Home

Installation & Servicing Manual

1. Energy Efficiency Checklist completed Yes No Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number CORGI ID Number CORGI ID Number Comments Comments Signature Signature SERVICE 3 Date SERVICE 4 Date Energy Efficiency Checklist completed Yes No Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number CORGI ID Number CORGI ID Number Comments Comments Signature Signature SERVICE5 Date SERVICE6 Date Energy Efficiency Checklist completed Yes No Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number CORGI ID Number CORGI ID Number Comments Comments Signature Signature SERVICE7 Date SERVICE8 Date Energy Efficiency Checklist completed Yes No Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number CORGI ID Number CORGI ID Number Comments Comments Signature Signature SERVICE9 Date SERVICE 10 Date Energy Efficiency Checklist completed Yes No Energy Efficiency Checklist completed Yes No
2. A system shut off taps kit B 3 way valve kit for storage tank C hydraulic separator kit 15 1 Heat generator 2 Expansion tank connection 3 Heating valve 4 Not return valve 5 3 way valve 6 Storage tank delivery T connection point 7 Hydraulic separator 8 Gas valve kit A kit A kit B kit B kit C mh 225 165 Go 46 417 72 5 763 215 152 135 502 1265 126 5 16 STANDARD HEATING DHW SYSTEM OMDNOORWN A DD Programmer pv TA EE EE AE N EE EE eek lacey Standard CH system DHW system Boiler Expansion tank System filter System valve System pum
3. Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number CORGI ID Number CORGI ID Number Comments Comments Signature Signature Vokera heating for life RANGE RATED EN 483 The max CH input of this boiler has been adjusted to equivalent to rpm max CH fan speed Date _ Signature Boiler serial number kW Registered address Vok ra Ltd Borderlake House Unit 7 Riverside Industrial Estate London Colney Herts AL2 1HG enquiries vokera co uk www vokera co uk www vokera ie Sales General Enquires T 0844 391 0999 F 0844 391 0998 Vok ra Ireland West Court Callan Co Kilkenny T 056 7755057 F 056 7755060 Vok ra Limited reserve the right to change specification without prior notice Consumers statutory rights are not affected A Riello Group Company Company Reg No 1047779 Cod 20040022 09 11 Ed 1
4. OO Boiler at OFF standby Select this position when you want the boiler to be switched off for short periods days or if the boiler reduires to be reset correct pressure Pressure gauge shows the current pressure of your heating system the gauge should be set between 1 5 and 2 0 BAR When the appliance is operating the gauge may rise or fall slightly this is quite normal The minimum permissible level for the safe and efficient operation of the appliance is 0 5 BAR Should the pressure fall below 0 5 BAR the boiler may lockout value 2 GETTING STARTED 2 1 BEFORE SWITCHING ON Before switching the appliance on please familiarise yourself with how to isolate the appliance from the gas water and elec tricity supplies how to check and top up if necessary the system water pressure the time clock or programmer if fitted any external thermostats and their functions the appliance controls 2 2 APPLIANCE CONTROLS see fig 1 The appliance controls are situated on the lower front of the appliance The appliance controls include pressure gauge appliance mode selector temperature selector display burner ON mode green fault indicator red servicing mode indicator yellow optional integral time clock programmer if fitted NOTE The appliance frost protection is active in a
5. 20 15 10 5 0 5 410 15 20 EXTERNAL TEMPERATURE C Parallel night reduction T T DAY temperature curve NIGHT temperature curye oS LU a E lt LU Q LU gt LU gt W ja 15 10 5 0 5 10 EXTERNAL TEMPERATURE C 7 4 CHECKING ADJUSTING THE APPLIANCE FAN SPEEDS The boiler has already been set during fabrication by the manufacturer However if it is necessary to set it again after extraordinary maintenance work for example after replacing the gas valve or after switching from natural gas to LPG follow the procedures described below The maximum and minimum power the maximum heating and slow ignition setting must strictly be done in the sequence indicated and only by qualified personnel Disconnect the power supply to the boiler Turn the heating water temperature selector to the maximum value that is the selector turned to the 10 Then lift and rotate the control panel towards you Remove the board cover by releasing the fixing hooks Insert jumpers JP1 and JP3 fig 41 Put the power to the boiler on The three LEDs on the control panel flash simultaneously and the display reads ADJ for about 4 sec Proceed to modify the following parameters 1 Absolute maximum 2 Minimum 3 Maximum heating 4 Slow ignition as described below Turn the heating water temperature selector to set the va
6. Height mm 858 with hydraulic cover Width mm 553 Depth mm 284 Dry weight kg 39 2 4 Clearances Sides 100 mm Top see section 4 Bottom see section 4 Front 600 mm 2 5 Connections Flow amp return 1 mm Gas 22 mm Safety valve 15 mm Condense 21 mm 2 6 Electrical Power consumption Watts 164W Supply V Hz 230 50 Internal fuse 3 15A T for PCB 3 15A F for connections block External fuse 3A 2 7 Flue Details concentric 60 100 Maximum horizontal flue length 60 100mm 1 8m Maximum vertical flue length 60 100mm 2 8m 2 8 Flue Details concentric 80 125 Maximum horizontal flue length 80 125mm 4 8m Maximum vertical flue length 80 125mm 7 0m 2 9 Flue Details twin pipes Maximum horizontal flue length 80mm 80mm 20m 20m Maximum vertical flue length 8 0mm 80mm 20m 20m 2 10 Efficiency SEDBUK 90 08 2 11 Emissions CO maximum output 9 0 CO minimum output 9 5 CO maximum output ppm 200 CO minimum output ppm 20 NOx maximum output ppm 30 NOx minimum output ppm 25 NOx rating class 5 Ref Condition 15 C 1013 25 mbar dry gas NOTE L PG data refer to section 10 The system should be so designed and balanced to ensure a minimum and maximum temperature differential of 10 C and 20 C respectively when the appliance is operating at maximum output 2 12 PUMP DUTY Fig 6 shows the flow rate available after allowing for pressure loss through the appliance
7. E BE g a lt ERR Gil 2 PORT VALVE 2 PORT VALVE Fig 46 32 2 2 Q 2 gt 5 2 c 2 2 c 8 ET lt l i z lt x lt Q l lt o 2 LL 1 VGL E asna Ld OPA ve sowy 10SUas su puoo 6 WOOI IOSUSS JEu1e1sa way uado JO duis Jeuiuus OW Josues owej4 L S4 apoujoaje eds JFS UOHNA uoloun ZOD MS Jawuojsues UONIUB ZOSL OPA pz Jejsouuauyi WOOY SNO S10108UU02 SLNO LNO Jejsouuaui Buneau soojepun Jo duls jeuiuua ZIN 1no sool 4eliod pau pe 1e1ISOUMSUI yeay 18A0 MOJA L HO 4 NO uonoun ZOO molle z pe Josues n j S4 dois Aie1oduia Jo snyeys Bupuom uaalb L paT qa D N Jojsiuuayi MOIH 14 pesol2 8dr 91N Jo siwueu uny sy Wejs s Bune u eimeiadwe 100 Japun piepuejs Builgeua Zaf 1e1souu u 1ejlod 10 dus eu uu L VZIN pajpauuoo 1osuas jewame YM Ajuo ASNoNURUOS yams ainssauid ete MA SdM dwnd pue uopoun uolyesuadwoo awn jyBiu Builqeug 9dr Joyou Aem ME pasop Buryeey Ajuo Hulyesedo uono s Gd Jo10u em JO duis peua L YEN p snun bdr jou4juoo jeubis ues Nd udeiBered Buysnfpe pue Bumes aes Bumes edf A 0 z lddns 1amod uey AH d Jawn Bune u Bumesey dr Splougjos aAleA seg do pete1 aBuey qouy Bumes 1u04 Buiiqeug Ldr 10198UU09 alge 9 p snun vd aunsseid eljuaiajjid da anno uone n6 1i ainyesaduu9 ajas o 1ajawonuajod d dwnd d pesnun Zd Jamod Bly uono uuo2 e999 10 diuis uier N Je aworusjod Buneey pue VONMS J10 99
8. LED STATUS combustion analysis mode press once burner running at maximum heating yellow led blinking gas valve maximun setting press twice burner running at maximum absolute yellow led blinking red led fixed gas valve minimum setting press three time burner running at minimum yellow led blinking green led fixed NOTE 1 Any additional pressing of CO button after the third time the burner switched between maximum DHW and minimum 2 To restart the CO function it is necessary to pass throught the 4 position with the main selector switch 34 IMPORTANT A GAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED REPLACED OR DISTURBED ATTENTION Gas type and appliance output must be set according to the specific appliance specification Vok ra accepts no responsibility if the gas type and or appliance output is not correctly adjusted according to the respective appliance specification as detailed on the appliance data badge 10 7 ADJUSTING THE APPLIANCE FAN SPEEDS The maximum and minimum power the maximum heating and slow ignition setting must strictly be done in the sequence indicated and only by qualified personnel Disconnect the power supply to the boiler Turn the heating water temperature selector to the maximum value that is the selector turned to the 10 Then lift and rotate the control panel towards you Remove the board cover b
9. for system requirements When using this graph apply only the pressure loss of the system The graph is based on a 20 C temperature differential Residual head x 100 mbar i sn EE ee ae Ede AE ERTA HARA EAE is Eq Mad bad N simus susu Es ad ea Se Ed sm siwis aes l L eed LAER AA ee Ee 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 Fig 5 Flow rate I h Fig 6 E T lS d L GE T Lv w p ha i t nd i lt L f lp gt e 1 L j u 6 TA i Key Location Minimum distance A Below an opening window air brick etc 300 mm B Above an opening window air brick etc 300 mm C To the side of an opening window air brick etc 300 mm D Below gutter drain pipe etc 25 mm E Below eaves 25 mm F Below balcony car port roof etc 25 mm G To the side of a soil drain pipe etc 25 mm 60mm for 80 125 5 flue H From internal external corner 25 mm 60mm for 80 125 5 flue l 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 building 1200 mm M Vertically from a terminal on the same wall 1500 mm N Horizontally from a terminal on the same wall 300 mm P From a structure to the side of the vertical terminal 300 mm Q From the top of the vertical terminal to the roof flashin
10. 4 5 FITTING THE FLUE The top flue outlet permits both horizontal and vertical flue applications to be considered alternatively the Vok ra 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 The appliance can be used with Vok ra condensing 60 100mm concentric flue system using the specific adapter supplied as accessory NOTE These instructions relate only to the Vok ra condensing 60 100mm concentric flue system The appliance flue outlet elbow can be rotated through 360 on its vertical axis In addition the flue may be extended from the outlet elbow in the horizontal plane A reduction must also be made to the maximum length see table below when additional bends are used Reduction for additional bends Bend Reduction in maximum flue length for each bend 45 bend 0 5 metre 90 bend 1 0 metre Horizontal flue terminals and accessories Part No Description Length 20028027 convertor box N A 29450120 Horizontal flue kit 900mm 29450121 Telescopic flue kit 350 530mm 487 Plume diverter 45 N A 29450123 90 degree bend N A 29450124 45 degree bends pair N A 12 29450125 500mm extension 500mm 29450126 1000mm extension 1000mm 29450128 Telescopic extension 350 730mm 529 Wall bracket pack 5 208mm Mar
11. Remove the retaining nut S for condense sensor T an dremove 22 Fig 31 Fig 32 Fig 33 6 14 FLUE FAN fig 34 Carry out component removal procedure as described in 6 4 Disconnectthe ancillary wiring from their respective connectors Remove the retaining screws U to disconnect mixer Remove the retaining screws V and remove fan Replace in the reverse order 6 15 MIXER fig 35 Carry out component removal procedure as described in 6 4 Disconnect jubilee clip W and remove flexible air duct Disconnect gas pipe from mixer remove the retaining screws X and remove mixer Replace in the reverse order WARNING A GAS TIGHTNESS CHECK MUST BE CARRIED OUT 6 16 BURNER fig 36 Carry out component removal procedure as described in 6 4 Disconnect jubilee clip and disconnect flexible air duct Disconnect gas pipe from mixer disconnect the electrode as described in 6 13 Remove the retaining nuts and gently ease the fan assembly out of its location Once the assembly has been removed the burner can be withdrawn from the heat engine Ensure the seal is in good condition taking care to ensure it is replaced correctly Replace in the reverse order 6 17 MAIN HEAT EXCHANGER fig 37 Carry out component removal procedure as described in 6 4 Disconnect all the wiring connections Disconnect the gas pipe at the air mixer connection Disconnect the f
12. 1 PIPEWORK It is recommended that copper tubing be used in conjunction with soldered capillary joints Where possible pipes should have a gradient to ensure 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 attention should be paid to pipes passing through ventilated areas such as under floors loft space and void areas 3A 6 2 HYDRAULIC SEPARATOR Vokera advise that the appliance should be combined with a hydraulic separator 20028475 to supply the heating system to ensure the correct flow rate through the boiler at all times see fig 19 3A 6 3 DRAIN COCKS These must be located in accessible positions to facilitate draining of the appliance and all water pipes connected to the appliance 3A 6 4 AIR RELEASE POINTS These must be positioned at the highest points in the system where air is likely to be trapped They should be used to expel trapped air and allow complete filling of the system 3A 6 5 EXPANSION VESSEL WARNING the boiler is not fitted with an expansion tank so you must install a closed tank on the system to ensure the correct appliance functions The dimensions of the expansion tank must be suitable for the heating system characteristics and the tank capacity must meet the requisites of the current regulations 3A 6 6 FILL
13. 3A 8 Mounting on a combustible surface 11 3A 9 Timber framed buildings 11 RANGE RATED 3 18 Inhibitors 1 This boiler can be adapted to the plants thermal needs 3A 12 Declaration of conformity T1 In fact the maximum flow rate can be set for the boiler operating in heating mode See the Settings chapter Installation Page for how to set it as ee Once the required maximum heating power is set 13 Unpackin 9 3 indicate the value on the self adhesive label provided 4 4 _ Preparation for mounting the appliance 1D For subsequent checks and adjustments see the value 4 5 Fitting the flue 12 set 4 6 Connecting the gas amp water 15 4 7 Electrical connections 16 USERS INSTRUCTIONS INTRODUCTION Dear Customer Your Vok ra Verve boiler has been designed to meet and exceed the very latest standards in gas central heating technology and if cared for will give years of reliable use and efficiency Please therefore take some time to read these instructions carefully Do s and Don t s Do ensure that the system pressure is periodically checked Do ensure that the boiler should not be used by children or unassisted disabled people Do ensure that you know how to isolate the appliance in an emergency Do ensure that you are familiar with the appliance controls Do ensure that your installer has completed the appliance log book section Do not attempt to remove the appliance casing or gain internal access
14. 8S ld 3 VSL St leuiepag 3 8Od ule DIV sels Eels da gpD01 99 9 o leds e E SdM I GYS Ja 1VISOWNHIHL INO df 2a a Pat Gar Gat GINO 831108 eag B E 8 Osea 8N2 1VISOINH3HL HOSN3S MISINI NOOY WNADA G 1 ONLLWH F410 WNIGAW SIA HOOT4HAANN 00000 33 SECTION 10 LPG INSTRUCTIONS 10 1 RELATED DOCUMENTS BS 5440 PARTS 1 amp 2 FLUES amp VENTILATION REQUIREMENTS BS 5449 PART 1 FORCED CIRCULATION OF HOT WATER SYSTEMS BS 5482 PART 1 DOMESTIC BUTANE amp PROPANE GAS BURNERS IN PERMAMENT DWELLINGS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 6798 INSTALLATION OF BOILERS OF RATED NOT EXCEEDING 60kW 10 2 TECHNICAL DATA Gas Pressures Verve Inlet pressure 37 0 mbar Heating maximum gas rate 3 65 kg hr Minimum gas rate 0 93 kg hr Injector size 5 7 mm Efficiency SEDBUK 91 5 Band A Emissions CO max 220 ppm CO min 40 ppm NOx max 30 ppm NOx min 30 ppm CO max 10 0 CO min 10 0 10 3 CONVERTING THE APPLIANCE GAS TYPE To convert the appliance to another gas type it is necessary to change the injector and adjust the gas valve CO e To change the injector see 6 12 1 e To adjust the fan speen see 10 7 e To adjust CO2 values see 10 6 10 4 GAS SUPPLY The gas supply must be connected to the appliance by a competent LPG installer and must be of suffici
15. COMBUSTIBLE SURFACE If the appliance is to be fitted on a wall of combustible material a sheet of fireproof material must protect the wall 3A 9 TIMBER FRAMED BUILDINGS If the appliance is to be fitted in a timber framed building it should be fitted in accordance with I S 813 and local Building Regulations The Institute of Gas Engineers publication IGE UP 7 Guide for Gas Installations in Timber Frame Buildings gives specific advice on this type of installation 3A 10 INHIBITORS Vok ra recommend that an inhibitor suitable for use with 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 accordance with the manufacturers instructions Water treatment of the complete heating system including the boiler should be carried out in accordance with I S 813 and the Domestic Water Treatment Association s DWTA code of practice 3A 11 SHOWERS If the appliance is intended for use with a shower the shower must be thermostatically controlled and be suitable for use with a combination boiler 3A 12 DECLARATION OF CONFORMITY A Declaration of Conformity as defined in I S 813 must be provided on completion of the installation A copy of the declaration must be given to the responsible person and also to the gas supplier if required 11 SECTION 4 INSTALLATION 4 1 DELIVERY Due to the w
16. Do not hang clothes etc over the appliance Do not forget to have the appliance serviced annually This booklet is an integral part of the appliance It is therefore necessary to ensure that the booklet is handed to the person responsible for the property in which the appliance is located installed A replacement copy can be obtained from Vokera customer services 1 THINGS YOU SHOULD KNOW 1 1 GAS APPLIANCES Gas Safety Installations and Use Regulations UK In the interests of your safety and that of others it is a legal requirement that all gas appliances are installed and correctly maintained by a competent person and in accordance with the latest regulations 1 2 ELECTRICAL SUPPLY Please ensure that this appliance has been properly con nected to the electrical supply by means of a double pole isolator or un switched socket and that the correct size of fuse 3 AMP has been fitted Warning this appliance must be earthed 1 3 GUARANTEE REGISTRATION CARD Please take the time to fill out your guarantee registration card The completed warranty card should be posted within 30 days of installation 1 4 APPLIANCE LOG BOOK UK only A logbook section can be found at the rear of the appliance installation booklet This important document must be completed during the installation commissioning of your boiler All GAS SAFE registered installers carry a GAS SAFE ID card and have a registration number These details should be
17. Final checks 20 2 2 Appliance controls 3 5 13 Instructing the user 20 2 3 Lighting the boiler 3 2 4 Adjusting the heating temperature 3 Servicing Page 2 5 Explanation of features 3 6 1 General 21 2 6 Automatic temperature control 3 6 2 Routine annual servicing 21 6 3 Replacement of components 21 How to Page 6 4 Component removal procedure 21 3 1 How to top up the system pressure 3 6 5 Pump assembly 21 3 2 How to reset the appliance 3 6 6 Safety valve 21 3 3 How to shut down the system for short periods 3 6 7 Lower automatic air release valves 21 3 4 How to shut down the system for long periods 3 6 8 Water pressure switch 21 3 5 How to care for the appliance 3 6 9 Flow thermistor 22 6 10 Return thermistor 22 What if Page 6 11 Printed circuit board 22 4 1 What if T suspect a gas leak 4 6 12 Gas valve 22 4 2 What if have frequently top up the system 4 6 13 Electrodes 22 43 What if the appliance is due its annual service 4 6 14 Flue fan 23 4 4 What if I need to call an engineer 4 6 15 Mixer 23 6 16 Burner 23 Installation and Servicing instructions 6 17 Main heat exchanger 23 Design principles amp operating sequence Page 6 20 Condense trap removal 24 1 1 Principle components 6 6 21 Flue collector removal 24 1 2 Mode of operation at rest 6 I 1 3 Mode of operation heating 6 Checks adjustments and fault finding Page 1 4 Safety devices 6 7 1 Checking appliance operation 25 7 2 Appliance modes of operation 25 Technical data Page 7 3 Setting
18. SWITCH HEATING TEMPERATURE SELECTOR Mode selector switch HYDROMETRE DISPLAY DEO ss cc S L LI a W 2 P DISPLAY Description of the icons Li System loading this icon is visualised together with a fault code A 04 Y Heat adjustment indicates the connection to an external probe x Flame failure this icon is visualised together with a fault code A 01 A Irregularity indicates any operating irregularities together with a fault code Ill Heating operation Domestic hot water operation optional g Anti freeze indicates that the anti freeze cycle has been activated 55 Heating domestic hot water temperature or fault code Heating temperature selector move the selector clockwise to increase the heating outlet temperature or counter clockwise to reduce the temperature range 40 C 80 C for standard systems 20 C 45 C for floor heating heating contact Vokera technical if used in conjunction with DHW cylinder The automatic temperature control function SARA is set within position 4 and 6 55 65 C the display indicates the heating water temperature Heating amp hot water Select this position when you want the boiler to respond to a heating request from the time clock programmer and hot water request from the tank thermostat way valve kit Hot water only only used in conjunction with the optional 3
19. a further 4 times then go to lockout When the set point has been reached the position of the heating temperature selector as measured at the primary thermistor the appliance will begin the modulation phase whereby the fan and gas valve will continuously modulate to maintain the set point ATTENTION Gas type and appliance output must be set according to the specific appliance specification Vok ra accepts no responsibility if the gas type is not correctly adjusted according to the respective appliance specification as detailed on the appliance data badge 25 7 3 SETTING THE THERMOREGULATION Contact Vokera technical for advice if Vokera DHW 3 way valve kit is not being used Heat regulation only works with the external sensor connected and so once installed connect the external sensor to the relevant connections provided on the terminal board in the boiler This enables the HEAT REGULATION function Choosing the compensation curve The heating compensation curve provides for maintaining a theoretical ambient temperature of 20 C for outside temperatures of between 20 C and 20 C The choice of the curve depends on the minimum outside design temperature and therefore the geographical location and the design delivery temperature and therefore the type of plant and is to be calculated carefully by the installer using the following formula KT T design delivery Tshift 20 T min external design Tshift 30 C
20. although particular attention is drawn to the requirements of the current ETCI National Rules for Electrical Installations and I S 813 Annex K When an appliance is installed in a room or internal space containing a bath or shower the appliance or any control pertaining to it must not be within reach of a person using the bath or shower The location chosen for the appliance must permit the provision of a safe and satisfactory flue and termination The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the appliance Where the installation of the appliance will be in an unusual location special procedures may be necessary refer to l S 813 for detailed guidance on this aspect Acompartment used to enclose the appliance must be designed 10 and constructed specifically for this purpose An existing compartment cupboard may be utilised provided that it is modified to suit This appliance is not suitable for external installation 3A 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 I S 813 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
21. be fitted centrally over the terminal Refer to BS 5440 Part 1 when the terminal is 0 5 metres or less below plastic guttering or 1 metre or less below painted eaves 3 5 AIR SUPPLY The following notes are intended for general guidance only This appliance is a room sealed fan flued boiler consequently it does not require a permanent air vent for combustion air supply When installed in a cupboard or compartment ventilation for cooling purposes is also not required 3 6 WATER CIRCULATION Detailed recommendations are given in BS 5449 Part 1 and BS 6798 The following notes are for general guidance only 3 6 1 PIPEWORK It is recommended that copper tubing to BS 2871 Part 1 is used in conjunction with soldered capillary joints Where possible pipes should have a gradient to ensure air is carried naturally to air release points and that water flows naturally to drain BS 5440 PART 1 FLUES BS 5440 PART 2 FLUES amp VENTILATION BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW BS 6891 LOW PRESSURE INSTALLATION PIPES BS 7074 PART 1 APPLICATION SELECTION AND INSTALLTION OF EXPANSION VESSELS AND ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS installation of the appliance in a room or internal space containing a bath or shower When an appliance is installed
22. finding section will assist in determining which component is malfunctioning 6 4 COMPONENT REMOVAL PROCEDURE To remove a component access to the interior of the appliance is essential Isolate the appliance from the electrical supply and remove the fuse And when necessary close all service valves on the appliance remove the appliance casing as described in section 4 7 1 and drain the water content from the appliance via the drain valve Ensure some water absorbent cloths are available to catch any residual water that may drip from the appliance or removed component Un dertake a complete commissioning check as detailed in section 5 after replacing any component ALWAYS TEST FOR GAS TIGHTNESS IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED OR DISTURBED 6 5 PUMP ASSEMBLY fig 27 Carry out component removal procedure as described in 6 4 Slacken and unscrew pump inlet and outlet connectors Please note the sealing washers must be discarded and replaced with new sealing washers The pump assembly can now be removed from the appliance Replace carefully in the reverse order Fig 27 6 6 SAFETY VALVE fig 28 Carry out component removal procedure as described in 6 4 Disconnect the outlet pipe A from the safety valve remove safety valve locking pin B from the hydraulic manifold Replace in the reverse order Fig 28 tig Ds AUTOMATI
23. heat the appliance will operate in hot water mode The external 3 way valve switches on tank circuit the pump and fan will be activated via the flow temperature sensor When the fan is sensed to be operating correctly tacho signal the ignition sequence commences Ignition is sensed by the electronic circuit to ensure flame stability at the burner Once successful ignition has been achieved The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow temperature sensor of the boiler consequently a high temperature at the flow sensor results in a lower fan speed As the water temperature increases the temperature sensors located on the flow pipe of the boiler reduce the fan speed via the electronic circuitry Depending on the load either the water temperature will continue to rise until the set point 80 C is achieved or the water temperature will fall whereby fan speed will increase relative to the output required When the boiler has reached the set point hysterisis the burner will switch off When the temperature of the flow sensor falls below the set point hysterisis the burner will re light When the hot water reaches the desired temperature tank thermostat opened the burner will shut down the pump is off and 3 way valve switches on heating circuit NOTE If the spark sensing electrode does not sense ignition the appliance will re attempt ignition
24. if switched off and operate the burner and or pump should the temperature drop below 5 C for the main In particular the burner will be in ON status until the main temperature reaches 35 C for CH appliance Please note that the frost protection system is designed to protect the appliance only should frost protection be required for the heating system additional controls may be required NOTE The frost protection system is reliant on the appliance having a permanent electrical supply and being in a non fault condition 1 9 APPLIANCE STATUS INDICATORS Your boiler is equipped with 3 status LED indicators the Green LED indicates that the flame is present the Red LED indicates the appliance has detected a fault whilst the Yellow LED indicates that there is Servicing operation in progress and with a display that indicates the operating temperature and the fault codes Fig 1 GREEN LED RED LED YELLOW LED MODE SELECTOR SWITCH HEATING TEMPERATURE SELECTOR DISPLAY BOILER STATUS LED Green LED Boiler is working responding to a heating hot water reguest Red LED Boiler has identified a fault and has failed safe Refer to instructions on how to reset Yellow LED Service operation DISPLAY Indicates the operating temperature and the fault codes PRESSURE GAUGE Ensure the system pressure is set correctly minimum 0 5 bar MODE SELECTOR
25. in strict accordance with the manufacturers instructions Water treatment of the complete heating system including the boiler should be carried out in accordance with BS 7593 and the Domestic Water Treatment Association s DWTA code of practice 3 11 SHOWERS If the appliance is intended for use with a shower the shower must be thermostatically controlled and be suitable for use with a combination boiler control valve A control emporary valve connection f f double A flow return AV pipe check valve supply Fig 7 pipe Make up vessel or tank i Automatic 5 air vent P lt gt lt Non return Stopcock 2 valve E fe 0 SS mm Heating f return Fig 8 SECTION 3A GENERAL REQUIREMENTS EIRE This appliance must be installed by a competent person in accordance with and defined by the Standard Specification Domestic Gas Installations Declaration I S 813 3A 1 RELATED DOCUMENTS The installation of this boiler must be in accordance with the relevant requirements of the local building regulations the current ETCI National Rules for Electrical Installations and the bylaws of the local water undertaking It should be in accordance also with any relevant requirements of the local and or district authority 3A 2 LOCATION OF APPLIANCE The appliance may be installed in any room or internal space
26. in strict accordance with these instructions GUIDANCE NOTES ON TWIN FLUE INSTALLATION e The flue must have a have a minimum 1 maximum 3 1 17mm per 1000mm fall back to the appliance to allow any condensate that may form in the flue system to drain via the condensate drain Consideration must also be given to the factthat there is the possibility of a small amount of condensate dripping from the terminal e Ensure that the entire flue system is adequately supported use at least one bracket for each extension e The entire flue system must be adequately insulated to maintain heat within the flue system thereby reducing the possibility of condensate production e As the exhaust outlet pipe can reach very high temperatures it must be protected to prevent persons touching the hot 73 surface DA EE E 1 lt J Fig 15 14 e The condensate drain pipe must be connected in accordance with building regulations Reduction for bends Bend Reduction in maximum flue length for each bend 45 bend 1 0 metre 90 bend 1 0 metre Twin flue accessories Part No Description Length 0225805 Horizontal flue terminal 1 0 metre 0225810 Vertical flue terminal 1 0 metre 359 Twin adapter kit N A 531 Pitched roof flashing plate N A 532 Flat roof flashing plate N A 022
27. is correct proceed to gas valve minimum setting 10 6 3 However if the CO reading is incorrect the maximum gas pressure must be adjusted as follows e using a 2 5mm Allen key very slowly turn the maximum adjustment screw see fig 42 clockwise to decrease counter clockwise to increase until the correct value is displayed on the CO analyser allow time for the analyser to stabilise 10 6 3 GAS VALVE MINIMUM SETTING Set the CO button at minimum see 10 6 1 once the minimum is obtained yellow led blinking green led fixed check that it corresponds with the appropriate CO value Minimum for the respective appliance If the CO reading is correct proceed to completion 10 6 4 However if the CO reading is incorrect the minimum gas pressure must be adjusted as follows e locate the minimum adjustment screw fig 42 using a suitable screwdriver remove the protection plug e using a 4mm Allen key very slowly turn the minimum adjustment screw see fig 42 clockwise to increase counter clockwise to decrease until the correct value is displayed on the CO analyser allow time for the analyser to stabilise 10 6 4 COMPLETION On completion of the combustion analysis check and or any gas valve adjustment refit the plug L2 fig 40 and move the mode selector to the position Remove the test probe from the test point and refit the sealing screw s and or cap CO FUNCTIONS ACTION ON THE BUTTON
28. is illuminated the appliance will require to be reset manually Before resetting the boiler check what action is required to be taken using the information on the fault code table below Allow a period of two minutes to elapse before rotate the mode selector knob across the OO position see fig 1 IMPORTANT If the appliance reduires to be reset freguently it may be indicative of a fault please contact your installer or Vok ra Customer Services for further advice 2 3 LIGHTING THE BOILER Ensurethe gas and electrical supply to the boiler are turned on Turn the mode selector switch to the ON position After being powered the boiler begins an automatic vent cycle lasting approximately 2 minutes During this phase the display shows the icons To interrupt the automatic vent cycle proceed as follows access the electronic board by removing the casing turning the control panel towards you and opening the board cover push the SW1 CO button fig 40 When there is a request for heating or hot water the boiler will begin an ignition sequence When the appliance reaches the target temperature the burner will go off for a minimum period of approximately 3 minutes When the programmer time clock or external thermostats request has been satisfied the appliance will switch off automatically 2 4 ADJUSTING THE HEATING TEMPERATURE Rotate the temperature selector clockwise to increase counter clockwise
29. recorded in the Benchmark logbook section within the installation booklet You can check your installers details by calling GAS SAFE direct on 08004085500 Failure to install and commission the appliance in accordance with the manufacturers instructions may invalidate the warranty This does not affect your statutory rights 1 5 HOW DOES IT WORK Your Verve boiler supplies heated water to your radiators and hot water to your hot water tank The central heating is controlled via a time clock and any thermostats that your installer may have fitted The boiler will light when it receives a request from the time clock via any thermostat that may be installed Your Verve boiler lights electronically and does not have a pilot light In the unlikely event of a fault developing with your boiler the supply of gas to the burner will be terminated automatically For the installation it is recommended to use an hydraulic separator to supply the heating fig 20 in case of hot water use a three way valve to supply the tank fig 20 1 6 DIMENSIONS Verve HEIGHT 858mm WIDTH 553mm DEPTH 284 mm with hydraulic cover 1 7 CLEARANCES REQUIRED ABOVE see section 4 BELOW see section 4 LEFT SIDE 100mm RIGHT SIDE 100 mm FRONT 600 mm 1 8 FROST PROTECTION SYSTEM The Verve is equipped with a built in frost protection system this enables the boiler to over ride the time controls even
30. standard plants 25 C floor standing plants If the calculation gives an intermediate value between two curves we recommend choosing the compensation curve closest to the value obtained Example If the calculation produces a value of 1 3 this lies between the 1 and 1 5 curves In this case choose the closest curve that is 1 5 The KT selection must be done using trimmer P3 on the board see multi line wiring diagram To access P3 Remove the casing Turn the control panel towards you Unhook the board cover Live electrical parts 230 Vac The KT values that can be set are as follows standard plant 1 0 1 5 2 0 2 5 3 0 floor standing plant 0 2 0 4 0 6 0 8 and these will be shown on the display for about 3 seconds after trimmer P3 is turned TYPE OF HEAT REQUEST If the boiler has an ambient thermostat connected to it JUMPER 6 not inserted The heat request is made by the ambient thermostat s contact closing and when the contact opens it switches it off The delivery temperature is calculated automatically however the user can interact with the boiler When the interface is used to change HEATING the value of the HEATING SET POINT will not be available but a value that can be set as you wish between 5 and 5 C Changing this value does not change the delivery temperature directly but acts in the calculation that determines the value automatically changing the reference temperature in the system 0 20 C I
31. system of service valves to cennect an hydraulic separator on flow and return joints 4 6 3 SAFETY VALVE fig 18 A Connect a discharge pipe to the other end of the safety valve connection pipe 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 possibly boiling discharges safely without causing damage or injury but is still visible 4 6 4 CONDENSE PIPE During normal operation the boiler produces condense which is collected in a trap located in the lower part of the boiler A flexible pipe condense outlet pipe is connected to the outlet of the trap The flexible pipe must be connected to a plastic waste pipe only The plastic waste pipe must have a minimum of a 3 fall towards the drain Any external run of pipe should be insulated to prevent the risk of freezing 4 6 5 CONNECTING THE CONDENSATE OUTLET Gently pull the condense outlet pipe down from its location inside the boiler until approximately 100mm protrudes from the underside of the boiler Connect a suitable plastic not copper pipe no less than 20mm diameter to the outlet pipe and ensure it discharges in accordance with building regulations or other rules in force Fig 17 Fig 19
32. terminal fits over the flashing Push fit the twin flue pipes onto the concentric to twin converter ensuring that the exhaust pipe connects to the exhaust connection on the concentric to twin converter If necessary cut the plain ends male of the twin flue pipes to allow connection to the concentric to twin converter NOTE e Before cutting twin flue pipes ensure allowances have been made for connection onto the previous piece and onto the concentric to twin converter The last twin flue pipes must be pushed 50mm onto the male spigots of the concentric to twin converter e You must ensure that the entire flue system is properly supported and connected e Ensure that any horizontal sections of pipe have a 1 fall towards the appliance 17mm per 1000mm 4 6 CONNECTING THE GAS AND WATER The appliance is supplied with an accessory pack that includes service valves The accessory pack contains sealing washers etc for use with the service valves NOTE It will be necessary to hold the valve with one spanner whilst tightening with another besides where necessary use a seal fittings to ensure the sealing of the system fig 18 4 6 1 GAS fig 18 The appliance is supplied with a 22mm service valve and a pipe for welding NOTE It will be necessary to calculate the diameter of the gas supply pipe to ensure the appliance has an adequate supply of gas 4 6 2 FLOW amp RETURN fig 18 The appliance is supplied with a
33. the thermoregulation 26 2 1 Central heating 7 7 4 Checking adjusting the appliance fan speed 27 2 2 Gas pressures 7 7 5 Checking the CO amp adjusting the valve 27 53 Dimensions 7 7 6 Range rated 28 24 Clearances 7 7 7 Combustion analysis test 29 25 Connections 7 7 8 External faults 30 3 6 Electrical 7 7 9 Electrical checks 30 2 7 Flue details concentric 60 100 7 7 10 Component values amp characteristics 30 2 8 Flue details concentric 80 125 7 7 11 Appliance status led and fault codes 31 2 9 Flue details twin pipes 7 7 12 Boiler configuration 31 2 10 Efficiency 7 211 Emissions 7 Wiring diagrams Page 2 12 Pump duty 8 8 1 External wiring 26 82 Typical control applications 26 General requirements UK Page 8 3 Other devices 26 3 1 Related documents g 3 2 Location of appliance 9 L P G instructions Page 3 3 Gas supply 9 10 1 Related documents 33 eee 2 10 2 Technical data 33 36 Water circulation 9 10 3 Converting the appliance gas type 33 3 7 Electrical supply 10 10 4 Gas supply 33 3 8 Mounting on a combustible surface 10 10 5 Gas supply installation 33 3 9 Timber framed buildings 10 10 6 Checking the CO and adjusting the gas valve 33 3 10 Inhibitors 10 10 7 Adjusting the appliance fan speeds 34 3 11 Showers 10 General requirements EIRE Page Benchmark 98 94 3A 1 Related documents TO 3A 2 Location of appliance 10 3A 3 Gas supply 10 3A 4 Flue system 10 3A 5 Air supply 11 3A 6 Water circulation TT 3A 7 Electrical supply TI
34. to decrease to the desired temperature setting Depending on the type of the system it is possible to pre select the suitable temperature range standard systems 40 80 C floor systems 20 45 C For further details consult the Boiler configuration section 7 12 2 5 EXPLANATION OF FEATURES Although the Vok ra Verve has been designed for simplicity of use it utilises the latest in boiler technology enabling a host of functions to be carried out simultaneously 2 6 AUTOMATIC TEMPERATURE CONTROL The automatic temperature control function SARA permits the boiler when the heating temperature selector is set within 4 and 6 sector to automatically adjust raise the heating The activation and the disable of the function is visualized by blinking the green led 3 3 HOW TO SHUT DOWN THE SYSTEM FOR SHORT PERIODS The system and boiler can be shut down for short periods by simply turning the time clock to the off position It is also advisable to turn off the main water supply to the house 3 4 HOW TO SHUT DOWN THE SYSTEM FOR LONG PERIODS If the house is to be left unoccupied for any length of time especially during the winter the system should be thoroughly drained of all water The gas water and electricity supply to the house should also be turned off For more detailed advice contact your installer 3 5 HOW TO CARE FOR THE APPLIANCE To clean the outer casing use only a clean damp cloth Do not u
35. 40 W 30 20 10 0 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 Nominal input kW HTG curve heating Qn 6000 5600 5200 4800 I 4400 E 4000 _ c 3600 D 3200 2800 2400 2000 1600 1200 t T T T t T T T T T 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 Nominal input kW REPLACED OR DISTURBED 7 7 COMBUSTION ANALYSIS TEST A combustion analysis check can easily be carried out on the appliance via the test points located on the top ofthe appliance see 7 5 e Insert the flue gas analyser probe into the flue gas test point pos 11 fig 3 e Operate the boiler in combustion analysis mode see 7 5 1 and compare the values with those shown in section 2 Nat Gas or section 10 LPG If different adjust the gas valve according to 7 5 1 7 5 2 amp 7 5 3 29 7 10 COMPONENT VALUES amp 7 8 EXTERNAL FAULTS CHARACTERISTICS Before carrying out any faultfinding or component replacement ensure the faultis not attributable to any aspectofthe installation COMPONENT VALUE 7 8 1 INSTALLATION FAULTS Fan 230Vac Symptom Possible cause Pump 230Vac No led ignition Check wiring check electrical inelo Vee 9 g supply 9 Gas valve j 230Vac No hot water Check pipe work Room thermostat connection 24Vdc ermistor dry contact 10Kohm Ne heating Cheek externa
36. 5815 Condensate drain kit N A 0225820 0 25m extension pair 250mm 0225825 0 5m extension pair 500mm 0225830 1 0m extension pair 1000mm 0225835 2 0m extension pair 2000mm 0225840 45 bend pair N A 0225845 90 bend pair N A 0225850 Twin bracket 5 N A 0225855 Single bracket 5 N A MOUNTING THE BOILER The fixing holes for the wall mounting bracket should now be drilled and plugged an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely Once the bracket has been secured to the wall mount the appliance onto the bracket The twin flue pipes extensions and accessories can 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 HORIZONTAL TERMINATION fig 16 The twin flue system must be converted to the dedicated concentric flue kit for termination e The horizontal terminal is supplied with a built in converter box and cannot be shortened e A 130mm hole is required for the passage of the concentric terminal through the wall e The air inlet pipe must always be level with or below that of the exhaust pipe Depending on site conditions it may be preferable to install the terminal assembly prior to fitting the twin flue pipes Mark and drill a level 130mm hole for the passage of the horizontal flue terminal Insert the terminal assembly into the flue hole Pu
37. 7 CHECKS ADJUSTMENTS AND FAULT FINDING 7 1 CHECKING APPLIANCE OPERATION When carrying out any repairs or servicing to the appliance the relevant commissioning procedure must be undertaken to ensure the continued safe operation of the appliance Particular attention should be made to ensure gas tightness water tightness and the electrical integrity of the appliance 7 2 APPLIANCE MODES OF OPERATION NOTE There must be sufficient system water pressure min 0 5 bar to ensure the water pressure switch is activated If there is insufficient system pressure the pump and fan will be prevented from operating and the low pressure fault code will be indicated 7 2 1 SELECTOR SWITCH IN THE OFF RESET POSITION When the selector switch is in the OFF RESET position the following functions are active Active functions e frost protection system e pump anti block 7 2 2 ON BOARD FUNCTIONS e CO FUNCTION the CO function when activated will allow the appliance to run at CH maximum whilst a combustion analysis check or a mechanical gas valve calibration is being carried out Whilst the CO function is active all other functions are disabled minimum power operating period anti cycle set point etc Once enabled the CO function will remain active for a 15 minute period or until the function is manually deactivated e FROST PROTECTION this function is only active when there are no requests for heating or HW If the temperature drops be
38. C AIR RELEASE VALVE ig Carry out component removal procedure as described in 6 4 Remove the AAV locking pin C from the deaerator assembly and remove the AAV assembly D Replace in the reverse order Fig 29 6 8 WATER PRESSURE SWITCH fig 30 Carry out component removal procedure as described in 6 4 Locate and remove the locking pin E from the water pressure switch F Remove the wiring Carefully withdraw the switch Replace in the reverse order Fig 30 21 6 9 FLOW THERMISTOR fig 3 pos 18 Carry out component removal procedure as described in 6 4 Unclip the flow thermistor from the flow outlet pipe Disconnect thermistor electrical plug Replace in the reverse order 6 10 RETURN THERMISTOR fig 3 pos 8 Carry out component removal procedure as described in 6 4 Unclip the return thermistor from the return inlet pipe Disconnect thermistor electrical plug Replace in the reverse order 6 11 PRINTED CIRCUIT BOARD fig 31 Carry out component removal procedure as described in 6 4 Pull the control fascia forward and lower it Push the clips G which secure the PCB cover remove cover after carefully taking note of all wiring connections and jumper tag configu ration Unhook and remove connection block H Disconnect all wiring from the PCB locate and remove the PCB securing screws remove the required PCB Replace in the reverse order ensuring that the posi
39. Connect the supply cable wires LIVE NEUTRAL amp EARTH to their corresponding terminals L N amp E on the appliance high voltage terminal block When connecting the EARTH wire ensure that it s left slightly longer that the others this will prevent strain on the EARTH wire should the cable become taut Do not remove the link wire unless additional external controls are to be fitted see section 8 The securing screw on the cable anchorage should now be tightened This must be done before the terminal block cover is re fitted in its position NOTE It is the installers responsibility to ensure that the appliance is properly Earthed Vok ra Ltd cannot be held responsible for any damages or injuries caused as a result of incorrect Earth wiring 18 SECTION 5 COMMISSIONING 5 1 GAS SUPPLY INSTALLATION Inspect the entire installation including the gas meter test for tightness and purge Refer to BS 6891 I S 813 in ROI for specific instruction 5 2 THE HEATING SYSTEM The appliance contains components that may become damaged or rendered inoperable by oils and or debris that are residual from the installation of the system conseguently it is essential that the system be flushed in accordance with the following instructions 5 3 INITIAL FILLING OF THE SYSTEM Ensure both flow and return service val
40. ING POINT A method for initial filling of the system and replacing water lost during servicing etc is provided see fig 7 You should ensure this method of filling complies with the local water authority regulations 3A 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 8 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 3A 6 8 FREQUENT FILLING Frequent filling or venting of the system may be indicative of a leak Care should be taken during the installation of the appliance to ensure all aspects of the system are capable of withstanding pressures up to at least 3 bar 3A 7 ELECTRICAL SUPPLY The appliance is supplied for operation on 230V 50Hz 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 3 5 mm 3 high voltage category The switch must only supply the appliance and its corresponding controls i e time clock room thermostat etc 3A 8 MOUNTING ON A
41. OPERATING SEGUENCE 1 1 PRINCIPLE COMPONENTS e A fully integrated electronic control board featuring electronic temperature control anti cycle control pump over run self diagnostic fault indicator full air gas modulation e Aluminium heat exchanger e Electronic ignition with flame supervision e Integral high head pump e Fan e Water pressure switch e Flue sensor e Pressure gauge e Safety valve e Differential pressure switch 1 2 MODE OF OPERATION at rest When the appliance is at rest and there are no requests for heating or hot water the following functions are active e frost protection system the frost protection system protects the appliance against the risk of frost damage For CH line if the main temperature falls to 5 C the appliance will function on minimum power until the temperature on main reaches 35 C e anti block function the anti block function enables the pump to be energised for short periods when the appliance has been inactive for more than 24 hours 1 3 MODE OF OPERATION Heating Main heat When there is a request for heat via the time clock and or any ae OON external control the pump and fan are started the fan speed REH I Manualvent will modulate until the correct signal voltage is received at the AWW WW A Ep valve control PCB At this point an ignition sequence is enabled IE AN Ignition is sensed by the electronic circuit to ensure flame ees WW WW WE
42. OR AS THAT OF THE APPLIANCE The supply cable from the isolator to the appli ance must be 3 core flexible sized 0 75mm to BS 6500 or equivalent Wiring to the appliance must be rated for operation in contact with surfaces up to 90 C 4 7 1 CASING REMOVAL To gain internal access to the appliance you must first remove the casing proceed as outlined below e locate and unscrew the 3 screws of the upper cover A fig 22 e locate and unscrew the 3 screws B that secure the outer casing to the appliance fig 23 e lift the casing upward to disengage it from the top locating hooks and then remove fig 24 e store the casing and screws safely until required Re fit in the reverse order e gently lower the control fascia until it rests 4 7 2 APPLIANCE TERMINAL BLOCK The appliance terminal block is located under the shelf Remove the hydraulic cover by loosening the screw A fig 23 Loosen the screw that fixes the electric connection box and than remove the box from its seat Locate the terminal block cover fig 25 NOTE The appliance comes with a factory fitted link TA to allow basic operation of the boiler via the mode selector switch If it is anticipated that external controls will be required please refer to the wiring diagrams in section 8 for more detailed information 4 7 3 CONNECTING THE MAINS 230V INPUT Unhook and remove the terminal block cover 230V Pass the cable through the cable anchorage point
43. Vokera heating for life Verve High efficiency system boiler Users Instructions Installation amp Servicing Instructions C THESE INSTRUCTIONS TO BE RETAINED BY USER THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Users instructions Things you should know Page Commissioning Page 1 1 Gas appliances 1 5 1 Gas supply installation 19 1 2 Electrical supply 1 5 2 The heating system 19 13 Guarantee registration card 1 5 3 Initial filling of the system 19 1 4 Appliance Log Book UK only 1 5 4 Initial flushing of the system 19 1 5 How does it work 1 5 5 Pre operation checks 19 1 6 Dimensions 1 5 6 Initiallighting 19 1 7 Clearances required 1 5 7 Checking gas pressure amp combustion analysis 19 1 8 Frost protection system 1 5 8 Final flushing of the heating system 19 1 9 Appliance status indicators 1 5 9 Setting the boiler operating temperature 19 5 10 Setting the system design pressure 19 Getting started Page 5 11 Regulating the central heating system 20 2 1 Before switching ON 3 5 12
44. afe operation is ensured by e a water pressure switch that monitors system water pressure and will de activate the pump fan and burner should the system water pressure drop below the rated tolerance Fig 4 e fan speed sensor to ensure safe operation of the burner e ahigh limit thermostat that over rides the temperature control circuit to prevent or interrupt the operation of the burner e flame sensor that will shut down the burner when no flame signal is detected e flue sensor e a safety valve which releases excess pressure from the primary circuit e asensor that interrupts the operation of the appliance if the condense pipe becomes blocked e adifferential pressure switch that monitors system water flow and will de achtivate the gas valve SECTION 2 TECHNICAL DATA 2 1 Central Heating VERVE Heat input kW 47 00 Maximum heat output KW 60 80 C 45 78 Mimum heat output KW 60 80 C 9 00 G20 12 00 G31 Maximum heat output kW 30 50 C 49 91 Mimum heat output KW 30 50 C 9 72 G20 12 71 G31 Minimum working pressure 0 5 bar Maximum working pressure 3 5 bar Minimum flow rate 2000 I h 2 2 Gas Pressures Inlet pressure G20 20 0 mbar Heating maximum gas rate m hr 4 97 Minimum gas rate m hr 0 95 Injector size mm 9 2 2 3 Dimensions
45. and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record Gas Rate m3 hr OR ft3 hr Burner Operating Pressure if applicable mbar OR Gas Inlet Pressure mbar Central Heating Flow Temperature C Central Heating Return Temperature C COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes has a water scale reducer been fitted Yes No What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate m3 hr _OR ft hr Burner Operating Pressure at maximum rate mbar OR Gas Inlet Pressure at maximum rate mbar Cold Water Inlet Temperature C Hot water has been checked at all outlets Yes Temperature C Water Flow Rate Vmin CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 Yes ALL INSTALLATIONS If required by the manufacturer record the following CO OR CO ppm OR CO CO Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and
46. ash board L2 fig 40 locate and press the CO button see fig 40 pos SW1 The display shows ACO and the yellow led blinks Press the button the number of timing according the function requirement as par 7 5 1 use the supplied screwdriver to push the CO botton SW1 SW1 Fig 40 caa 00 1 E C 15 JP7 JPG JP5 JP4 JP3JP2 JP1 CN12 CNS n M A Os o lc SIDE P rr O EE EEEE CN14 ps P2 Fig 41 27 7 5 1 CO FUNCTION SETTINGS Locate the CO button see 7 3 I Me dd Select the main selector switch in position O CO FUNCTIONS ACTION ON THE BUTTON LED STATUS combustion analysis mode press once burner running at maximum heating yellow led blinking gas valve maximun setting press twice burner running at maximum absolute yellow led blinking red led fixed gas valve minimum setting press three time burner running at minimum yellow led blinking green led fixed this step has not to be used for the system boiler If you find in this situation press the button once again NOTE 1 Any additional pressing of CO button after the third time the burner switched between maximum absolute and minimu
47. associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineers Signature Customer s Signature Toconfirm satisfactory demonstration and receipt of manufacturer s literature AI installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls SERVICE 1 Date SERVICE 2 Date
48. be tested for tightness in accordance with I S 813 If the gas supply serves more than one appliance it must be ensured that an adequate supply is 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 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 I S 813 In cold and or humid weather water vapour will condense on leaving the terminal the effect of such pluming must be considered If installed less than 2m above a pavement or platform to which people have access including balconies or flat roofs the terminal must be protected by a guard of durable material The guard must be fitted centrally over the terminal Refertol S 813 when the terminal is 0 5 metres or less below plastic guttering or 1 metre or less below painted eaves 3A 5 AIR SUPPLY The following notes are intended for general guidance only This appliance is a room sealed fan flued boiler consequently it does not require a permanent air vent for combustion air supply When installed in a cupboard or compartment ventilation for cooling purposes is also not required 3A 6 WATER CIRCULATION Specific recommendations are given in I S 813 The following notes are for general guidance only 3A 6
49. bends up to the maximum equivalent flue length to the flue terminal The flue system should have a minimum of 1 maximum of 3 rise from the boiler to outside to ensure any condense fluid that forms is allowed to drain back to the appliance NOTE When cutting an extension to the required length you must ensure that the excess is cut from the plain end of the extension Remove any burrs and check that all seals are located properly You must ensure that the entire flue system is properly supported and connected Seal the flue assembly to the wall using cement or a suitable alternative that will provide satis factory weatherproofing The interior and exterior trim can now be fitted Bend Reduction in maximum flue length for each bend 45 bend 0 5 metre 90 bend 1 0 metre Vertical flue terminal and accessories Part No Description Length Exe 20028027 convertor box N A 29450122 Vertical flue terminal 1000mm 531 Pitched roof flashing plate N A h 5 532 Flat roof flashing plate N A E 29450123 90 degree bend N A 29450124 45 degree bends pair N A Goi 29450125 500mm extension 500mm 29450126 1000mm extension 1000mm 29450127 2000mm extension 2000mm 29450128 Telescopic extension 350 730mm 529 Wall bracket pack 5 208mm Using the dimensions given in fig 11 as a reference mark and Timm ae cut a 125mm hole in the ceiling and or roof is 7 Fit the appropriate flashing pla
50. connecting the flue pipe to the bend You must ensure thatthe entire flue system is properly supported and connected Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weather proofing The exterior trim can now be fitted N l EN 235 6 Fig 13 4 5 2 CONCENTRIC VERTICAL FLUE The appliance can be used with either the Vok ra condensing 60 100mm concentric flue system using the specific adaptor supplied as accessory NOTE These instructions relate only to the Vok ra condensing 60 100mm concentric flue system The vertical flue terminal can be connected directly to the adaptor flue outlet Alternatively an extension or bend can be connected to the adaptor flue outlet if desired however if additional bends are fitted a reduction must be made to the maximum flue length see table below Reduction for bends X 65mm Y Fig 12 EXTENDING THE FLUE Connect the bend supplied with the terminal kit to the top of the adaptor using clamp supplied see fig 12 The additional bends amp extensions have push fit connections care should be taken to ensure that the correct seal is made when assem bling the flue system Connect the required number of flue extensions or
51. d safe and efficient operation the appliance must be serviced annually by a competent person IMPORTANT To validate the appliance warranty it s necessary to register the appliance details with us The warranty can be registered in several ways e by completing the warranty registration card and posting to us using the envelope supplied e online at vokera co uk e for UK residents by calling 0870 607 0281 e for ROI residents by calling 056 6655057 20 SECTION 6 SERVICING INSTRUCTIONS 6 1 GENERAL To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked and serviced at regular intervals To ensure correct and safe operation of the appliance it is essential that any worn or failed compo nent be replaced only with a genuine Vok ra spare part It should be remembered that although certain generic components may look similar they will be specific to an individual appliance or product range Use of non genuine Vok ra spare parts could invalidate your warranty and may pose a potential safety hazard The frequency of servicing will depend upon the particular installation conditions but in general once per year should be sufficient It is the law that any servicing work is carried out by competent person such as a Vok ra engineer an approved service agent British Gas GAS SAFE registered personnel or other suitably qualified personnel The following instructions apply to t
52. e individual return temperatures are correct and are approximately egual 5 12 FINAL CHECKS e ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS VALVE ARE TIGHT AND CHECKED FOR TIGHTNESS e ENSURE THE APPLIANCE FLUE SYSTEM IS FITTED CORRECTLY AND IS PROPERLY SECURED e ENSURE ALL PIPE WORK IS RE CHECKED FOR TIGHTNESS e RE FIT APPLIANCE CASING e COMPLETE BENCHMARK CHECKLIST FOR UK ONLY Complete details of the boiler controls installation and commissioning in the Benchmark checklist at the back of this book It is important that the Benchmark checklist is correctly completed and handed to the user Failure to install and com mission the appliance to the manufacturers instructions may invalidate the warranty 5 13 INSTRUCTING THE USER Hand over all documentation supplied with this appliance including these instructions and explain the importance of keeping them in a safe place Explain to the user how to isolate the appliance from the gas water and electricity supplies and the locations of all drain points Show the user how to operate the appliance and any associated controls correctly Show the user the location of the filling valve and how to top up the system pressure correctly and show the location of all manual air release points Explain to the user how to turn off the appliance for both long and short periods and advise on the necessary precautions to prevent frost damage Explain to the user that for continue
53. eight of the appliance it may be necessary for two people to lift and attach the appliance to its mounting The appliance is contained within a heavy duty cardboard carton Lay the carton on the floor with the writing the correct way up 4 2 CONTENTS Contained within the carton is e the boiler e the wall bracket e carton template e an accessories pack containing appliance service connections and washers e hydraulic lower cover e the instruction pack containing the installation servicing amp user instructions guarantee registration card and a 3 amp fuse 4 3 UNPACKING At the top of the carton pull both sides open do not use a knife unfold the rest of the carton from around the appliance carefully remove all protective packaging from the appliance and lay the accessories etc to one side Protective gloves should be used to lift the appliance the appliance back frame should be used for lifting points 4 4 PREPARATION FOR MOUNTING THE AP PLIANCE The appliance should be mounted on a smooth vertical non combustible surface which must be capable of supporting the full weight of the 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 9 and flue hole if applicable
54. ent size to supply the appliance at its maximum output An existing supply must be checked to ensure that it is of adequate size to deal with the maximum rated input of this and any other appliances that it serves 10 5 GAS SUPPLY INSTALLATION The entire installation including the meter must be purged and checked for gas tightness 10 6 CHECKING THE CO AND ADJUSTING THE GAS VALVE THE GAS VALVE MUST BE SET UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYSER Isolate the appliance from the electrical supply and remove the appliance casing as described in 4 7 1 Set the flue gas analyser to read CO and insert the probe into the flue analysis test point Y1 Z1 fig 39 Restore the electrical supply to the boiler and switch the boiler to the OFF mode Have access to the printed circuit board locate and open the closing plug on the dash board L2 fig 40 locate and press the CObutton see fig 36 pos SW1 The display shows ACO and the yellow led blinks The appliance will now operate in CO mode for approximately 15 minutes 10 6 1 CO FUNCTION SETTINGS Locate the CO button see 7 4 Select the main selector switch in position 10 6 2 GAS VALVE MAXIMUM SETTING Set the CO button at maximum absolute see 10 6 1 once the maximum absolute is obtained yellow led blinking red led fixed check that it corresponds with the appropriate CO value Maximum for the respective appliance If the CO reading
55. er carry out a resistance test Connect test leads between the Live amp Earth connections at the appliance terminal strip 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 These series of checks must be carried out before attempting any faultfinding procedures on the appliance On completion of any task that required the disconnection and re connection of any electrical wiring or component these checks must be repeated Disconnect any external controls from terminal plug CN5 fig 47 and insert a link wire between the two wires at the TA connections 30 7 11 APPLIANCE STATUS LED AND FAULT CODES When the boiler detects a temporary fault condition the appropriate led indication is shown If when the fault is final the pump will perform a 60 second post circulation and red LED will be illuminated See table on pag 4 Fault A 09 with the green and red LEDs flashing The boiler has a self diagnosis system that is able based on the hours totalled under particular operating conditions to indicate the need for cleaning of the primary exchanger alarm code 09 with green and red LEDs flashing and the fume sensor counter gt 2 500 Once cleaning has been completed using the specific kit supplied as an accessory the counter for the totalled hours must be reset using the following procedure Disconnect the elect
56. es more than one appliance it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time 3 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 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 fig 7 In cold and or humid weather water vapour will condense on leaving the terminal the effect of such pluming must be considered If installed less than 2m above a pavement or platform to which people have access including balconies or flat roofs the terminal must be protected by a guard of durable material cocks Except where providing useful heat pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing Particular attention should be paid to pipes passing through ventilated areas such as under floors loft space and void areas 3 6 2 HYDRAULIC SEPARATOR Vokera advise that the appliance should be combined with a hydraulic separator 20028475 to supply the heating system to ensure the correct flow rate through the boiler at all times see fig 19 3 6 3 DRAIN COCKS These must be located in accessible positions to facilitate draining of the appliance and all water pipes connected to the appliance The drain cocks must be manufactured in accordance
57. f F A The three LEDs on the control panel flash alternately and an OE M rarer os CNS P4 ADJ message is shown on the display for about 4 sec after l JP8 which the maximum heating value can be changed using the an e PS 9 TE heating temperature selector and SW1 CO button to set and PI a o es confirm the required value The display shows the icon l THH CONIA P3 P2 End the procedure by removing jumper JP1 to save the values set in the memory fig 43 28 Once the required maximum heating power is set indicate the value on the instruction manual see back cover For subsequent checks and adjustments see the value set Setting does not switch on the boiler When the heating set point selector knob is turned the display automatically shows the number of rpm expressed in hundreds e g 25 2500 rpm The boiler is supplied with the settings shown in the table However this value can be adjusted based on plant needs or regional regulations on combusted gas emission limits by referring to the graphs shown below Emissions curve heating Qn 200 190 180 170 o 160 D 150 gt 140 E 130 G 120 amp 110 100 Oo 90 2 80 o 70 5 60 9 50
58. f the boiler has a timer programmer connected to it JUMPER JP6 inserted When the contact is closed the heat request is made by the delivery sensor based on the outside temperature to have a nominal ambient temperature at the DAY level 20 C Opening of the contact does not switch the boiler off but reduces the climatic curve by parallel translation to the NIGHT level 16 C This is how the night time function is activated The delivery temperature is calculated automatically by the boiler however the user can interact with the boiler When interacting with the interface to change HEATING you will not have the HEATING SET POINT value available but a value that can be set as you wish between 5 and 5 C Changing this value does not directly change the delivery temperature but affects the calculation that determines this value automatically by changing the reference temperature system 0 20 C for the DAY level 16 C for the NIGHT level 26 DELIVERY TEMPERATURE C Thermoregulation curves 37 5 32 5 1 35 30 27 5 25 22 5 40 o o o o o 15 10 5 0 5 10 EXTERNAL TEMPERATURE C maximum heating temperature set point standard plants JP7 not inserted maximum heating temperature set point floor standing plants JP7 inserted Temperature curve correction oc DELIVERY TEMPERATURE C
59. g As determined by the fixed collar of the vertical terminal R To the side of a boundary 300 mm s To the side of an opening or window on a pitched roof 600 mm T Below an opening or window on a pitched roof 2000 mm V From a vertical terminal to an adjacent opening window air brick etc call Vokera technical for advice w From a vertical terminal to an adjacent vertical terminal 300 mm only if both terminals are the same hight SECTION 3 GENERAL REGUIREMENTS UK This appliance must be installed by a competent person in accordance with the Gas Safety Installation amp Use Regulations 3 1 RELATED DOCUMENTS The installation of this boiler must be in accordance with the relevant requirements of the Gas Safety Installation amp Use Regulations the local building regulations the current l E E wiring regulations the bylaws of the local water undertaking the Building Standards Scotland Regulation and Building Standards Northern Ireland Regulations It should be in accordance also with any relevant requirements of the local authority and the relevant recommendations of the following British Standard Codes of Practice 3 2 LOCATION OF APPLIANCE The appliance may be installed in any room or internal space although particular attention is drawn to the reguirements of the current E E wiring regulations and in Scotland the electrical provisions of the Building Regulations with respect to the The guard must
60. he appliance and its controls but it should be remembered that the central heating and the domestic hot water systems would also require attention from time to time 6 2 ROUTINE ANNUAL SERVICING e Check the operation of the appliance and ensure it functions as described in section 7 e Compare the performance of the appliance with its design specification The cause of any noticeable deterioration should be identified and rectified without delay e Thoroughly inspect the appliance for signs of damage or deterioration especially the flue system and the electrical apparatus e Check and adjust if necessary all burner pressure settings see 7 4 e Check and adjust if necessary the system design pressure see 5 10 e Carry out an analysis of the flue gases see 7 5 and visually check the condition of the entire flue assembly e Compare the results with the appliance design specification Any deterioration in performance must be identified and rectified without delay e Check that the burner and main heat exchanger are clean and free from any debris or obstruction e Check and clean if necessary the condense trap to ensure correct operation 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 Should the appliance develop a fault the fault
61. he appliance will operate in the heating mode The pump and fan will be activated via the flow temperature sensor When the fan is sensed to be operating correctly tacho signal the ignition sequence commences Ignition is sensed by the electronic circuit 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 The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow temperature sensor consequently a high temperature at the flow sensor results in a lower fan speed As the water temperature increases the temperature sensors located on the flow pipe of the boiler reduce the fan speed via the electronic circuitry Depending on the load either the water temperature will continue to rise until the set point is achieved or the water temperature will fall whereby fan speed will increase relative to the output required When the boiler has reached the set point hysterisis the burner will switch off The built in anti cycle device prevents the burner from re lighting for approximately 3 minutes When the temperature of the flow sensor falls below the set point hysterisis the burner will re light 7 2 3 HOT WATER optional 3 way valve kit installed With the selector switch in the heating amp hot water or hot water position and tank thermostat calling for
62. in a room or internal space containing a bath or shower the appliance or any control pertaining to it must not be within reach of a person using the bath or shower The location chosen for the appliance must permit the provision of a safe and satisfactory flue and termination The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the appliance Where the installation of the appliance will be in an unusual location special procedures may be necessary BS 6798 gives detailed guidance on this aspect A compartment used to enclose the appliance must be designed and constructed specifically for this purpose An existing compartment cupboard may be utilised provided that it is modified to suit Details of essential features of compartment cupboard design including airing cupboard installations are given in BS 6798 This appliance is not suitable for 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 connection must not be used The installation must be tested for tightness in accordance with BS6891 If the gas supply serv
63. k and drill a 125mm hole for the passage of the flue pipe The hole should be drilled to ensure any condense fluid that forms is allowed to drain back to the appliance see fig 12 The fixing holes for the wall mounting bracket should now be drilled and plugged an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely Once the bracket has been secured to the wall mount the appliance onto the bracket Fig 9 46 Ge lt seer 763 98 178 5 n 153 53 5 70 T T T 553 Fig 10 FITTING THE HORIZONTAL FLUE KIT Carefully measure the distance from the centre of the appliance flue outlet to the edge of the finished outside wall dimension X Add 65mm to dimension X to give you Dimension Y see fig 12 Measure dimension Y from the terminal end of the concentric flue pipe and cut off the excess ensuring any burrs are removed Pass the concentric flue pipe through the previously drilled hole Fit the flue bend to the adaptor flue outlet and insert the concentric 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 NOTE Fit the internal white trim to the flue assembly prior to
64. l eentrols NTC thermistor wet contact 10Kohm Fault Possible cause FUNCTION VALUE Red led fixed Check Standard Heating temperature system check polarity range min max C 40 80 Floor Heating temperature 7 9 ELECTRICAL CHECKS range min max C 20 45 Any electrical checks must be carried out by a suitably qualified 75 maximum CH time 15 min person Heating OFF hysterisis C SP 5 7 9 4 EARTH CONTINUITY TEST Heating ON hysterisis C SP 5 Isolate the appliance from the electrical supply and using a Anti cycle delay 3 min suitable multi meter carry out a resistance test Connect test Pump over run 30 sec leads between an appliance earth point and the earth wire of Low output min output Min 25 the appliance supply cable The resistance should be less than CO function max temp C 90 1 OHM If the resistance is greater than 1 OHM check all earth CO re light temp C 78 wires and connectors for continuity and integrity CO function time 15 min Flow NTC max temp C 90 7 9 2 SHORT CIRCUIT CHECK High limit thermostat C 105 Isolate the appliance from the electrical supply and using a Flue NTC max temp C 125 suitable multi meter carry out a short circuit test between the Maxi differential C 35 Live amp Neutral connections at the appliance terminal strip sr Repeat above test on the Live amp Earth connections at the IGNITION CONTROL VALUE appliance terminal strip Ignition attempts before L O lockou
65. ll the boiler modes The temperature selector can be used to vary the temperature of the water that circulates around your radiators The display and LEDS normally show the status of the appliance When the status indicator Green is lit it indicates that the flame is present and the burner is ON When the fault indicator Red is lit it indicates that the appliance has identified a possible fault and performed a safety lockout When the fault indicator Yellow is lit it indicates that there is a Servicing operation in progress The integral time clock when fitted can be used to switch the heating on and off at pre determined intervals 3 HOWTO 3 1 HOW TO TOP UP THE SYSTEM PRESSURE fig 1 2 The system pressure must be checked periodically to ensure the correct operation of the boiler The needle on the gauge should be reading between 1 5 and 2 0 BAR when the boiler is in an off position and has cooled to room temperature If the pressure requires topping up use the following instructions as a guide Locate the filling valve connections usually beneath the boiler see fig 2 Attach the filling loop to both connections Open the filling valve slowly until you hear water entering the system Close the filling valve when the pressure gauge on the boiler reads between 1 5 and 2 0 BAR see fig 1 Remove the filling loop from the connections 3 2 HOW TO RESET THE APPLIANCE When the red fault LED
66. lling or venting of the system may be indicative of a leak Care should be taken during the installation of the appliance to ensure all aspects of the system are capable of withstanding pressures up to at least 3 5 bar 3 7 ELECTRICAL SUPPLY The appliance is supplied for operation on 230V 50Hz 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 3 5mm 3 high voltage category The switch must only supply the appliance and its corresponding controls i e time clock room thermostat etc Alternatively an un switched shuttered socket with a fused 3 pin plug both complying with BS 1363 is acceptable 3 8 MOUNTING ON A COMBUSTIBLE SURFACE If the appliance is to be fitted on a wall of combustible material a sheet of fireproof material must protect the wall 3 9 TIMBER FRAMED BUILDINGS If the appliance is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineers publication IGE UP 7 Guide for Gas Installations in Timber Frame Buildings 3 10 INHIBITORS Vok ra recommend that an inhibitor suitable for use with 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
67. low return and condense connections on the heat exchanger Locate and remove the 4 screws that secure the heat exchanger to the combustion chamber D Move the heat exchanger to the right and disconnectitfrom the flue collector The heat exchanger and fan assembly can now be lifted up and withdrawn from the appliance Fig 34 V Fig 35 Fig 36 23 Fig 37 6 18 CONDENSE TRAP AND COLLECTOR REMOVAL fig 38 Carry out component removal procedure as described in 6 4 Disconnect the 2 upper rubber condense pipes Remove the pin B that secures the trap to the chassis Disconnect the lower rubber condense pipe from the condense trap Remove the pins D that secures the collector to the exchanger Carefully remove the condense trap and collector Replace in the reverse order 6 20 FLUE COLLECTOR REMOVAL fig 39 Carry out component removal procedure as described in 6 4 Disconnect the rubber condense pipe disconnect the thermistor wiring connection disconnect the analysis test point Z1 unscrew the retaining bar from the exchanger pull the upper retaining bar to the left pull the flue collector down and to the right to remove Ensure the seal is in good condition taking care to ensure it is replaced correctly Replace in the reverse order 24 Fig 38 i SECTION
68. low 5 C the boiler will operate on minimum power until the temperature of the thermistors reaches 35 C Thereafter the pump amp fan will over run for 30 seconds e ANTI CYCLE FUNCTION the anti cycle function ensures the burner remains switched off for at least 3 minutes after the set point hysterisis set point 5 deg for CH heat request e PUMP ANTI BLOCK FUNCTION when there has been no heating or HW request for 24 hours the anti block cycle is activated The pump will be activated for a period of 30 seconds e PUMP CYCLE MODE when power is restored to the PCB and or the PCB is powered for the first time the appliance will enter a 2 minute purge cycle whereby only the pump will run for 15 seconds then off for 15 seconds and will not fire until this period has elapsed e ACTUATOR ANTI BLOCK FUNCTION when there has been no heating or HW request for 24 hours the anti block cycle is activated The divertor valve actuator will motor briefly to the heating position and then back to the DHW position e SARA function the SARA function permits the boiler when the set point is within the SARA range to automatically adjust raise the heating flow outlet temperature should the room thermostat contacts remain closed for more that 20 minutes 7 2 3 HEATING MODE With the selector switch in the heating amp hot water position and any additional controls time clock programmer room thermostat etc calling for heat t
69. lue required Press the CO button SW1 and move on to setting the next parameter Live electrical parts 230 Vac The following icons switch on on the display 1 During absolute maximum setting MAX 2 SM During minimum setting MIN 3 w During maximum heating setting HTG 4 P During slow ignition setting IGN End the procedure by removing jumpers JP1 and JP3 to save the values set in this way The procedure can be ended at any time without saving the values set and keeping the initial settings Turning the function selector to y lt OFF RESET Switching off the mains power supply After a delay of 15 min after switching it on Setting does not switch on the boiler When the heating selector knob is turned the display automatically shows the number of RPM expressed in hundreds e g 25 2500 rpm Fan speed rpm table MAX MIN HTG IGN 5800 1400 5800 3000 7 5 CHECKING THE CO AND ADJUSTING THE GAS VALVE THE GAS VALVE MUST BE SET UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYSER Isolate the appliance from the electrical supply and remove the appliance casing as described in 4 7 1 Set the flue gas analyser to read CO and insert the probe into the flue analysis test point Y1 Z1 fig 39 Restore the electrical supply to the boiler and switch the boiler to the OFF mode Have access to the printed circuit board locate and open the closing plug on the d
70. m 2 To restart the CO function it is necessary to pass throught the OO position with the main selector switch 7 5 2 GAS VALVE MAXIMUM SETTING Set the CO button at maximum absolute see 7 5 1 once the _ maximum maximum absolute is obtained yellow led blinking red led adjustment screw fixed check that it corresponds with the appropriate CO value Maximum for the respective appliance see 2 11 If the CO reading is correct proceed to gas valve minimum setting compensation 7 5 3 pipe connection However if the CO reading is incorrect the maximum gas pressure must be adjusted as follows minimum e using a 2 5mm Allen key very slowly turn the maximum adjustment screw adjustment screw see fig 42 clockwise to decrease Inlet gas pressure counter clockwise to increase until the correct value is connection displayed on the CO analyser allow time for the analyser to stabilise 7 5 3 GAS VALVE MINIMUM SETTING fig 42 Set the CO button at minimum see 7 5 1 once the minimum is obtained yellow led blinking green led fixed check that it corresponds with the appropriate CO value Minimum for the respective appliance see 2 11 If the CO reading is NATURAL GAS LPG correct proceed to completion 7 5 4 CO maximum output 9 0 10 0 However if the CO reading is incorrect the minim
71. nel programmers The appliance can be used in conjunction with typical S Plan systems for Y Plan systems a relay is reduired please contact Vokera technical should you reduire further detailed instruction 8 3 OTHER DEVICES Contact the controls manufacturer and or Vokera technical department should you require more specific information on the suitability of a particular control Further guidance on the recommended practice for the installation of external controls can be found in CHeSS HC5 HC6 Fuse 3 15A F 230 V ONL 3 M N o o Umoq W an q Xoelg yQ T T M6 Beedle Fig 45a blue brown Room Thermostat 24 Vdc Ho A NOTE Use contacts free of voltage 230 V ONL Fuse 3 15A F www energyefficiency gov uk Fig 45b ROOM OT THERMOSTAT _ BOILER EXTERNAL _ 24 Vdc UNDERFLOOR THERMOSTAT SENSOR HEATING THERMOSTAT m2 S MA M6 E ele elle olol olol o o el JOJ O oO b Oo YW ere oo oo O O O O Fig 45c S PLAN m M6__ N ou THERMOSTAT CYLINDER N THERMOSTAT 44 Bo p tt 3 s EE
72. nnular co axial combustion air intake that can be rotated horizontally through 360 degrees for various horizontal or vertical applications The Verve can also be used with the Vok ra twin flue system The Verve is approved for use with C13 amp C33 type flue applications These appliances are designed for use with a sealed system only consequently they are not intended for use on open vented systems This booklet is an integral part of the appliance It is therefore necessary to ensure that the booklet is handed to the person responsible for the property in which the appliance is located installed A replacement copy can be obtained from Vok ra customer services Fig 3 General layout 1 Return valve 2 Drain valve 3 Condense trap 4 Pump 5 Gas nozzle 6 Differential pressure switch 7 Condense collector 8 Return thermistor NTC 9 Main heat exchanger 10 Flues thermistor NTC 11 Flue gas analysis test point 12 Flue outlet 13 Air intake 14 Ignition transformer 15 Air suction pipe 16 Top AAV 17 High limit thermostat 18 Flow thermistor NTC 19 Sensing Electrode 20 Spark Electrode 21 Burner 22 Condensate level sensor 23 Air gas mxer 24 Fan assembly 25 Gas valve 26 Pressure switch 27 Safety valve 28 Drain valve 29 Gas valve 30 Electric connection box 31 Flow valve R Heating return connection F Heating flow connection G Gas connection SECTION 1 DESIGN PRINCIPLES AND
73. oned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission this equipment to the manufacturer s instructions may invalidate the warranty but does not affect statutory rights Customer Name Telephone Number Address Boiler Make and Model Boiter Seria number AAN AE DAE NAOE DEER HEERS OER EAE KH AU Commissioned by print name CORGI ID Number Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer Room Thermostat Compensation Control Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer Timer Combination Boiler Heating Zone Valves Fitted Not Required Hot Water Zone Valves Fitted Not Required Thermostatic Radiator Valves Fitted Not Required Automatic Bypass to System Fitted Not Required Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593
74. p Two port valve DHW thermostat Room thermostat DHW tank HEATING DHW SYSTEM USING OPTIONAL 3 WAY ASKA KIT 2 gt O O O QI R O N o TA 8 Standard CH system Boiler Expansion tank System filter System valve Heating system pump Not return valve DHW tank Room thermostat Relay DHW tank thermostat Fig 21 17 4 7 ELECTRICAL CONNECTIONS The boiler is supplied with a 2 metre fly lead This lead can be used for connection to the electrical supply Connect the fly lead to a fused plug or fused isolator in the following way e brown wire to LIVE supply e blue wire to NEUTRAL supply e green yellow to EARTH connection Insert the supplied 3 AMP fuse into the fused isolator or fused plug Should the fly lead be unsuitable refer to 4 7 3 for details on how to connect the electrical supply directly to the boiler The electrical supply must be as specified in section 3 3A A qualified electrician should connect the appliance to the electrical supply If controls external to the appliance are required acompetent person must undertake the design of any external electrical circuits please refer to section 8 for detailed instructions ANY EXTERNAL CONTROL OR WIRING MUST BE SERVED FROM THE SAME ISOLAT
75. rical power supply Remove the casing and turn the control panel around Remove the board cover While applying the electrical power supply to the boiler press the CO button for at least 4 seconds to check that the counter has been reset and put the power to the boiler on again The display shows the value for the counter after indicating C Live electrical parts 230 Vac Note The counter resetting procedure must be done after each thorough cleaning of the primary exchanger or if it is replaced To check the status of the hours totalled multiply the value read by 100 e g value read 18 1800 hours totalled value read 1 100 hours totalled The boiler continues to function normally even when this alarm is active 7 12 BOILER CONFIGURATION The electronic board has a series of jumpers on it JPX that are used to configure the boiler Access to the board as follows Turn the plant s main switch off Unscrew the fixing screws for the casing move it forward and then down to disconnect it from the chassis Then lift and rotate the control panel towards you Remove the cover by releasing the fixing hooks JUMPER JP7 Pre selection of the heating temperature adjustment range that is most suitable for the type of plant Jumper not inserted standard plant Standard plant 40 80 C Jumper inserted floor standing plant Floor standing plant 20 45 C During fabrication the boiler was configured for
76. rrosion must be pH neutral i e they should ensure that the level of the pH in the system water remains neutral Premature failure of certain components can occur if the level of pH in the system water is out with normal levels 5 8 1 INHIBITORS See Section 3 General Requirements eee AS THE FLOW OUTLET TEMPERA The flow outlet temperature can be adjusted between 40 C 80 C for standard CH system and between 20 C 45 C for under floor systems by using the Heating thermostat knob see fig 1 For further details consult Boiler configuration section 5 10 SETTING THE SYSTEM DESIGN PRESSURE The design pressure should be a minimum of 0 5 BAR and a maximum of 2 0 BAR The actual reading should ideally be 1 5 BAR plus the equivalent height in metres 0 1 BAR 1 metre to the highest point in the system above the base of the appliance up to the maximum of 2 0 BAR total N B The safety valve is set to lift at 3 5 BAR 35 metres 45 psig To lower the system pressure to the required value drain off some water from the appliance drain valve until the required figure registers on the pressure gauge see fig 1 19 5 11 REGULATING THE CENTRAL HEATING SYSTEM Fully open all radiator and circuit valves and run the appliance for both heating and hot water until heated water is circulating If conditions are warm remove any thermostatic heads Adjust radiator return valves and any branch circuit return valves until th
77. se any scourers or abrasive cleaners control Fig 2 valve tempora control porary valve connection flow return double pipe check valve supply pipe FAULT CODES Alarm Alarm Display Led Led Led type code RED YELLOW GREEN Purge cycle mode active NA E B BLINKING BLINKING BLINKING Ignition failure flame not sensed condense sAr sensor activated differential pressure fault Final N x O ON OFF GFF Alarm high limit thermostat Final A 02 A BLINKING OFF OFF Failure fan speed Finale A03 O ON OFF ON Alarm system water pressure Final A 04 lt Q ON OFF ON Flow temperature too high temperature differential too high flow thermistor fault Final A07 A ON OFF OFF Return temperature too high temperature differential too high return thermistor fault Final A 08 Q ON OFF OFF Failure flue sensor cleaning primary exchanger Final A 09 A BLINKING OFF BLINKING Alarm high limit flue sensor Final A091 Q ON OFF OFF Alarm underfloor heating thermostat Final ATT Q ON OFF OFF Combustion analysis test NA acol Q OFF BLINKING OFF Service operation NA ADJ OFF BLINKING OFF Flame ON NA OFF OFF ON Boiler stand by NA OFF OFF BLINKING 4 WHAT IF 4 1 WHAT IF SUSPECT A GAS LEAK If you suspect a gas leak turn off the gas supply at the gas meter and contact your installer or local gas supplier If you require further advice please contact your neare
78. sh fit the twin flue pipes onto the concentric to twin converter box ensuring that the exhaust pipe connects to the exhaust connection on the concentric to twin converter If necessary cut the plain ends male of the twin flue pipes to allow connection to the concentric to twin converter NOTE Before cutting twin flue pipes ensure allowances have been made for connection onto the previous piece and onto the concentric to twin converter The last twin flue pipes must be pushed 50mm onto the male spigots of the concentric to twin converter Seal the flue 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 bm 1 deg 17mm L a EE m Fig 16 VERTICAL TERMINATION fig 17 The twin flue system must be converted to the dedicated concentric flue kit for termination e The vertical terminal is supplied with a built in converter box and cannot be shortened e A 130mm hole is required for the passage of the concentric terminal through the ceiling and or roof Depending on site conditions it may be preferable to install the terminal assembly prior to fitting the twin flue pipes 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
79. ssary to gas rate the appliance using the gas meter that serves the appliance If the installation does not include a gas meter for example LPG and there are no means by which to calculate the gas rate then a combustion analysis test must be carried out in accordance with BS 7967 UK to ensure the appliance is left working safely and correctly Additionally if the gas valve has been adjusted replaced or the appliance has been converted for use with another gas type then it becomes necessary to carry out a combustion analysis check to ensure that correct combustion is occurring If there are no means to gas rate the appliance and or carry out a combustion analysis check then it will not be possible to complete the commissioning procedure Details on how to carry out the combustion analysis can be found in section 7 IMPORTANT It s imperative that a sufficient dynamic gas pressure is maintained at all times Should the dynamic gas pressure fall below an acceptable level the appliance may malfunction or sustain damage 5 8 FINAL FLUSHING OF THE HEATING SYSTEM The system shall be flushed in accordance with BS 7593 I S 813 ROI Should a cleanser be used it must be suitable for Aluminium heat exchangers It shall be from a reputable manu facturer and shall be administered in strict accordance with the manufacturers instructions and the DWTA code of practice NOTE Chemicals used to cleanse the system and or inhibit co
80. st Vok ra office 4 2 WHAT IF HAVE FREQUENTLY TO TOP UP THE SYSTEM If the system regularly requires topping up it may be indicative of a leak Please contact your installer and ask him to inspect the system 4 3 WHAT IF THE APPLIANCE IS DUE ITS AN NUAL SERVICE Advice for tenants only Your landlord should arrange for servicing Advice for homeowners Please contact Vok ra Customer Service 0844 3910999 UK or 056 7755057 ROI if you would prefer a Vok ra service engineer or agent to service your appliance Alternatively your local GAS SAFE registered engineer may be able to service the appliance for you 4 4 WHAT IF NEED TO CALL AN ENGINEER If you think your boiler may have developed a fault please contact your installer or Vok ra Customer Services 0844 3910999 UK or 056 7755057 ROI have all your details to hand including full address and postcode relevant contact numbers and your completed appliance log book INSTALLATION AND SERVICING INSTRUCTIONS INTRODUCTION The Verve is a high efficiency boiler with outputs of 47kW This appliance by design incorporate electronic ignition circulating pump differential pressure switch safety valve pressure gauge premix combustion and radial aluminium heat exchanger Verve is produced as room sealed category IIZH3P appliances suitable for internal wall mounting applications only Each appliance is provided with a fan powered flue outlet with an a
81. stability at the burner Once successful ignition has been Ee Sea Wa achieved the boiler s output will either be increase to maximum I REI or modulate to suit the set requirement IUUUUUU When the appliance reaches the desired temperature the Differential burner will shut down and the boiler will perform a three minute pressure anti cycle timer delay switch When the request for heat has been satisfied the appliance ete pump and fan may continue to operate to dissipate any residual heat within the appliance T Flow temperature sensor TopAAV ui Hot water optional 3 way valve kit installed When there is a request for heat via tank thermostat the external 3 way valve switches on tank circuit the pump and fan 7 are started the fan speed will modulate until the correct signal bumi N voltage is received at the control PCB At this point an ignition Pressure seguence is enabled switch Ignition is sensed by the electronic circuit to ensure flame T fa Safety stability at the burner Once successful ignition has been valve achieved the boiler s output will either be increase to maximum VZ or modulate to suit 80 C nd When the hot water reaches the desired temperature tank Drain thermostat opened the burner will shut down the pump is off valve and 3 way valve switches on heating circuit CH CH 1 4 SAFETY DEVICES um flow When the appliance is in use s
82. standard plants JP1 Enabling front setting knobs Range Rated JP2 Resetting heating timer JP3 Setting see checking and adjusting paragraph JP4 Unused JP5 donot use closed JP6 Enabling night time compensation function and pump continuously only with external sensor connected JP7 Enabling standard low temperature heating system see above JP8 donotuse closed fig 44 D B JP7 JP 0 RARER RES lee CN15 JPTJPGJPS JP4 JP3JP2 JP1 CNT2 CNS a sa P4 O SW o LS 26 P1 O P L 1 CN14 P3 P2 Jumper not in standard plant JP Ei Jumper in floor standing plant 31 SECTION 8 WIRING DIAGRAMS 8 1 EXTERNAL WIRING The appliance comes with a factory fitted TA link to allow basic operation of the boiler via the mode selector switch If external controls are to be added to the system they must be connected to the appliance as shown in the following diagrams For advice on controls that are not featured in this book please contact Vokera technical on 0844 3910999 8 1 1 EXTERNAL WIRING LIMITATIONS Any external wiring must remain within the limits as detailed in the table below CONNECTION MAX LENGTH Room thermostat 30 metres 8 2TYPICAL CONTROL APPLICATIONS The appliance can be used with the following controls e single channel voltage free time clocks fig 45a e programmable room thermostats fig 45b e twin chan
83. t 5 NOTE Re ignition attempts after loss Should it be found that the fuse has failed but no fault is of flame signal 5 indicated a detailed continuity check will be required to trace the fault A visual inspection of components may also assist in locating the fault 7 9 3 POLARITY CHECK With the appliance connected to the electrical supply and using a suitable multimeter carry out the following voltage tests e connect test leads between the Live amp Neutral connections at the appliance terminal strip The meter should read approximately 230V ac If so proceed to next stage If not see 7 9 4 e connect test leads between the Live amp Earth connections at the appliance terminal strip The meter should read approximately 230V ac If so proceed to next stage If not see 7 9 4 e connect test leads between the Neutral amp Earth connections at the appliance terminal strip The meter should read approximately 0 15Vac If so polarity is correct If not see 7 9 4 7 9 4 REVERSED POLARITY OR SUPPLY FAULT Repeat the above tests at the appliance isolator if testing reveals correct polarity and or supply at the isolator re check wiring and connections between the isolator and the appliance If tests on the isolator also reveal reversed polarity or a supply fault consult the local electricity supplier for advice 7 9 5 RESISTANCE TO EARTH CHECK Isolate the appliance from the electrical supply and using a suitable multi met
84. te to the roof and insert the l C vertical flue terminal through the flashing plate from the outside g ensuring that the collar on the flue terminal fits over the flashing T The fixing holes for the wall mounting bracket should now be Se drilled and plugged an appropriate type and quantity of fixing 1 3 degree 0 degree should be used to ensure that the bracket is mounted securely Once the bracket has been secured to the wall mount the appliance onto the bracket IMPORTANT The vertical flue terminal is 1 0 metre in length and cannot be cut therefore it may be necessary to adjust the height of the appliance to suit or use a suitable extension Connect the vertical flue assembly to the adaptor flue spigot using the 100mm clip gasket amp screws supplied ensuring the correct seal is made The flue support bracket supplied with the vertical flue kit can now be fitted If the vertical flue requires extension s or additional bend s connect the required number of flue extensions or bends up to the maximum equivalent flue length between the boiler and vertical flue assembly Ensure that any horizontal sections of the flue system have a minimum 1 maximum 3 fall back to the boiler 1 17mm per 1000mm NOTE When cutting an extension to the required length you must ensure that the excess is cut from the plain end of the extension Remove any burrs and check that any seals are located properly You mustensure that
85. the entire flue system is properly supported and connected 13 295 Fig 14 CONCENTRIC DUCTS 80 125 DIAMETER The relative adapter kit must be installed for this configuration Concentric ducts can be arranged in the most suitable direction for installation requirements To install the ducts follow the instructions provided with the specific condensing boiler kits Reduction for bends Bend Reduction in maximum flue length for each bend 45 bend 0 5 metre 90 bend 1 0 metre Horizontal Vertical 80 125 flue terminal and accessories Part No Description Length 20028029 convertor box N A 414 Vertical flue terminal 1000mm 413 Horizontal flue terminal 1000mm 531 Pitched roof flashing plate N A 532 Flat roof flashing plate N A 415 90 degree bend N A 416 45 degree bends pair N A 417 250mm extension 250mm 418 500mm extension 500mm 419 1000mm extension 1000mm 420 2000mm extension 2000mm 421 3000mm extension 3000mm 423 Wall bracket pack 5 208mm 4 5 3 TWIN FLUE SYSTEM The Vok ra twin flue system enables greater flue distances to be achieved than that of a concentric flue system It can be used for horizontal or vertical applications and it can be connected directly on the boiler fig 15 It is essential that the installation of the twin flue system be carried out
86. tion of the 2 control knobs are correctly aligned with the respective potentiometers on the PCB Ensure that the correct jumper tag configuration has been respected It will be necessary to check the functioning of the PCB is set for the correct boiler type application 6 12 GAS VALVE fig 32 Carry out component removal procedure as described in 6 4 The gas valve must be changed as complete unit Disconnect the electrical plug and leads from the gas valve slacken and unscrew gas valve inlet and outlet connections Please note the sealing washers i must be discarded and replaced with new sealing washers Disconnect the compensation pipe L Unscrew gas pipe connections M N the gas valve can now be removed Replace in the reverse order Check and adjust burner pressure settings WARNING A GAS TIGHTNESS CHECK MUST BE CARRIED OUT 6 12 1 INJECTOR fig 32 Carry out component removal procedure as described in 6 4 Unscrew and remove gas pipe connections M N Locate and remove the injector O inside the upper connection pipe Replace in the reverse order Check and adjust burner pressure settings WARNING A GAS TIGHTNESS CHECK MUST BE CARRIED OUT 6 13 ELECTRODES fig 33 Carry out component removal procedure as described in 6 4 Disconnect the electrode leads and ancillary wiring from their respective connectors Remove the retaining screws P for electrode Remove the spark ignition Q and sensing R electrodes W
87. um gas CO minimum output 9 5 10 0 pressure must be adjusted as follows e locate the minimum adjustment screw fig 42 using a suitable screwdriver remove the protection plug e using a 4mm Allen key very slowly turn the minimum adjustment screw see fig 42 clockwise to increase counter clockwise to decrease until the correct value is displayed on the CO analyser allow time for the analyser to stabilise 7 5 4 COMPLETION On completion of the combustion analysis check and or any gas valve adjustment refit the plug fig 40 L2 and move the mode selector throught D position Remove the test probe from the test point and refit the sealing screw s and or cap IMPORTANT A GAS TIGHTNESS CHECK MUST BE CARRIED OUT IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED 7 6 RANGE RATED This boiler can be adapted to the plant s thermal need in fact the maximum flow rate can be set for the boilers heating function Disconnect the power supply to the boiler Turn the heating water temperature selector to the maximum value that is the selector turned to 10 Lift and rotate the control panel towards you ES Remove the cover by releasing the fixing hooks Insert jumper JP1 fig 43 Put the power to the boiler on lee EO F
88. ves are open remove appliance casing as described in 4 7 1 identify the automatic air release valves AAV and loosen the dust cap s by turning the cap anti clockwise one full turn Ensure all manual air release valves located on the heating system are closed Connect the filling loop slowly proceed to fill the system by firstly opening the inlet valve connected to the flow pipe and then turning the lever on the fill valve to the open position As water enters the system the pressure gauge will begin to rise Once the gauge has reached 1 5 BAR close both valves and begin venting all manual air release valves starting atthe lowest first It may be necessary to go back and top up the pressure until the entire system has been filled Inspect the system for water tightness rectifying any leaks 5 3 1 MANUAL AIR RELEASE fig 26 When the boiler has been filled for the first time or the system has been drained and refilled it will be necessary to release any air that may have become trapped within the appliance heat exchanger Slacken the bleed screw until water is released and then close IMPORTANT THERE ARE NO OTHER MANUAL AIR RELEASE VALVES LOCATED ON THE APPLIANCE Fig 26 5 4 INITIAL FLUSHING OF THE SYSTEM The whole of the heating system must be flushed both cold and hot as detailed in 5 8 Open all radiator or heating valves and the appliance flow amp return service valve Drain the boiler and system from the lo
89. west points Open the drain valve full bore to remove any installation debris from the boiler prior to lighting Refill the boiler and heating system as described in 5 3 5 5 PRE OPERATION CHECKS Before attempting the initial lighting of the appliance the following checks must be carried out e ensure all gas service valves from the meter to the appliance are open and the supply pipe has been properly purged e ensure the proper electrical checks have been carried out see 7 9 particularly continuity polarity and resistance to earth e ensure the 3 AMP fuse supplied with the appliance has been fitted e ensure the system has been filled vented and the pressure set to 1 5 BAR e ensure the flue system has been fitted properly and in accordance with the instructions e ensure all appliance service valves are open 5 6 INITIAL LIGHTING Ensure the electrical supply to the appliance is switched on Ensure any external controls are switched to an ON position and are calling for heat Move the selector switch to the ON position the appliance will now operate as described in 1 2 Should the appliance fail to ignite refer to 5 6 and or section 7 mode of operation parameter setting amp faultfinding 5 7 CHECKING GAS PRESSURE AND COM BUSTION ANALYSIS The appliance is factory set and requires no additional adjustment once installed However to satisfy the requirements of GSIUR 26 9 I S 813 ROI it will be nece
90. with BS 2879 3 6 4 AIR RELEASE POINTS These must be positioned at the highest points in the system where air is likely to be trapped They should be used to expel trapped air and allow complete filling of the system 3 6 5 EXPANSION VESSEL The boiler is not fitted with an expansion tank so you must install a closed tank on the system to ensure the correct appliance functions The dimensions of the expansion tank must be suitable for the heating system characteristics and the tank capacity must meet the requisites of the current regulations 3 6 6 FILLING POINT A method for initial filling of the system and replacing water lost during servicing etc directly from the mains supply is provided see fig 7 This method of filling complies with the current Water Supply Water Fittings Regulations 1999 and Water By laws 2000 Scotland If an alternative location is preferred it should be connected as detailed in fig 7 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 8 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 9 3 6 8 FREQUENT FILLING Frequent fi
91. y releasing the fixing hooks Insert jumpers JP1 and JP3 fig 41 Put the power to the boiler on The three LEDs on the control panel flash simultaneously and the display reads ADJ for about 4 sec Proceed to modify the following parameters 1 Absolute maximum 2 Minimum 3 Maximum heating 4 Slow ignition as described below Turn the heating water temperature selector to set the value required Press the CO button SW1 and move on to setting the next parameter Live electrical parts 230 Vac The following icons switch on on the display 1 During absolute maximum setting MAX 2 During minimum setting MIN 3 During maximum heating setting HTG 4 During slow ignition setting IGN End the procedure by removing jumpers JP1 and JP3 to save the values set in this way The procedure can be ended at any time without saving the values set and keeping the initial settings Turning the function selector to O OFF RESET Switching off the mains power supply After a delay of 15 min after switching it on Setting does not switch on the boiler When the heating selector knob is turned the display automatically shows the number of RPM expressed in hundreds e g 25 2500 rpm Fan speed rpm table MAX MIN HTG IGN 5800 1600 5800 3000 35 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissi

Installation & Servicing Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Installation &amp; Servicing Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Installation & Servicing Manual