VOKERA Option Installation And Servicing Instructions
VOKERA Option Installation And Servicing Instructions

VOKERA Option Installation And Servicing Instructions

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INTRODUCTION
The Vokèra Option is a combined central heating and
domestic hot water appliance. By design, it incorpo-
rates full sequence electronic ignition, circulating pump,
expansion vessel, safety valve, pressure gauge, and
mechanical timeclock.
The appliance is produced as a room sealed boiler,
suitable for wall mounted applications only. It is pro-
vided with a fan powered flue outlet with an annular co-
axial combustion air intake located on the top rear of the
appliance.
The appliance has been designed for use with a sealed
heating system, consequently it is not intended for use
with an open vented system.
2 4
2 3
2 2
2 1
2 0
1 9
1 8
1 7
1 6
1 5
Fig. 1
1
1 4
1 3
The appliance can be used in conjunction with an 'Y' or
'S' Plan system when stored hot water via an in-direct
cylinder is required.
An automatic range-rating facility is incorporated in the
boiler, which automatically adjusts boiler output to match
the current demand.
Domestic hot water is provided directly, via the bi-
thermic heat exchanger
2
Fig.1 General Layout
1
Flue Analysis Test Point
2
Pressure Tube Negative
3
3
Fan Assembly
4
Heat Exchanger
4
5
Secondary thermistor
6
Combustion chamber
5
7
Burner
8
Expansion vessel
6
9
Water pressure switch
10
Domestic Hot Water Flow Switch
11
Gas Valve
7
12
Mode selector switch
13
Fault indicator led
8
14
Timeclock
15
Low pressure indicator led
16
Pressure gauge
9
17
Safety valve
18
Pump
1 0
19
Auto air vent
1 1
20
Electrode
21
High limit thermistor
22
Primary thermistor
23
Air chamber (with cover removed)
24
Air pressure switch
25
Auto by pass (fig. 2)
26
Water flow restrictor (fig. 2)
1 2
1

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Summary of Contents for VOKERA Option

  • Page 1 INTRODUCTION The Vokèra Option is a combined central heating and The appliance can be used in conjunction with an ‘Y’ or domestic hot water appliance. By design, it incorpo- ‘S’ Plan system when stored hot water via an in-direct rates full sequence electronic ignition, circulating pump, cylinder is required.
  • Page 2: Principle Components

    SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE PRINCIPLE COMPONENTS A fully integrated, electronic control board Once the desired temperature is reached, the featuring mode selection switch, full sequence- burner will modulate to maintain that tempera- electronic ignition, temperature control sys- ture, however should the temperature within the tem, and appliance status indicator.
  • Page 3: Technical Data Page

    SECTION 2 TECHNICAL DATA 2.1 Central heating Heat input 28.86 kW 98,464 BTU Heat output (max) 23.65 80,006 BTU Heat output (min) 9,3 kW 31,700 BTU Maximum working pressure 3.0 bar Minimum flow rate 350 l/h 90 °C Max temperature Minimum working pressure 0,5 bar 2.2 Domestic hot water...
  • Page 4: Pump Duty

    2.10 PUMP DUTY Fig. 3 shows the flow rate available – after allowing for pressure loss through the appliance – against system pressure loss. When using this graph apply only the pressure loss of the sys- tem. The graph is based on a 20ºC temperature differential.
  • Page 5: General Requirements Page

    SECTION 3 GENERAL REQUIREMENTS This appliance must be installed by a competent A compartment used to enclose the appliance must be designed and constructed specifically person in accordance with the Gas Safety (Installa- for this purpose. tion And Use) Regulations. An existing compartment/cupboard may be uti- lised provided that it is modified to suit.
  • Page 6: Air Supply

    (A suitable guard is available from Vokera pipes connected to the appliance. The drain cocks Ltd. Part no. 018). The guard must be fitted must be manufactured in accordance with BS centrally over the terminal.
  • Page 7: Low Pressure Sealed System

    3.6.7 LOW PRESSURE SEALED SYSTEM An alternative method of filling the system would be from an independent make up vessel or tank mounted in a position at least 1 metre above the highest point in the system and at least 5 metres above the boiler. (see fig.5a) The cold feed from the make-up vessel or tank must be fitted with an approved non-return valve and stopcock for isolation purposes.
  • Page 8: Delivery

    FITTING THE FLUE The top flue outlet permits both horizontal and vertical flue applications to be considered, alternatively, the Vokera twin flue system can be utilised if longer flue runs are required. 4.5.1 CONCENTRIC HORIZONTAL FLUE (For concentric vertical flue, see 4.5.2) (For twin flue applications, see 4.5.3)
  • Page 9 FITTING THE TELESCOPIC FLUE KIT (0225705 The internal trim should be fitted to the flue pipe & 0225710) before connection of the 90º bend. Carefully measure the distance from the centre of Insert the flue restrictor ring (supplied with the appliance flue outlet to the face of the outside instruction pack) into the appliance flue gas outlet wall (dimension ‘X’...
  • Page 10 NOTE IMPORTANT When cutting the horizontal flue terminal or an The vertical flue terminal is 1.0 metre in length extension to the required length, you must ensure and cannot be cut; therefore it may be necessary that the excess is cut from the plain end of the to adjust the height of the appliance to suit or use terminal or extension, and that the inner (60mm) a suitable extension.
  • Page 11 4.5.3 TWIN FLUE SYSTEM 4.5.3.1 INSTALLATION OF TWIN ADAPTOR KIT (fig. 10) The Vokera twin flue system enables greater flue Insert the restrictor ring (supplied with the distances to be achieved (see 2.8) than that of instruction pack) if the total flue length –...
  • Page 12 4.5.3.3 HORIZONTAL TERMINATION Depending on site conditions it may be preferable (See fig. 10b) to install the terminal assembly prior to fitting the The twin flue system must be converted to the twin flue pipes. dedicated concentric flue kit for termination. The horizontal terminal is supplied with a built- Fit the appropriate flashing plate to the roof and in converter box and cannot be shortened.
  • Page 13: Connecting The Gas And Water

    must be 3-core flexible sized 0.75mm to BS 6500. CONNECTING THE GAS AND WATER (fig. 6) Wiring to the appliance must be rated for opera- The appliance is supplied with an accessories tion in contact with surfaces up to 90ºC. pack that contains large and small sealing wash- ers, service valves, and pipe connections.
  • Page 14 cable entry LINK Fig.13 Fig.14 Connect the supply cable wires (earth, live, & neutral) to their corresponding terminals on the appliance terminal strip, ensuring the Earth wire is slightly longer than the Live and Neutral, this prevents strain on the earth wire should the cable become taut.
  • Page 15: Gas Supply Installation

    SECTION 5 COMMISSIONING PRE-OPERATION CHECKS GAS SUPPLY INSTALLATION Before attempting to initial lighting of the appli- Inspect the entire installation including the gas ance, the following checks must be carried out. meter, test for soundness and purge. Refer to BS Ensure all gas service valves from the meter to 6891 for specific instruction.
  • Page 16: Final Flushing Of The Heating System

    15,17) Restore the electrical supply to the appli- 5.10 SETTING THE BOILER OPERATING TEM- ance and open a hot water outlet – preferably the PERATURE bath-tap – ensuring a high flow rate. The appli- The flow outlet temperature can be adjusted from ance will now fire and go to maximum gas rate 40ºC.
  • Page 17: Regulating The Domestic Hot Water

    INSTRUCTING THE USER 5.12 REGULATING THE CENTRAL HEATING SYS- Hand over all documentation supplied with this appliance Fully open all radiator and circuit valves and run – including these instructions – and explain the impor- the appliance in the central heating mode until tance of keeping them in a safe place.
  • Page 18: Servicing Instructions Page

    It is the law that any servicing work is carried out can be de-scaled using a proprietary de-scalant by a competent person such as a Vokera service without having to remove it from the appliance. engineer, approved service agent, British Gas, or However the appliance must be disconnected other CORGI registered personnel.
  • Page 19: Safety Valve

    SAFETY VALVE fig. 18 6.10 DOMESTIC WATER FLOW SWITCH fig. 21 Carry out component removal procedure as de- Carry out component removal procedure as de- scribed in 6.5. scribed in 6.5. Disconnect the outlet pipe from the safety valve, Remove black electrical plug from the domestic unscrew and remove the hex bush from the water flow switch, disconnect and remove inlet safety valve outlet, remove safety valve locking...
  • Page 20: High Limit Thermostat

    6.13 HIGH LIMIT THERMOSTAT fig. 22 Remove outer combustion cover by un-clipping Carry out component removal procedure as de- the two retaining clips located at the base of the scribed in 6.5. combustion cover, gently pull the cover towards Pull off electrical plug from the high limit thermo- you before lifting and disengaging it from the top stat, slacken and remove retaining screws.
  • Page 21: Fan

    6.19 HEAT EXCHANGER fig. 24 & 26 Carry out component removal procedure as de- scribed in 6.5. Remove outer combustion cover by un-clipping the two retaining clips located at the base of the combustion cover, gently pull the cover towards you before lifting and disengaging it from the top retaining lugs.
  • Page 22: Checks, Adjustments, And Fault Finding Page

    SECTION 7 CHECKS, ADJUSTMENTS, AND FAULT FINDING CHECKING APPLIANCE OPERATION 7.4 HEATING MODE When carrying out any repairs or servicing to the With all controls calling for heat, the pump and fan appliance the relevant commissioning procedure will run. When the fan runs it proves the air must be undertaken to ensure the continued safe pressure switch.
  • Page 23: Burner Pressure Settings

    Any demand for hot water or heating will reset heating potentiometer (fig.17b), and – with the any frost protection settings. aid of a small screwdriver – gently rotate the potentiometer clockwise to increase the pressure BURNER PRESSURE SETTINGS or anti-clockwise to decrease. Once the checks/ There are three burner pressure settings, which adjustments has been concluded, isolate the require to be checked –...
  • Page 24: Possible Installation Faults

    7.10 POSSIBLE INSTALLATION FAULTS FAULT POSSIBLE CAUSES REMEDY APPLIANCE FIRES THEN LOCKOUTS INCORRECT GAS PRESSURE CHECK INCOMING PRESSURE AND/OR BURNER PRESSURES FLUE BLOCKED OR BROKEN CHECK FLUE ASSEMBLY APPLIANCE WON’T FIRE FOR HOT WATER HOT & COLD PIPES REVERSED CHECK EXTERNAL PLUMBING FLOW REGULATOR BLOCKED REMOVE AND CLEAN INSUFFICIENT FLOW RATE...
  • Page 25 7.12 FAULT FINDING TEST ‘A’ CHECKING OPERATION OF ELECTRONIC CONTROL BOARD AT START UP VOKERA START OPTION Rev. 1 21/04/2000 SWITCH ON BOILER TEST A : CHECKING OPERATION OF ELECTRONIC AND SELECT MODE CONTROL BOARD AT START UP TO WINTER C/H THERMOSTAT AT MAX.
  • Page 26 7.13 FAULT FINDING TEST ‘A’ RED LED BLINKS RED LED SENSOR LIGHT MAINS PRESENT BETWEEN TERMINALS M2.1 & CHECK NTC M2.2 ON CONTROL REPLACE SENSOR OR BOARD CONTROL BOARD CONNECTIONS CHECK FUSE F1 ON CONTROL BOARD YELLOW LIGHT MAINS PRESENT BETWEEN BLUE &...
  • Page 27 7.14 FAULT FINDING TEST ‘A2’ VOKERA OPTION START Rev. 1 21/04/2000 TEST B : CHECK CONTROL IN DHW MODE SWITCH ON BOILER AND SELECT MODE TO SUMMER. DHW THERE 0 Vdc THERMOSTAT AT MAX. BETWEEN TERMINALS M4.12 & M4.17 ON PCB...
  • Page 28 7.15 FAULT FINDING TEST ‘B’ CHECK CONTROL IN HOT WATER MODE VOKERA START OPTION Rev. 1 21/04/2000 SWITCH ON BOILER TEST C: CHECK CONTROL AND SELECT MODE IN C/H MODE TO WINTER C/H THERMOSTAT AT MAX. MADE A LINK BETWEEN BLACK &...
  • Page 29 7.16 TEST ‘B’ CONT’D SPARK AT ELECTRODE THERE 0 VCC BETWEEN TERMINALS M6.24 & M6.25 ON PCB IGNITION DO THE CHECK AIR FLOW SWTCH SENSING/SPARK TURN ON ELECTRODE AND LEAD OR REPLACE LOCKOUT AFTER IGNITION CHECK WIRING AND CONNECTIONS ,AIR FLOW SWITCH AND CHEK CONTROL BOARD...
  • Page 30 7.17 TEST ‘C’ CHECK CONTROL IN HEATING MODE SPARK AT ELECTRODE THERE 0 Vdc BETWEEN TERMINALS M6.24 & M6.25 ON PCB IGNITION DO THE CHECK AIR FLOW SWTCH SENSING/SPARK TURN ON ELECTRODE AND LEAD OR REPLACE LOCKOUT AFTER IGNITION CHECK WIRING AND CONNECTIONS ,AIR FLOW SWITCH AND CHEK...
  • Page 31 7.18 TEST ‘C’ CONT’D WAIT WATER FLOW TEMPERATURE BURNER AND FAN >40 ˚C SWITCH OFF SWITCH CH THERMOSTAT AT WATER FLOW MAX. TEMPERATURE >40 ˚C REPLACE BURNER AND FAN CONTROL SWITCH ON BOARD TIMER JUMPER REMOVE REPLACE JUMPER WAIT 3 MIN. CONTROL BOARD RESTART THE...
  • Page 32: Wiring Diagrams Page

    SECTION 8 WIRING DIAGRAMS Instructions for installation of room thermostat: Room thermostat connection - isolate appliance from electrical supply Common load - remove casing as described in 4.7.1 - remove electrical cover as described in 4.7.1 Neutral if reqd. - connect common and load wires from room thermostat as shown in fig.
  • Page 33: Functional Flow Diagram

    FUNCTIONAL DIAGRAM Fig. 32 R.T. Room thermostat Pump relay S.F.S. Domestic hot waterflow switch Fun relay P.S. Pressure switch Led alarm (red) H.L. High limit thermostat Led ok (green) S.R. Heat thermistor Led analysis test (blink yellow) S.S. Domestic hot water thermistor Transformer Modulator D.P.S...
  • Page 34 FUNCTIONAL DIAGRAM Fig. 33...
  • Page 35: Exploded Diagrams Page

    SECTION 9 EXPLODED DIAGRAMS Description Code R.H. PANEL 10020597 TIME SWITCH 10020892 L.H. PANEL 10020599 CONTROL PANEL 10020891 L.H. PANEL 10020604 LH CASING HOOK 63611882 LOWER TRANVERSE PANEL 10020605 RH CASING HOOK 63611881 DISTRIBUTION PANEL 10020603 APPLIANCE CASING 10020601 CABLE ENTRY 61715371 BADGE SUPPORT 10020308...
  • Page 36 Tav.1 Tav.3 Tav.1 Description Code 22MM COMPRESSION RING 62811822 COMPLETE PUMP 60312225 22MM NUT 62811824 MANIFOLD PLUG 63612261 SAFETY VALVE OUTLET TAIL 10020898 SCREWED CONNECTION 63612217 SAFETY VALVE EXTENSION 63612260 SAFETY VALVE 62811806 FIBRE WASHER 69915237 FLOW MANIFOLD 10020621 _IN. LOCK NUT 63114026 AUTO BYPASS 62912047...
  • Page 37 Tav.1 Tav.2 Tav.2 Description Code HEAT EXCHANGER 61712310 8 LITRE EXPANSION VESSEL 63612204 3.9MM X 9.5MM SCREW 69915079 EXPANSION PIPE 62912164 _IN. LOCKNUT 67114274 EXCHANGER RETURN PIPE 63612219 FIBRE WASHER 69915026 EXCHANGER FLOW PIPE 63612218 LOCKING PIN 62912165 HIGH LIMIT THERMOSTAT 63612258 LOCKING PIN 63612223...
  • Page 38 Tav.1 Description Code AIR CHAMBER 10020894 INSULATION SIDE PANEL 63612231 FRONT INSULATION PANEL 63612232 AIR PRESSURE SWITCH 62818195 COMBUSTION COVER 63612228 SEAL 66018975 AIR CHAMBER COVER 10021568 BLANKING PLATE 63118084 SIGHT GLASS 10021558 BLANKING PLATE 63612233 3.9MM X 9.5MM SCREW 69915079 TEST POINT PLATE 10020624...
  • Page 39 Tav.4 Tav.1 Description Code GROMMET 63611835 BURNER 63612234 ELECTRODE LEAD 63612255 CLIP 69915172 GAS COCK 10020897 CROSSLIGHT STRIP 63612238 2.9MM X 9.5MM SCREW 69915169 BURNER BAR 63612235 4.2MM X 9.5MM SCREW 69915082 63612236 3.2MM X 7MM RIVET 69915093 GAS VALVE OUTLET PIPE 63612243 C3/4IN.
  • Page 40: Technical Data

    SECTION 10 L.P.G. INSTRUCTIONS For details of converting appliances to LPG please refer to the instructions supplied with the relevant conversation kit 10.1 TECHNICAL DATA BURNER PRESSURES MAXIMUM MINIMUM Hot water 37 mbar 5.1 mbar Heating 37 mbar 6.5 mbar Gas rate (consumption) 2.02 kg/h 0.76 kg/h...
  • Page 41: Rear Flue

    There are two telescopic flue kits for use with the appliance flue spigot (fig. 20 a) and – using the Option boiler. The standard telescopic flue is a twisting action – ensure the correct seal is suitable for a wall thickness of 200mm – 425mm.
  • Page 42: Table Of Contents

    Contents Design principles and operating sequence Page Servicing instructions Page general principle components routine annual servicing central heating mode replacement of components hot water mode de-scaling heat exchanger safety devices component removal procedure frost protection pump head removal safety valve automatic air release valve Technical data Page...
  • Page 43 Vokèra Ltd. Web. www.vokera.co.uk Southern Region. Morson Road, Enfield, Middlesex EN3 4NQ. Sales. 020 8216 6300. Fax. 020 8805 6320. Parts. 020 8216 6310. Technical Helpline. 020 8216 6320. Customer Services. 0870 333 0220. Email. enfield.spares@vokera.co.uk Northern Region. Stubs Beck Lane, West 26 Business Park, Whitehall Road, Cleckheaton, West Yorkshire BD19 4TT. Sales. 01274 866100.
  • Page 44 Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER...

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