANCE FLUE SYSTEM IS FITTED CORRECTLY AND IS PROPERLY SECURED ENSURE...

Page 20: ...though it is anticipated that this appliance will give years of reliable trouble free service the life spanofcomponentswillbedeterminedbyfactors such as operating conditions and usage Should the appliance develop a fault the fault finding section will assist in determining which compo nent is malfunctioning 6 4 COMPONENT REMOVAL PROCEDURE To remove a component access to the interior of the applian...

Page 21: ...cken and remove the thermistor and sealing washer 1 2 from the main heat exchanger Replace in the reverse order 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 6 12 PRINTED CIRCUIT BOARD ...

Page 22: ...ver 3 pullthecovertowards you before lifting and disengaging Disconnect the electrode lead and burner thermostat from their respective connectors Ease the electrode sealinggrommetfromitsseating 4 Removethe retaining screw for the burner thermostat and remove the thermostat FIG 26 locate and remove the four screws which secure the burner in position 1 gently ease the burner out of its location Once...

Page 23: ... Locate and remove the six screws that secure the front combustion cover then remove the cover Remove the air chamber side panels if necessary by unscrewing the securing screws Disconnect the flow and return connec tions 4 5 fig 28 on the heat exchanger The heat exchanger can now be withdrawn from the appliance Replace in the reverse order Ensure all seals are in good condition taking care to ensu...

Page 24: ...re needs to be re placed if it s suspected as being damaged or worn Replace in the reverse order ensuring that the seating cam inserts into the locating groove correctly see fig 30a Ensure all seals are in good condition taking care to ensure they are replaced correctly 6 24 DHW THERMISTOR fig 31 Carry out component removal procedure as de scribed in 6 4 Disconnect the electrical plug Using a suit...

Page 25: ...ly can now be lifted clear from the appliance Locate and remove the 4 screws that secure the vessel see fig 32 The expansion vessel can now be removed Replace in the reverse order Take extreme care when refitting the wiring to the air chamber Ensure all seals are in good condi tion taking care to ensure they are replaced correctly 6 28 1 LATENT HEAT COLLECTOR fig 33 34 35 Carry out component remov...

Page 26: ...actuator anti block fan over run 7 2 3 SELECTOR SWITCH IN THE HEATING HOT WATER POSITION When the selector switch is in the heating HW position the Green LED is illuminated SECTION 7 CHECKS ADJUSTMENTS AND FAULT FINDING flashing every 6 seconds if no Heat or DHW request is active constant during a heat or DHW request The divertor valve remains in the DHW position if no heat request is active The a...

Page 27: ...tive The opera tion of the fan causes the air pressure switch to deliverasignalvoltagetothecontrolPCB Aslow ignition sequence is enabled whereby the cur rent supplied to the gas valve modulating coil is progressively increased from minimum to maxi mum over a period of 8 seconds During this period the ignition electrode sparks continuously even if the burner has ignited NOTE If the spark sensing el...

Page 28: ... wires from the modulating coil Compare the reading on the manometer with the value de scribed in 2 3 If adjustment is required turn the inner red crosshead screw clockwise to in crease or counter clockwise to decrease the burner pressure whilst ensuring that the outer 10mm nut does not move When checking and or adjustment has been completed isolate the appliance from the electrical supply replace...

Page 29: ...itable multi meter carry out a short circuit test between the Live Neutral connec tions at the appliance terminal strip fig 16 Repeat above test on the Live Earth connec tions at the appliance terminal strip fig 16 NOTE Should it be found that the fuse has failed but no fault is indicated a detailed continuity Check will be required to trace the fault A visual inspection of components may also ass...

Page 30: ...t the minimum heating output P5 set at maximum EFFECT OF JUMPER TAGS FITTED TO THE MAIN PCB AT JP1 disables DHW function JP2 cancels anti cycle function and initial heating output 75 of maximum at start up JP3 for LPG boilers only JP4 enables DHW temperature stabiliser function boiler modulates at set point and remains on minimum power even if the set point is exceeded NOTE IftheVokeraremote contr...

Page 31: ... ON PCB NO NO YES MADE A LINK BETWEEN BLACK BLACK WIRES AT BOILER TERMINAL STRIP AND CLOSE THE TIMER CONTACT SWITCH ON BOILER AND SELECT MODE TO WINTER C H THERMOSTAT AT MAX YES LOOSE THE PUMP ACTING WITH A SCREWDRIVER ON THE IMPELLER RESTART THE TEST NO NO NO NO IS ROOM THERMOSTAT INPUT LINKED MADE A LINK BETWEEN THE ROOM THERMOSTAT INPUT CHECK IDRAULIC CIRCUIT WATER PRESSURE SWITCH ARE OK NO IS ...

Page 32: ...5 2 ON PCB IS THERE 0 Vdc BETWEEN TERMINALS CN8 7 CN8 8 ON PCB NO YES NO CHECK WIRING AND CONNECTIONS NO DO THE AIR FLOW SWTCH TURN ON CHECK WIRING AND CONNECTIONS AIR FLOW SWITCH AND CONTROL BOARD YES NO ARE THE VENTURI TUBE AND THE SILICONE AIR TUBES CLEAN CHECK CLEAN THE VENTURI TUBE AND SILICONE AIR TUBES IS THE AIR DP 11 mmCH2O CHECK THE FAN AND OR FLUE GAS TUBE CHECK REPLACE AIR FLOW SWITCH ...

Page 33: ...TCH AND HYDRAULIC CIRCUIT NO RECHECK SUPPLY FUSE CONNECTORS TO BOILER TERMINALS MAINS PRESENT BETWEEN BLUE BROWN WIRES AT BOILER TERMINAL STRIP NO REPLACE WIRING OR CONNECTIONS TERMINAL STRIP AND CONTROL BOARD YES YELLOW LED BLINKS CHIMNEY SWEEPER CYCLE RESET AND RESTART TEST NO IS THERE 0 VCC BETWEEN TERMINALS CN9 1 CN9 2 ON PCB IS THERE 24 Vdc BETWEEN TERMINALS CN8 4 CN8 7 ON PCB IS THERE 24 Vdc...

Page 34: ...K WIRING AND CONNECTIONS OR DHW SWITCH YES NO IS DHW FLOW SWITCH NO WAIT TILL THE VOLTAGE BETWEEN TERMINAL CN9 3 CN9 4 ON PCB IS 1 2 Vdc IS THE VOLTAGE BETWEEN TERMINAL CN9 3 CN9 4 ON PCB IS 1 2 Vdc IS TEMPERATURE 60 C WAIT D H W TEMPERATURE 60 C YES YES NO IS D H W NTC OK REPLACE D H W NTC REPLACE CONTROL BOARD YES B NO D H W D H W OK NO NO NO YES REPLACE WIRE AND CONNECTIONS REPLACE CONTROL BOAR...

Page 35: ...E THE TIMER CONTACT SWITCH ON BOILER AND SELECT MODE TO WINTER C H THERMOSTAT AT MAX START RESTART THE TEST NO NO YES REPLACE WIRE AND CONNECTIONS REPLACE CONTROL BOARD REPLACE MODULATOR COIL IS THE RESISTENCE OF MODULATOR COIL ABOUT 70 80 OHM IS THERE A VOLTAGE 8 VDC BETWEEN TERMINALS CN9 3 CN9 4 ON PCB YES C IS VOLTAGE ACROSS TERMINALS OF MODULATOR COIL 10 VDC SWITCH CH THERMOSTAT AT MIN NO YES ...

Page 36: ... MAX DO BURNER AND FAN SWITCH ON IS WATER FLOW TEMPERATURE 80 C WAIT WATER FLOW TEMPERATURE 80 C NO YES REPLACE CONTROL BOARD REMOVE JUMPER IS TIMER JUMPER ON RESTART THE TEST DO BURNER AND FAN SWITCH ON OPEN THE TIMER CONTACT REPLACE CONTROL BOARD DO BURNER AND FAN SWITCH OFF DO PUMP SWITCH OFF END REPLACE CONTROL BOARD YES YES YES NO NO NO NO NO NO YES YES YES WAIT 30 SECS NO IS C H NTC OK REPLA...

Page 37: ... whereby the RC05 con trols only the functions of the appliance Heat ing DHW temperature reset function fault code display etc Boiler control with room thermostat func tion whereby the RC05 controls the functions of the appliance Heating DHW temperature reset function fault code display etc and also functions as a room thermostat Boiler control with programmable room thermostat whereby the RC05 co...

Page 38: ... Setting timer JP3 Natural gas or L P G selector JP4 Jumper disable enable DHW absolut thermostat P1 Domestic hot water temperature control P2 Central heating temperature control P3 Off summer winter combustion test P4 Minimum heating regulation P5 Heating potentiometer must be set to max F1 F2 Fuse 2 AF S S E Spark Sense electrode CP04X Control board CN1 CN9 Connectors RL1 Pump relay RL2 Fan rela...

Page 39: ...6 Instrumental panel 10027547 10027547 27 Control knob 10023937 10023937 28 Selection knob 10023936 10023936 31 Case 10026164 10026179 40 Instrumental panel cover 10027549 10027549 49 Adapter 10023935 10023935 61 Cover assembly 01005404 01005404 76 Timer 10023938 10023938 90 Fuse 3478 3478 226 Edge clip 5128 5128 270 Transformer 10021272 10021272 300 Wiring harness clock 10023840 10023840 301 Wiri...

Page 40: ...0024646 63 Pipe 10026228 10026228 112 Pressure switch 10027535 10027535 201 Washer 5026 5026 265 Washer 5236 5236 266 Washer 5237 5237 288 Washer 6898 6898 290 Clip 2165 2165 351 Nut 1823 1823 353 Nut 1824 1824 432 Clip 10024958 10024958 433 Clip 10024986 10024986 434 Nipple 10024985 10024985 435 Connection 10025059 10025059 436 Clip 10025062 10025062 438 O Ring 10024988 10024988 439 Washer 100250...

Page 41: ...136 10024136 48 Pipe 10024311 10024129 49 Pipe 10024313 10024313 66 Flexible pipe 10027545 10027545 200 Washer 24 x 17 5023 5023 201 Washer 18 5 x 11 5026 5026 202 Washer 5041 5041 288 O Ring 6898 6898 290 Clip 2165 2165 314 Connection 2186 2186 370 O Ring 10023533 10023533 371 Clip 10023532 10023532 393 O Ring 10024141 10024141 394 O Ring 10024142 10024142 395 O Ring 10024143 10024143 396 Connect...

Page 42: ...2 12 Gas pipe 10027537 10027537 13 Gas valve 10025074 10025074 14 Gas pipe 10026703 10026703 15 Gas cock 10020897 10020897 16 Air box cover 10020216 10020217 17 Washer 5072 5072 18 Glass 3139 3139 19 Flange 4007 4007 20 Gas valve solenoid 10020838 10020838 21 Washer 5905 5905 27 Hole cap 8084 8084 200 Washer 5023 5023 300 N G conversion kit 01005225 01005225 301 LPG conversion kit 01005407 0100540...

Page 43: ...ood assembly 10024310 10024125 10 Fan 10024035 10024035 13 Venturi and pressure tube kit 01005405 01005405 16 Clamp for tube 10024126 10024126 19 Fan flue connection 10024137 10024137 20 Block with combustion analysis check 10026933 10026933 23 Brass cap 8086 8086 25 Pressure differential switch 10020889 10020889 100 Combustion fan cable PCB ground faston fan H2 O limit thermostat CH NTC flue pres...

Page 44: ...rease the burner pressure 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 DOMESTIC BUTANE PROPANE GAS BURNERS IN PERMAMENT DWELLINGS 10 1 RELATED DOCUMENTS 10 2 TECHNICAL DATA GAS PRESSURES 25 29 35 Inlet pressure 37 mbar 37 mbar 3...

Page 45: ...EDUCER BEEN FITTED YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE 3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INS...

Page 46: ...OMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD...

Page 47: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 48: ...olney 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 specification without prior notice Consumers statutory rights are not affected A Riello Group Company Company Reg No 1047779 ...