Installation & Servicing Instructions - FREE BOILER MANUALS · Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER Vokèra is a licensed member of the

Installation

& Servicing

Instructions

THESE INSTRUCTIONSTO BE RETAINEDBY USER

Vokèra is a licensed member of the Benchmark schemewhich aims to improve the standards of installation and commissioning of domestic hot water systems in the UK.

AquaNovaWater heater

ContentsDesign principles & operating sequence Page1.1 Principle components 21.2 Mode of operation 21.3 Safety devices 2

Technical data Page2.1 Performance 32.2 Gas pressure 32.3 Dimensions 32.4 Clearances 32.5 Connections 32.6 Electrical 32.7 Flue details 3

General requirements Page3.1 Related documents 43.2 Location of appliance 43.3 Gas supply 43.4 Flue system 43.5 Air supply 43.6 Water pipe work 43.7 Electrical supply 53.8 Timber framed buildings 5

Installation Page4.1 Delivery 54.2 Contents 54.3 Unpacking 54.4 Preparation for mounting the appliance 54.5 Fitting the flue 64.6 Connecting the gas & water 104.7 Electrical connections 10

Commissioning Page5.1 Gas supply installation 115.2 Water pipe work 115.3 Pre-operation checks 115.4 Initial lighting 115.5 Checking the burner pressure 115.6 Setting the outlet temperature 115.7 Final checks 115.8 Instructing the user 11

Servicing Page6.1 General 126.2 Routine annual servicing 126.3 Replacement of components 126.4 Component removal procedure 126.5 NTC thermistors removal 126.6 High limit thermostat removal 126.7 Flow switch removal 126.8 Gas valve removal 136.9 Burner, injectors and spark/sense electrode removal 136.10 Flue fan removal 136.11 Heat exchanger removal 146.12 Air pressure switch removal 14

Checks, adjustments, and fault finding Page7.1 Checking appliance operation 147.2 Appliance mode of operation 147.3 Checking/adjusting burner pressure 147.4 External faults 157.5 Electrical checks 157.6 Fault finding 157.7 Fault codes 16

Wiring diagrams Page8.1 External wiring 21

Exploded diagrams Page9.1 Table 1 239.2 Table 2 24

L.P.G. instructions Page10.1 Technical data 2510.2 Related documents 2510.3 Gas supply 2510.4 Gas supply installation 2510.5 Checking/Adjusting the burner pressure 25

1

INTRODUCTION

General layout

1 Gas valve2 High limit thermostat3 Electrode4 NTC sensor5 Pressure differential switch6 Silicone pressure tube (+)7 Silicone pressure tube (-)8 Fan assembly9 Heat exchanger10 Main burner11 Flow switch

The Vokera AquaNova is an instantaneous water heater,which - by design - incorporates electronic ignition, NTCtemperature control, continuous gas modulation, andstatus/fault indicators.

It is produced as a room sealed, category II2H3+ appliance,suitable for wall mounting applications only. It is provided

with a fan powered flue outlet with an annular co-axialcombustion air intake that can be rotated – horizontally –through 360 degrees for various horizontal or verticalapplications.

The AquaNova can also be used with the Vokera twin fluesystem.

Fig. 1

2

SECTION 1 DESIGN PRINCIPLE AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS● A fully integrated electronic control board

featuring electronic temperature control, self-diagnostic fault indicator, continuous gasmodulation.

● Electronic ignition with flame supervision.● Fan.● Differential air pressure switch.● Two-stage gas valve.

1.2 MODE OF OPERATIONWhen there is a request for hot water via a hotwater outlet or tap, the water flow switch senseswater movement thereby energising the fan, thefan proves the differential air pressure switchwhich in-turn allows an ignition sequence to begin.Ignition is sensed by the electronic circuitry toensure flame stability at the burner. Oncesuccessful ignition has been achieved, theelectronic circuitry increases the gas rate tomaximum or modulates to suit the set requirement.

When the appliance reaches the desiredtemperature the burner will modulate to maintainthe desired temperature. Should the temperaturecontinue to increase, the burner will shut off whenthe maximum operating temperature is attained.When the request for hot water has been satisfiedthe appliance fan may continue to operate todissipate any residual heat within the appliance.

1.3 SAFETY DEVICESWhen the appliance is in use, safe operation isensured by:● a high limit thermostat that over-rides the

temperature control circuit to prevent or interruptthe operation of the burner;

● a differential air pressure switch that checks theoperation of the fan and flue thereby allowingsafe operation of the burner;

● a flame supervision device that will shut off thegas supply to the burner if there is no flamesensed within 7 seconds.

Fig. 2

inlet cold water

Fan assembly

Air pressure switch

outlet cold water

Heat exchanger

Burner

Flow regulator

Gas

Flow switch

High limit thermostat

NTC sensor

3

SECTION 2 TECHNICAL DATA

2.1 PerformanceHeat input 32,0 kWHeat output (max) 28,8 kWHeat output (min) 10,0 kWMinimum working pressure 0,15 kWMaximum working pressure 10,0 barMinimum flow rate 2 litres per minuteHot water - 35°C temperature rise 11,8 litres per minute2.2 Gas pressureInlet pressure (G20) 20,0 mbarMaximum burner pressure 12,0 mbarMinimum burner pressure 1,5 mbarGas rate 3,5 m3/hInjector size 15 x 1,30mm2.3 DimensionsHeight 640 mmWidth 400 mmDepth 246 mmWeight 20 kg2.4 ClearancesTop 150 mm from casing or 25 mm above

flue elbow (whichever is applicable)Bottom 150 mmSides 50 mmFront 600 mm2.5 ConnectionsCold water inlet 15 mm (compression)Hot water outlet 15 mm (compression)Gas 15 mm copper2.6 ElectricalVoltage 230V/~ 50hzPower consumption 85 WInternal fuse 2 AFExternal fuse 3 A2.7 Flue detailsMaximum horizontal flue length (concentric) 2,4 metresMinimum horizontal flue length (concentric) 0,4 metresMaximum vertical flue length (concentric) 3,6 metresMinimum vertical flue length (concentric) 1,0 metresMaximum twin flue length (horizontal or vertical) 5m/5m + terminal

Fig. 3

Terminal position for fan assisted boiler(minimum distance) mmA - Directly above or below an open window 300

or other opening (e.g. air brick)B - Below gutters, soil pipes or drain pipes 25C - Below eaves 25D - Below balconies or car port roof 25E - From vertical drain pipes and soil pipes 75F - From internal or external corners 25G - Above ground or below balcony level 300H - From a surface facing a terminal 600I - From a terminal facing a terminal 1200

J - From an opening in the car port (e.g. doorwindow) into dwelling. 1200

K - Vertically from a terminal on the same wall 1500L - Horizontally from a terminal on the same wall 300M - Horizontally from a vertical terminal to a wall 300N - Horizontally from an opening, airbrick,

openable window, etc. 300

NOTE: The flue must be terminated in a place not likely to cause anuisance.

N

New minimum distance

4

This appliance must be installed by a competentperson in accordance with the Gas Safety (Instal-lation & Use) Regulations.

3.1 RELATED DOCUMENTSThe installation of this water heater must be inaccordance with the relevant requirements of theGas Safety (Installation & Use) Regulations, theWater supply (water fittings) Regulations, theWater Byelaws Scotland, the Building Standards(Scotland) Regulation and Building Standards(Northern Ireland) Regulations.It should be in accordance also with any relevantrequirements of the local authority and the relevantrecommendations of the following British StandardCodes of Practice.

3.2 LOCATION OF APPLIANCEThe appliance may be installed in any room orinternal space, although particular attention isdrawn to the requirements of the current I.E.E.wiring regulations, and in Scotland, the electricalprovisions of the Building Regulations, withrespect to the installation of the appliance in aroom or internal space containing a bath or shower.When an appliance is installed in a room orinternal space containing a bath or shower, theappliance or any control pertaining to it must notbe within reach of a person using the bath orshower.The location chosen for the appliance must permitthe provision of a safe and satisfactory flue andtermination. The location must also permit anadequate air supply for combustion purposesand an adequate space for servicing and aircirculation around the appliance. Where theinstallation of the appliance will be in an unusuallocation special procedures may be necessary,BS 6798 gives detailed guidance on this aspect.A compartment used to enclose the appliancemust be designed and constructed specificallyfor this purpose. An existing compartment/cup-board may be utilised provided that it is modifiedto suit.Details of essential features of compartment/cupboard design, including airing cupboard in-stallations, are given in BS 6798. This applianceis not suitable for external installation.

3.3 GAS SUPPLYThe gas meter – as supplied by the gas supplier– must be checked to ensure that it is of adequatesize to deal with the maximum rated input of allthe appliances that it serves. Installation pipes

must be fitted in accordance with BS 6891.Pipe-work from the meter to the appliance mustbe of adequate size. Pipes of a smaller size thanthe appliance gas inlet connection must not beused. The installation must be tested for sound-ness in accordance with BS 6891.If the gas supply serves more than one appliance,it must be ensured that an adequate supply ismaintained to each appliance when they are inuse at the same time.

3.4 FLUE SYSTEMThe terminal should be located where the disper-sal of combustion products is not impeded andwith due regard for the damage and discolorationthat may occur to building products located nearby.The terminal must not be located in a place whereit is likely to cause a nuisance (see fig. 3).In cold and/or humid weather, water vapour maycondense on leaving the terminal; the effect ofsuch pluming must be considered.If installed less than 2m above a pavement orplatform to which people have access (includingbalconies or flat roofs) the terminal must beprotected by a guard of durable material. Theguard must be fitted centrally over the terminal.Refer to BS 5440 Part 1, when the terminal is 0,5metres (or less) below plastic guttering or 1 metre(or less) below painted eaves.

3.5 AIR SUPPLYThe following notes are intended for generalguidance only.This appliance is a room sealed, fan-flued waterheater, consequently it does not require apermanent air vent for combustion air supply.When installed in a cupboard or compartment,ventilation for cooling purposes is also not required.

3.6 WATER PIPE WORKDetailed recommendations are given in BS 5449Part 1 and BS 6798. The following notes are forgeneral guidance only.

3.6.1 PIPEWORKIt is recommended that copper tubing to BS 2871Part 1 is used in conjunction with soldered capil-lary joints.Where possible pipes should have a gradient toensure air is carried naturally to an outlet and thatwater flows naturally to drain cocks.

SECTION 3 GENERAL REQUIREMENTS

BS 5440 PART 1 FLUES

BS 5440 PART 2 FLUES AND VENTILATION

BS 5546 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

BS 6891 LOW PRESSURE INSTALLATION PIPES

BS 6700 DESIGN, INSTALLATION, TESTING AND MAINTAINENCE OF SERVICES SUPPLYINGWATER FOR DOMESTIC USE

5

Pipes should be insulated to avoid heat loss andin particular to avoid the possibility of freezing.Particular attention should be paid to pipes passingthrough ventilated areas such as under floors, loftspace, and void areas.

3.6.2 DRAIN COCKSThese must be located in accessible positions tofacilitate draining of the appliance and all waterpipes connected to the appliance. The draincocks must be manufactured in accordance withBS 2879.

3.7 ELECTRICAL SUPPLYThe appliance is supplied for operation on 230V@ 50Hz electrical supply; it must be protectedwith a 3-amp fuse. The method of connection tothe mains electricity supply must allow forcomplete isolation from the supply. The preferredmethod is by using a double-pole switch with acontact separation of at least 3mm. The switchmust only supply the appliance. Alternatively anun-switched shuttered socket with a fused 3-pinplug both complying with BS 1363 is acceptable.

Fig. 4

4.1 DELIVERYThe appliance is delivered in a heavy-duty card-board carton. Lay the carton on the floor with thewriting the correct way up.

4.2 CONTENTSContained within the carton is:● the appliance;● the wall mounting bracket;● template;● an accessories pack containing the appliance

service valves and washers;● the instruction pack containing the installation

& servicing instructions, user instructions and a3-amp fuse.

4.3 UNPACKINGAt the top of the carton pull both sides open – donot use a knife – unfold the rest of the carton fromaround the appliance, carefully remove all pro-tective packaging from the appliance, and lay theaccessories etc. to one side.

4.4 PREPARATION FOR MOUNTING THEAPPLIANCEThe appliance should be mounted on a smooth,vertical, surface, which must be capable ofsupporting the full weight of the appliance. Careshould be exercised when determining the positionof the appliance with respect to hiddenobstructions such as pipes, cables, etc.When the position of the appliance has beendecided – using the template supplied – carefullymark the position of the wall-mounting bracket(see fig. 5) and flue-hole (if applicable).

3.8 TIMBER FRAMED BUILDINGSIf the appliance is to be fitted in a timber framedbuilding, it should be fitted in accordance withthe Institute of Gas Engineers publication (IGE/UP/7) “Guide for Gas Installations in TimberFrame Buildings”.

SECTION 4 INSTALLATION

Fig. 5

1= centre of rear flue hole using ONLY 0225705 or 0225710 flue2= centre of rear flue hole for ALL OTHER FLUES

ø 125

ø 6ø 6

Type 2

Type 1

320

4586

131

614,

5

803

57,5

74 74

6

4.4.1 IMPORTANTThere are two holes on the template.The lower hole should be used with thetelescopic flue kit (part n° 0225705 & 0225710).The upper hole is for use with all otherhorizontal flue kits.

4.4.2 MAXIMUM FLUE LENGTHS

4.5 FITTING THE FLUEThe top flue outlet permits both horizontal andvertical flue applications to be considered,alternatively, the Vokera twin flue system can beutilised 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 flue outlet elbow can be rotatedthrough 360° on its vertical axis. In addition theflue may be extended from the outlet elbow in thehorizontal plane (see 4.4.2), however if the flue isto be extended or additional bends are to befitted, the standard horizontal flue kit (part n°2359029) must be used. A reduction must alsobe made to the maximum length (see table) whenadditional bends are used.

Using the template provided, mark and drill a115mm hole for the passage of the flue pipe. Thehole should have a 1° drop from the boiler tooutside, to eliminate the possibility of rainwaterentering the appliance via the flue.The fixing holes for the wall-mounting bracketshould now be drilled and plugged, anappropriate type and quantity of fixing should beused to ensure that the bracket is mountedsecurely. Once the bracket has been secured tothe wall, mount the appliance onto the bracket.

Flue systemConcentric HorizontalConcentric VerticalTwin flue

AquaNova2,4m3,6m5m/5m + terminal

Reduction for bends

Bend

45° bend90° bend

0,5 metre1,0 metre

Reduction in maximum flue length for each bend

Horizontal flue terminals and accessories

Part No. Description Min-Max length

0225705

0225710

2359029

23590692359079235904923590590225760

Standard telescopic flue

Extended telescopic flue

Horizontal flue kit for use withadd. bends & extensions750mm extension1500mm extension45° bend (pair)90° bendWall bracket (5)

380mm-600mm(dimension X)600mm-920mm(dimension X)833mm(dimension X)750mm1500mmN/AN/AN/A

IMPORTANT

The flue restrictor ring must be inserted into theappliance flue outlet if the total flue length is lessthan 1.0m

FITTING THE TELESCOPIC FLUE KIT(0225705 & 0225710)Carefully measure the distance from the centreof the appliance flue outlet to the face of theoutside wall (dimension X see fig. 6). Add 50mmto dimension X to give the overall flue length(dimension Y). Using the complete telescopic flueassembly adjust the length to suit dimension Y.Once the telescopic flue terminal has beenadjusted to the correct length, secure the flueassembly with the screw supplied.Insert the flue assembly into the previously drilledflue hole and locate the flue bend over theappliance flue outlet. Push the flue bend downover the appliance flue outlet and ensure thecorrect seal is made. Pull the flue assemblytowards and over the flue bend - using a twistingaction - ensuring the correct seal is made. Checkthat the terminal protrudes past the finishedoutside wall by the correct length (115mm).

NOTEYou must ensure that the entire flue system isproperly supported and connected.Seal the flue assembly to the wall using cementor a suitable alternative that will providesatisfactory weatherproofing. The interior andexterior trim can now be fitted.

FITTING THE STANDARD (2359029)HORIZONTAL FLUE KIT (see 4.4.1)Carefully measure the distance from the centreof the appliance flue outlet to the face of theoutside wall (dimension X see fig. 7). Ensure theinner (60mm) pipe is fully inserted into the outer(100mm) pipe (when the inner pipe is fullyinserted, it stands proud of the outer pipe by7,5mm). Add 32mm to dimension X to give theoverall flue length (dimension Y). The standardhorizontal flue kit (part no. 2359029) is suitablefor a distance (dimension Y) of up to 865mm.

NOTEDimension Y is measured from the end of theterminal to the end of the outer (100mm) pipe.The internal trim should be fitted to the flue pipebefore connection of the 90° bend.

115 mm

“X”

“Y”

Fig. 6 “X” + 50 mm = “Y”

7

If the horizontal flue kit (2359029) requires to becut to the correct size (dimension Y), you mustensure that the inner (60mm) pipe stands proudof the outer (100mm) pipe by 7,5 mm (see fig. 8).Ensure any burrs are filed or removed and thatany seals are located properly before assembly.Hold the inner (60mm) pipe of the terminalassembly and connect to the push-fit end of the90° bend (supplied) using a twisting action. Insertthe assembled flue into the previously drilledhole. Using the clips & screws supplied, connectthe flue assembly to the boiler, ensuring that theterminal protrudes past the finished outside wallby the correct length (135mm).

You must ensure that the entire flue system isproperly supported and connected.Seal the flue assembly to the wall using cementor a suitable alternative that provides satisfactoryweatherproofing. The exterior trim can now befitted.

EXTENDING THE HORIZONTAL FLUEIf the horizontal flue requires extension/s oradditional bend/s, the horizontal flue terminal kit(2359029) must be used. Connect the bend -supplied with the terminal kit - to the top of thewater heater using the clips, screws, & gasketssupplied. The additional bends & extensions havean internal push-fit connection, care should betaken to ensure that the correct seal is madewhen assembling the flue system. Connect therequired number of flue extensions or bends (upto the maximum equivalent flue length) to the flueterminal using the clips, screws & gaskets supplied(see fig. 7 & 8).

Fig. 7

Max. 833mm

Dimension “X”

135mm

Dimension “Y”

7,5

110

Fig. 8

Extension

Push-fitconnection

Boiler

7,5 mm

IMPORTANTThe flue restrictor ring must be removed ordiscarded if the total flue length - including bends-exceeds 1.0m.

NOTEWhen cutting the horizontal flue terminal or anextension to the required length, you must ensurethat the excess is cut from the plain end of theterminal or extension, and that the inner (60mm)pipe is 7,5mm longer than outer (100mm) pipe(see fig. 7 & 8). Remove any burrs, and check thatany seals are located properly.You must ensure that the entire flue system isproperly supported and connected.Seal the flue assembly to the wall using cementor a suitable alternative that will providesatisfactory weatherproofing. The interior andexterior trim can now be fitted.

4.5.2 CONCENTRIC VERTICAL FLUEThe vertical flue terminal can be connected directlyto the appliance flue outlet.Alternatively, an extension or bend can beconnected to the appliance flue outlet if desired(see 4.4.2), however if additional bends are fitted,a reduction must be made to the maximum fluelength (see table below).

Using the dimensions given in fig. 9 as areference, mark and cut a 105mm hole in theceiling and/or roof.Fit the appropriate flashing plate to the roofand insert the vertical flue terminal through theflashing plate from the outside, ensuring thatthe collar on the flue terminal fits over theflashing.The fixing holes for the wall-mounting bracketshould now be drilled and plugged, an appropriatetype and quantity of fixing should be used toensure that the bracket is mounted securely.Once the bracket has been secured to the wall,mount the appliance onto the bracket.


Reduction for bends

Bend

45° bend 0,5 metre90° bend 1,0 metre

Vertical flue terminal and accessories

Part No. Description Length

2359039

0225770

0225765

2359069

2359079

2359049

2359059

0225760

Vertical flue terminal

Pitched roof flashing plate

Flat roof flashing plate

750mm extension

1500mm extension

45° bend (pair)

90° bend

Wall bracket (5)

1000 mm

N/A

N/A

750mm

1500mm

N/A

N/A

N/A

8

Fig. 9Twin flue accessories

Part No. Description Length

0225805022581030002257700225765022581502258200225825022583002258350225840022584502258500225855

Horizontal flue terminalVertical flue terminalConcentric to twin, adapterPitched roof flashing plateFlat roof flashing plateCondensate drain kit0,25m extension (pair)0,5m extension (pair)1,0m extension (pair)2,0m extension (pair)45° bend (pair)90° bend (pair)Twin bracket (5)Single bracket (5)

1000 mm1000 mmN/AN/AN/AN/A250mm500mm1000mm2000mmN/AN/AN/AN/A

166mm

465mm

300mm minimum

The vertical flue terminal is 1.0 metre in lengthand cannot be cut; therefore it may be necessaryto adjust the height of the appliance to suit or usea suitable extension.Remove or discard the flue restrictor ring from theappliance flue outlet (see fig. 1), if the total fluelength - including the allowance for any additionalbends - exceeds 1.0 metre.Connect the vertical flue assembly to the waterheater flue spigot using the 60mm & 100mm clips,gaskets & screws (supplied), ensuring the correctseal is made. The flue support bracket (suppliedwith the vertical flue kit) can now be fitted.If the vertical flue requires extension/s or additionalbend/s, connect the required number of flueextensions or bends (up to the maximumequivalent flue length) between the water heaterand vertical flue assembly (see fig. 8).

NOTEWhen cutting an extension to the required length,you must ensure that the excess is cut from theplain end of the extension and that the inner(60mm) pipe is 7,5mm longer than outer (100mm)pipe (see fig. 8). Remove any burrs, and checkthat any seals are located properly.You must ensure that the entire flue system isproperly supported and connected.

4.5.3 TWIN FLUE SYSTEMThe Vokera twin flue system enables greater fluedistances to be achieved (see 4.4.2) than that ofthe standard concentric flue system.It can be used for horizontal or verticalapplications, however the twin flue system mustbe converted to the dedicated concentric flue kitfor termination.It is essential that the installation of the twin fluesystem be carried out in strict accordance withthese instructions.

GUIDANCE NOTES ON TWIN FLUEINSTALLATION● The flue must have a fall back of 1° back to the

appliance to allow any condensate that may formin the flue system to drain via the condensatedrain. Consideration must also be given to thefact that there is the possibility of a small amountof condensate dripping from the terminal.

● Ensure that the entire flue system is adequatelysupported, use at least one bracket for eachextension.

● The entire flue system must be adequatelyinsulated to maintain heat within the flue systemthereby reducing the possibility of condensateproduction.

● As the exhaust outlet pipe can reach very hightemperatures it must be protected to preventpersons touching the hot surface.

● The condensate drain pipe must be connectedin accordance with building regulations.

MOUNTING THE WATER HEATERThe fixing holes for the wall-mounting bracketshould now be drilled and plugged, anappropriate type and quantity of fixing should beused to ensure that the bracket is mountedsecurely. Once the bracket has been secured tothe wall, mount the appliance onto the bracket.

4.5.3.1 INSTALLATION OF CONCENTRIC TO TWINADAPTOR KIT (see fig. 10)● Remove the flue restrictor ring from the

appliance flue outlet (if fitted).● Using the two holes in the concentric section

of the adaptor as a guide, drill two - 3mm -corresponding holes on the appliance flueoutlet.

● Fit the adaptor to the appliance flue outlet andsecure it using the screws provided.


Reduction for bends

Bend

45° bend

90° bend

1,0 metre

1,0 metre

9

Fig. 10

Fig. 11

Condensate drain kit

4.5.3.2 INSTALLATION OF CONDENSATE DRAIN KIT(see fig. 11)The condensate drain kit must be fitted within 1metre of the appliance flue outlet. It isrecommended that the condensate drain kitshould be fitted in the vertical plane, however itcan be fitted horizontally with care.● Fit the first bend to the condensate drain kit or

exhaust connection manifold by firmly pushingin to position.

● Using the two holes in the exhaust connectionmanifold as a guide, drill a 3mm hole in eachand secure using the screws provided.

● Connect the air inlet pipe to the air baffle asabove.

● The twin flue pipes extensions and accessoriescan now be installed by pushing together (theplain end of each extension or bend should bepushed approximately 50mm into the femalesocket of the previous piece).

4.5.3.3 HORIZONTAL TERMINATION (see fig. 12)

The twin flue system must be converted to thededicated concentric flue kit for termination.● The horizontal terminal is supplied with a built-

in converter box and cannot be shortened.● A 130mm hole is required for the passage of

the concentric terminal through the wall.● The air inlet pipe must always be level with or

below, that of the exhaust pipe.

Depending on site conditions it may be preferableto install the terminal assembly prior to fitting thetwin flue pipes.

Mark and drill a 130mm hole for the passage ofthe horizontal flue terminal, ensuring that thereis a 1° fall back to the water heater (17mm per1000mm). Insert the terminal assembly into theflue hole.Push-fit the twin flue pipes onto the concentric totwin converter box ensuring that the exhaust pipeconnects to the exhaust connection on theconcentric to twin converter.If necessary cut the plain ends (male) of the twinflue pipes to allow connection to the concentricto twin converter.

NOTE● Before cutting twin flue pipes ensure

allowances have been made for connectiononto the previous piece and onto the concentricto twin converter. The last twin flue pipes mustbe pushed 50mm onto the male spigots of theconcentric to twin converter.

● You must ensure that the entire flue system isproperly supported and connected.

● Seal the flue terminal assembly to the wall usingcement or a suitable alternative that will providesatisfactory weatherproofing. The interior andexterior trim can now be fitted.

4.5.3.4 VERTICAL TERMINATION (see fig. 13)The twin flue system must be converted to thededicated concentric flue kit for termination.● The vertical terminal is supplied with a built-in

converter box and cannot be shortened.● A 130mm hole is required for the passage of

the concentric terminal through the ceilingand/or roof.

Depending on site conditions it may be preferableto install the terminal assembly prior to fitting thetwin flue pipes.Fit the appropriate flashing plate to the roofand insert the vertical flue terminal through theflashing plate from the outside, ensuring thatthe collar on the flue terminal fits over theflashing.Push-fit the twin flue pipes onto the concentric totwin converter ensuring that the exhaust pipeconnects to the exhaust connection on theconcentric to twin converter.If necessary cut the plain ends (male) of the twinflue pipes to allow connection to the concentricto twin converter.

NOTE● Before cutt ing twin f lue pipes ensure

allowances have been made for connectiononto the previous piece and onto theconcentric to twin converter. The last twin fluepipes must be pushed 50mm onto the malespigots of the concentric to twin converter.

● You must ensure that the entire flue system isproperly supported and connected.

● Ensure that any horizontal sections of pipehave a 1° fall towards the appliance (17mmper 1000mm).

10

Fig. 12

Fig. 13

Fig.14

Convertor box

Condensate trap

4.6 CONNECTING THE GAS AND WATERThe appliance is supplied with an accessoriespack that contains sealing washers and servicevalves. The service valves are of the compressiontype.When connecting pipe work to the valves,tighten the compression end first, then insert thesealing washers before tightening the valve to theappliance.

NOTEIt will be necessary to hold the valve with onespanner whilst tightening with another.

4.6.1 GAS (see fig. 4)The appliance is supplied with a 15mm servicevalve, connect a 15mm pipe to the inlet of thevalve and tighten both nuts.

NOTEIt will be necessary to calculate the diameter ofthe gas supply pipe to ensure the appliance hasan adequate supply of gas.

4.6.2 COLD INLET (see fig. 4)The appliance is supplied with 15mm stopcock forthe cold water inlet connection, connect a 15mmpipe to the inlet of the valve and tighten the nut.

4.6.3 HOT WATER OUTLET (see fig. 4)The appliance is supplied with 15mm connectorfor the hot water outlet connection, connect a15mm pipe to the outlet of the connector andtighten the nut.

4.7 ELECTRICAL CONNECTIONSThe electrical supply must be as specified in 3.7.The appliance is supplied, pre-wired with a 0,9metre length of flex, connect the wires as follows:● connect the Brown wire to the L (Live) terminal

of the plug or fused isolator;● connect the Blue wire to the N (Neutral) terminal

of the plug or fused isolator;● connect the Green/Yellow wire to the E (Earth)

terminal of the plug or isolator;● ensure the plug or fused isolator is fitted with a

3-amp fuse.

4.7.1 CASING REMOVALTo gain internal access to the appliance you mustfirst remove the casing, proceed as outlined below:● locate and remove the 4 screws that secure the

controls fascia to the appliance casing (see fig. 14);● lift the casing upward to disengage it from the

top locating hooks and then remove;● gently lower the control fascia until it rests;● store the casing and screws safely until required.

Re-fit in the reverse order.

Fig.15

Screws

Screws

Outlet testnipple

Inlet testnipple Protective

cap

11

5.1 GAS SUPPLY INSTALLATIONInspect the entire installation including the gasmeter, test for soundness and purge. Refer to BS6891 for specific instruction.

5.2 WATER PIPE WORKThe water pipe work shall be flushed and testedin accordance with the Water Supply (waterfittings) Regulations (Water Byelaws Scotland).

5.3 PRE-OPERATION CHECKSBefore attempting the initial lighting of the appli-ance, the following checks must be carried out:● ensure all gas service valves from the meter to

the appliance are open and the supply pipe hasbeen properly purged;

● ensure the proper electrical checks have beencarried out (see 7.7), particularly continuity,polarity and resistance to earth;

● ensure the 3 amp fuse – supplied with theappliance – has been fitted;

● ensure the appliance and associated pipe workhas been filled and vented;

● ensure the flue system has been fitted properlyand in accordance with the instructions;

● ensure all appliance service valves are open.

5.4 INITIAL LIGHTINGEnsure the electrical supply to the appliance isswitched on. Turn the selector knob to the ‘on’position (fig. 1). Open a hot water outlet (preferablya bath tap) and ensure the flow rate exceeds 2litres per minute.The appliance will now go through an ignitionsequence as described in 1.2. Should theappliance fail to ignite, refer to 5.3 and/or section7 (fault finding).

5.5 CHECKING THE BURNER PRESSUREAlthough the burner pressure is factory set, it isnecessary to check it during commissioning.Isolate the appliance from the electrical supplyand attach a suitable manometer to the gas valveoutlet test nipple (see fig. 15). Light the applianceas described in 5.4 and compare the reading onthe manometer with the values described in 2.2.If adjustement is required, follow the detailedinstructions in section 7 (7.3).Once the burner pressure has been checked,isolate the appliance from the electrical supply,remove the manometer, and tighten the gasvalve outlet test nipple.

5.6 SETTING THE OUTLET TEMPERATUREThe hot water outlet temperature can be adjustedbetween 40°C - 65°C via the thermostat knob(see fig. 1).

5.7 FINAL CHECKS● ENSURE ALL TEST NIPPLES ON THE AP-

PLIANCE GAS VALVE HAVE BEEN

TIGHTENED AND CHECKED FORSOUNDNESS.

● ENSURE THE APPLIANCE FLUE SYSTEM ISFITTED CORRECTLY AND IS PROPERLYSECURED.

● ENSURE ALL PIPE WORK IS RE-CHECKEDFOR SOUNDNESS.

● RE-FIT APPLIANCE CASING.Complete details of the installation in the warrantycard supplied with the appliance. This is animportant document, which must be correctlycompleted and handed to the user. Failure toinstall and commission the appliance to the manu-facturers instructions may invalidate the warranty.

5.8 INSTRUCTING THE USERHand over all documentation supplied with thisappliance – including these instructions – andexplain the importance of keeping them in a safeplace.Explain to the user how to isolate the appliancefrom the gas, water and electricity supplies, andthe locations of all drain points.Show the user how to operate the appliance andits controls correctly.Explain to the user how to turn off the appliancefor both long and short periods, and advise on thenecessary precautions to prevent frost damage.Explain to the user that for continued safe andefficient operation, the appliance must be servicedannually by a competent person.

SECTION 5 COMMISSIONING

12

SECTION 6 SERVICING

6.1 GENERALTo ensure the continued safe and efficient opera-tion of the appliance, it is recommended that it ischecked and serviced at regular intervals.The frequency of servicing will depend upon theparticular installation conditions, but in general,once per year should be adequate.It is the law that any servicing work is carried outby competent person such as a Vokera engineer,an approved service agent, British Gas, or otherCORGI registered personnel.The following instructions apply to the appliance,but it should be remembered that the domestichot water system will also require attention fromtime to time.

6.2 ROUTINE ANNUAL SERVICING● Check the operation of the appliance and ensure

it functions as described in section 7.● Compare the performance of the appliance

with its design specification. The cause of anynoticeable deterioration should be identifiedand rectified without delay.

● Thoroughly inspect the appliance for signs ofdamage or deterioration especially the fluesystem and the electrical apparatus.

● Check and adjust – if necessary – all burnerpressure settings (see 7.3).

● Carry out an analysis of the flue gases (see7.4), and visually check the condition of theentire flue assembly.

● Compare the results with the appliance designspecification. Any deterioration in performancemust be identified and rectified without delay.

● Ensure both flue venturis are clean and freefrom any debris or obstruction.

● Ensure both the burner and heat exchanger areclean and free from any debris or obstruction.

● Inspect all joints for signs of leakage and repairif necessary.

● Refer to the commissioning section and/or re-placement of parts section for detailedinstruction if required.

6.3 REPLACEMENT OF COMPONENTSAlthough it is anticipated that this appliance willgive years of reliable, trouble free service, the lifespan of components will be determined by factorssuch as operating conditions and usage. Shouldthe appliance develop a fault, the fault findingsection will assist in determining which componentis malfunctioning.

6.4 COMPONENT REMOVAL PROCEDURETo remove a component, access to the interior ofthe appliance is essential. Isolate the appliancefrom the electrical supply and remove the fuse.And when necessary, close all service valves onthe appliance, remove the appliance casing asdescribed in section 4.7.1, drain the water contentfrom the appliance via an outlet or appropriate

drain point. Ensure some water absorbent clothsare available to catch any residual water that maydrip from the appliance or removed component.Undertake a complete commissioning check asdetailed in section 5, after replacing anycomponent. ALWAYS TEST FOR GASSOUNDNESS IF ANY GAS CARRYINGCOMPONENTS HAVE BEEN REMOVED ORDISTURBED.

6.5 NTC THERMISTORS (see fig. 1)Carry out component removal procedure as de-scribed in 6.4.Locate and remove the ten screws that securethe air chamber cover.Remove the air chamber cover.Disconnect thermistor electrical plug. Using a13mm spanner slacken and remove the thermistorand sealing washer. Replace in the reverse order.

6.6 HIGH LIMIT THERMOSTAT (see fig. 1)Carry out component removal procedure as de-scribed in 6.4.Locate and remove the ten screws that securethe air chamber cover. Remove the air chambercover.Pull off electrical connections from the high limitthermostat, slacken and remove retaining screws.Replace in the reverse order.

6.7 FLOW SWITCH (see fig. 16)Carry out component removal procedure as de-scribed in 6.4.Remove the appliance casing as described in4.7.1. Disconnect the cold water inlet pipe fromthe bottom connection of the flow switch.Disconnect the outlet pipe from the top connectionof the flow switch. Detach the electrical plug/wires from the flow switch. Slacken and removethe lock-nut that secures the flow switch to thelower frame. Replace in the reverse order.

Fig. 16

3

4

5

71

2

65

1 Screws2 High limit thermostat3 Outlet pipe4 DHW flow switch

5 Locknut6 Gas valve securing screws7 Gas valve

13

6.7.1 PRINTED CIRCUIT BOARD (PCB) (see fig. 17)Carry out component removal procedure as de-scribed in 6.4.Remove the appliance casing as described in4.7.1. Carefully slide out the control panel untilthe lugs on the lower right and left side of thepanel are free from the slots on the applianceframe. Remove the electrode lead from its clip onthe PCB housing. Locate and remove the twoscrews which secure the PCB cover & terminalcover, then remove cover, after carefully takingnote of all wiring connections, disconnect allwiring from the PCB, locate and remove the PCBsecuring screws, remove PCB.Replace in the reverse order.NOTEEnsure that the replacement PCB has the correct“Jumper Tag” configuration (see section 8).

6.8 GAS VALVE (see fig. 16)Carry out component removal procedure as de-scribed in 6.4. Remove the appliance casing asdescribed in 4.7.1.The gas valve must be changed as complete unit.Disconnect the electrical plug and leads from thegas valve. Disconnect compensator tube fromgas valve regulator. Slacken and unscrew gasvalve inlet and outlet connections. Please note,the sealing washers must be discarded and re-placed with new sealing washers. Locate andremove gas valve retaining screws on theunderside of the appliance. The gas valve cannow be removed. Replace in the reverse order.Check and adjust burner pressure settings.WARNING, A GAS SOUNDNESS CHECKMUST BE CARRIED OUT.

6.9 BURNER, INJECTORS AND SPARK/SENSEELECTRODE (see fig. 18a,b,c)Carry out component removal procedure as de-scribed in 6.4. Remove the appliance casing asdescribed in 4.7.1.Locate and remove the ten screws that securethe air chamber cover. Remove the air chambercover. Locate and remove the 5 screws securingthe front combustion cover and retaining plate,pull the cover towards you before lowering anddisengaging.

Disconnect the electrode lead from its connector.Disconnect the gas valve outlet pipe from itsconnection to the burner. Slacken and removethe lock-nut that secures the burner assembly tothe air chamber base. The burner can now beremoved. With the burner assembly removed,slacken and remove the burner bar retaining clipsin order to gain access to the injectors. Replacein the reverse order. Please note, the injectorsealing washers must be replaced if the injectorshave been removed, ensure all seals are in goodcondition, taking care to ensure they are replacedcorrectly.

6.10 FLUE FAN (see fig. 19)Carry out component removal procedure asdescribed in 6.4. Remove the appliance casingas described in 4.7.1.Locate and remove the 10 screws that secure theair chamber cover. Remove the air chamber cover.Locate and remove the 4 screws that secure theflue assembly. Disconnect the electricalconnections and silicone tubes attached to thefan, noting their positions. Disconnect themaintainence clip that secures the flue outlet pipeto the fan, ease the fan & flue hood assembly fromits location. Locate and remove the screws thatsecure the fan to the flue hood. Remove the fan

Fig. 17

Fig. 18a

Fig. 18b

Fig. 18c

14

7.1 CHECKING APPLIANCE OPERATIONWhen carrying out any repairs or servicing to theappliance, the relevant commissioning proceduremust be undertaken to ensure the continued safeoperation of the appliance. Particular attentionshould be made to ensure gas soundness, watersoundness, and the electrical integrity of theappliance.

7.2 APPLIANCE MODE OF OPERATIONWhen there is a request for hot water via a hotwater outlet or tap, the water flow switch senseswater movement thereby energising the fan.

NOTEThere must be sufficient inlet water pressure andflow (min. 0,15 bar/ 2 lpm) to ensure the waterflow switch is activated. If there is insufficientpressure and/or flow, the appliance will beprevented from operating. When the fan runs, itproves the differential air pressure switch whichin-turn allows an ignition sequence to begin.

NOTEThe ignition sequence lasts approximately 7seconds, during which the appliance will continueto spark even if the burner has already lit. If thespark/sensing electrode does not sense ignitionthe appliance will then go to lockout. Ignition issensed by the electronic circuitry to ensure flame

stability at the burner. Once successful ignitionhas been achieved, the electronic circuitry allowsthe full gas rate through the appliance.When the appliance reaches the desiredtemperature the burner will modulate to maintainthe set temperature. Should the temperaturecontinue to rise the burner will shut off when themaximum operating temperature is attained.When the request for heat and/or hot water hasbeen satisfied, the fan may continue to operate todissipate any residual heat within the appliance.

7.3 CHECKING AND ADJUSTING BURNERPRESSURE (see fig. 17)Altough the burner pressure is factory set, it isnecessary to check it during servicing or if the gasvalve has been removed. Isolate the appliancefrom the electrical supply and attach a suitablemanometer to the gas valve outlet test nipple.Remove the compensator tube.

7.3.1 SETTING THE MAXIMUM BURNER PRESSURELight the appliance as described in 5.6 andcompare the reading on the manometer with thevalue described in 2.2. If adjustement is required,remove the protective cap from the gas valvemodulating coil assembly and turn the outer(10mm) nut clockwise to increase, or counter-clockwise to decrease the burner pressure.

to flue elbow. Replace in the reverse order.Ensure all seals are in good condition, taking careto ensure they are replaced correctly.

6.11 HEAT EXCHANGER (see fig. 20)Carry out component removal procedure asdescribed in 6.4. Remove the appliance casingas described in 4.7.1.Locate and remove the 10 screws that secure theair chamber cover. Remove the air chambercover. Locate and remove the 5 screws securingthe front combustion cover and retaining plate.Disconnect the inlet and outlet connections onthe heat exchanger. The heat exchanger cannow be withdrawn from the appliance (ifnecessary, the burner should be removed tofacilitate access to the connections). Replace inthe reverse order. Ensure all seals are in goodcondition, taking care to ensure they are replacedcorrectly.

Fig. 19

6.12 AIR PRESSURE SWITCH (see fig. 1)Carry out component removal procedure asdescribed in 6.4. Remove the appliance casingas described in 4.7.1.Locate and remove the 10 screws that secure theair chamber cover. Remove the air chambercover. Locate and remove the two screws holdingthe air pressure switch to the air chamber.Disconnect the electrical connections and siliconetubes attached to the air pressure switch, notingtheir positions. Replace in the reverse order.Ensure all seals are in good condition, taking careto ensure they are replaced correctly.

Fig. 20

SECTION 7 CHECKS, ADJUSTMENTS, AND FAULT FINDING

15

NOTEYou should ensure that one or two hot wateroutlets are fully open during the above procedure.This will ensure that the output of the appliance(burner pressure) is not compromised due to ahigh outlet temperature.

7.3.2 SETTING THE MINIMUM BURNER PRESSUREOnce the maximum burner pressure has beenchecked and/or adjusted, remove one of the greywires from the modulating coil. Compare thereading on the manometer with the valuedescribed in 2.2. If adjustement is required, turnthe inner (red) cross-head screw clockwise toincrease, or counter-clockwise to decrease theburner pressure, whilst ensuring that the outer(10mm) nut does not move. When checking and/or adjustement has been completed, isolate theappliance from the electrical supply, replace theprotective cap, refit the compensator tube, refitthe grey wire to the modulating coil, remove themanometer, and tighten the outlet test nipple.IMPORTANT: A GAS SOUNDNESS CHECKMUST BE CARRIED OUT.

7.4 EXTERNAL FAULTSBefore carrying out any fault-finding or componentreplacement, ensure the fault is not attributable toany aspect of the installation.

7.4.1 INSTALLATION FAULTS

7.5 ELECTRICAL CHECKSAny electrical checks must be carried out by asuitably qualified person.

7.5.1 EARTH CONTINUITY TESTIsolate the appliance from the electrical supply,and using a suitable multi-meter carry out aresistance test. Connect test leads between anappliance earth point and the earth wire of theappliance supply cable. The resistance shouldbe less than 1 ohm. If the resistance is greaterthan 1 ohm check all earth wires and connectorsfor continuity and integrity.

7.5.2 SHORT CIRCUIT CHECKIsolate the appliance from the electrical supply,and using a suitable multi-meter, carry out a shortcircuit test between the Live & Neutral connectionsat the appliance.

Repeat above test on the Live & Earth connectionsat the appliance term.

NOTEShould it be found that the fuse has failed but nofault is indicated, a detailed continuity.Check will be required to trace the fault. A visualinspection of components may also assist inlocating the fault.

7.5.3 POLARITY CHECKWith the appliance connected to the electricalsupply and using a suitable multi-meter, carry outthe following voltage tests:● connect test leads between the Live & Neutral

connections at the appliance. The meter shouldread approximately 230V ac. If so proceed tonext stage. If not, see 7.5.4.

● connect test leads between the Live & Earthconnections at the appliance. The meter shouldread approximately 230V ac. If so proceed tonext stage. If not, see 7.5.4.

● Connect test leads between the Neutral & Earthconnections at the appliance. The meter shouldread approximately 0 – 15Vac. If so polarity iscorrect. If not, see 7.5.4.

7.5.4 REVERSED POLARITY OR SUPPLY FAULTRepeat the above tests at the appliance isolator,if testing reveals correct polarity and/or supply atthe isolator, re-check wiring and connectionsbetween the isolator and the appliance.If tests on the isolator also reveal reversed polarityor a supply fault, consult the local electricitysupplier for advice.

7.5.5 RESISTANCE TO EARTH CHECKIsolate the appliance from the electrical supply,and using a suitable multi-meter carry out aresistance test. Connect test leads between theLive & Earth connections at the appliance. If themeter reads other than infinity there is a fault thatmust be isolated, carry out a detailed continuitycheck to identify the location of the fault.

IMPORTANTThese series of checks must be carried outbefore attempting any fault-finding procedureson the appliance. On completion of any task thatrequired the disconnection and re-connection ofany electrical wiring or component, these checksmust be repeated.

7.6 FAULT FINDINGBefore attempting any fault-finding, the electricalchecks as detailed in 7.5 must be carried out.Isolate the appliance from the electrical supplyand remove the casing and PCB cover.Restore the electrical supply to the appliance,turn the selector switch to the “on” position, andopen a hot water outlet. The appliance shouldnow function as described in section 7.2. Shouldthe appliance fail to respond, the internal fuseand connectors should be checked to ensure

Symptom Possible causes

No ignition

Poor hot water

Unstable flamepicture

Check external wiring.Check cold supply is connected to coldinlet.

Check gas supply.Check adjust flow rate.

Check flue system

16

integrity and continuity. If the appliance still failsto respond, refer to the detailed fault-findingflowcharts overleaf.

Green LED

On for 1 second, off for 5seconds

OnOff

On

Flashing on/off every 0,5seconds


Red LED Action requiredStatus

Off

OffOn


Off


Switched off or at stand-by

DHW requestFlame lockout

Overheating

Air pressure switch “open”

NTC thermistor fault

NONE

NONECheck gas supply, checkignition sequence

Allow to cool, checkoperation of appliance

Check flue system, checkair pressure switch and/onfan

Check NTC thermistor

7.7 FAULT CODES

17

FAULT FINDING TEST ‘1’

NO

MAINS ON FAN

REPLACE FAN

YES

NOYES

ACHECK &/OR

REPLACEWIRING AND

CONNECTIONS

FAN RUNNING

START

REPLACEDRIVER BOARD

NO

NO YES

SWITCH ON WATERHEATER AND SELECT

WATER TEMPERATUREAT MAX.

TURN ON TAP WITHA FLOW RATE >THAN 2.5 LIT/MIN

MAINS PRESENT BETWEEN

TERMINALS 8 & 9 ON ACF

MAINS

PRESENT BETWEENTERMINALS 10 & 11

ON ACF MAINS

PRESENT BETWEEN TERMINALS

X1.5 & X1.6 ON DRIVER BOARD

CHECK &/ORREPLACE

WIRING ANDCONNECTIONS

MAINS PRESENT

BETWEEN TERMINALSX1.1 & X1.8 ON

DRIVER BOARD

YES

MAINS PRESENT


DRIVER BOARD

CHECK WIRING ANDCONNECTIONS OR

SAFETY THERMOSTAT

MAINS PRESENT


DRIVER BOARD

NOREPLACEDRIVER BOARD

FUSES OK

CHECK FUSESF1 & F2 ON

DRIVER BOARD

RESTART THETEST

REPLACE FUSES

YES

YES

CHECK &/OR REPALCEFUSE F3, MAIN SWITCH AND

SUPPLY & CONNECTORSTO BOILER TERMINALS

CHECK WIRINGBETWEEN MAIN

SWITCH AND DRIVERBOARD

NO

LINE LAMP

LIGHT?



A1 MAINS

PRESENT BETWEENTERMINALS 4 & 11

ON ACF

REPLACE ACFBOARD

MAINS PRESENT


DRIVER BOARD CHECK &/OR

REPLACEWIRING AND

CONNECTIONS

YES

CHECK &/OR REPALCEFUSE F3 MAIN SWITCH

AND SUPPLY &CONNECTORS TOBOILER TERMINALSCHECK WIRING

BETWEEN MAINSWITCH AND

DRIVER BOARD

LINE LAMP

LIGHT?

NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

18


YES

YES

NO

NO

A.C.F. OK

NO

YES

NO

NO

YES

YES

YES

NO

IS THERE

VOLTAGE ATSPARK ELECTRODE PIN?

ATTENTION !!VOLTAGE > 10 kV

A

REPLACESENSING

ELECTRODEAND LEAD

SENSING ELECTRODE AND LEAD

OK

CHEK SENSINGELECTRODE

AND LEAD

MODULATIONTEST

LOCKOUT AFTER

IGNITION

REPLACE EVG

CHECK GAS

IGNITION

SPARK ATELECTRODE

CHECK SPARKELECTRODE AND

LEAD

ISTHERE MECHANICAL

OPENING OF GAS VALVESOLENOIDS

NO

REPLACE A.C.F.BOARD

NO

DO THE

AIR FLOW SWTCHTURN ON

CHECK WIRING ANDCONNECTIONS ANDAIR FLOW SWITCH

YES

NO

ARE THEVENTURI TUBE

AND THE SILICONE AIR TUBES

CLEAN

CHECK/CLEAN THEVENTURI TUBE AND

SILICONE AIRTUBES

ISTHE AIR DP >11 mmCH2O

CHECK THE FANAND/OR FLUE

GAS TUBE

CHECKREPLACE AIRFLOW SWITCH

NO

YES

YES

YES

A2

ISTHERE A GAS

INPUT PRESSUREGREATHER THAN

13.7 mBAR

REPLACE EVG


TERMINALS 6 & 11ON ACF

REPLACE A.C.F.BOARD

NO

NO

YES

YES

19


NO

NO

NO

NO

YES

YES

YES

ISVOLTAGE

ACROSS TERMINALSOF MODULATOR

COIL >10 Vdc

REPLACEMODULATOR

COIL

REPLACE WIREAND

CONNECTIONS

REPLACECONTROL

BOARDREPLACE

MODULATORCOIL

ISTHERE A

VOLTAGE >10 VDCBETWEEN TERMINALS OF

MODULATORCOIL

IS THE RESISTENCE OFMODULATOR COIL

ABOUT 70/80OHM

ISTHERE A

VOLTAGE >10 VdcBETWEEN TERMINALS

X3.3 & X3.4 ON PCB

YES

WAIT TILL THE VOLTAGE

BETWEEN TERMINALSX3.3 & X3.4

ON PCB IS < 1.2 Vdc

ISVOLTAGE

ACROSS TERMINALS OFMODULATOR

COIL < 1.2 Vdc

ISWATER

TEMPERATURE >60 ˚C

WAIT WATERTEMPERATURE

>60 ˚C

SWITCH WATERTHERMOSTAT AT

MIN.

DO BURNER AND FAN SWITCH

OFF

ISWATER

TEMPERATURE > 40 ˚C

WAIT WATERTEMPERATURE

> 40 ˚C

REPLACECONTROL

BOARD

YES

YESYES

NO

NO

NO

MODULATIONTEST

IS THE WATER FLOW

SENSOROK REPLACE

WATER FLOWSENSOR

NO

YES

CHECK ANDREPLACE NTC

SENSOR

IS NTC SENSOR

OK

NO

YES

REPLACE

CONTROL BOARD

REPLACEWATER FLOW

SWITCH

IS WATER FLOW

SENSOR OK

YES

NO

YES

SWITCH WATERTHERMOSTAT AT

MAX.

DO BURNER

AND FAN SWITCH ON

ISWATER

TEMPERATURE > 60 ˚C

WAIT WATER

TEMPERATURE< 60 ˚C

REPLACECONTROL

BOARD

A3

YES

YES

NO

NO

NO

20


NOEND

DO BURNER AND FAN

SWITCH OFF

TURN OFF TAP

A3

YES

CHECK WIRINGAND CONNECTION

OR CONTROLBOARD

REPLACEWATER FLOW

SENSOR

ISWATER FLOW

SENSOR OK

YES NO



REPLACE ACFBOARD


WHITE WIRE ON AIR FLOWSWITCH AND PIN 11

ON ACF

CHECK &/ORREPLACE


A1

YES


RED WIRE ON AIR FLOWSWITCH AND PIN 11

ON ACF

CHECK &/ORREPLACE


IS AIR FLOW SWITCH

CONTACT ON N.C. POSITION

CHECK FLUEGAS TUBE

CHECK &/ORREPLACE AIR

FLOW SWITCH

THE

POLARITY OF FEEDING

IS INVERTED

INVERT THEPOLARITY OF

FEEDING

THE FEEDING IS PHASE

PHASE

REPLACE ACFBOARD

INSTALL PHASEPHASE KIT

A2

YES

YES

YES

NO

NO

NO

NO

NO

NO

YES

YES

21

SECTION 8 WIRING DIAGRAMS

8.1 EXTERNAL WIRINGThe appliance comes with a factory fitted cablethat should be connected to a suitable fusedisolator or plug. If this is unsuitable and a directconnection to the appliance is required, it must beconnected to the appliance as shown in thefollowing diagram. For further advice on theelectrical connection, please contact Vokeratechnical on 0870 333 0520.

TR1 DHW temperature controlTR2 Selector ON/OFFJP1 Natural gas or LPG selector jumperP.F. Air pressure switchT.L. High limit thermostatSAN Flow switchF1 Fuse 2A FE.A.R. Sense/ignition electrodeRL1 Fan relay

NOTE: L-N connection is advisable

RL2 Ignition relayMOD ModulatorV FanIWH01X Control boardT1 TransformerOPE Gas valve solenoidsCN1-CN7 ConnectorsT2 Ignition/transformer

FUNCTIONAL DIAGRAM

22

FUNCTIONAL DIAGRAM

NO

TE

: L

-N c

on

nec

tio

n is

ad

visa

ble

brown

blue

purple

purple

red

red

grey

grey

black

black

white

white

blue br

own

pink

23

SECTION 9 EXPLODED DIAGRAMS

Pos Description Code

Cable 100206881 Wall bracket W70604072 Air chamber top 100211313 Back panel W70503554 Silicone tube 14575 Pressure differential switch 100208906 Air chamber front panel W70501687 Casing clip W70502608 White casing 100206799 Earthing strip 1002123010 PCB 1002249111 Sight glass retaining ring W705021612 Sight glass seal W705021713 Sight glass W131A14 Air chamber bottom 1002066115 Lower panel 1002066316 Cable entry socket 537117 Rivet 5037

18 PCB cover 1002112019 Control panel 1002112720 Led lens 1002067621 Selector/thermostat knob 1002067422 Adhesive logo 147123 Air chamber seal W14024 Wall plug W98A25 Screw 6,5mm x 2,9mm 507726 Rivet 6mm x 3mm W21M127 Screw 12mm x 3,5mm 524028 Screw 6mm x 3,5mm W127G29 Screw 13mm x 3,9mm W113A30 Screw 13mm x 4,8mm W242D131 Screw 25mm x 4,8mm 517132 Screw 7mm x 4,8mm W74N33 Screw 9mm x 3,9mm W111024934 Nylon shaft 1002066935 Nylon shaft 10020670

AB

2

4

14

10

9

27

33

23

2328

1312

11

6 2678

1

24

3

5

17

33

32

3315

16

25

33

23

34

3118

29

27

20

19

29

21

30

35

22

24

Pos Description Code

1 Exhaust restrictor ring W70605042 60mm pipe W70500623 Gasket 59174 Clip 59165 Negative venturi W70501636 Positive venturi W70501647 Fan to flue connector 62288 Fan to flue connector W70801919 Fan gasket W92A10 Flue hood W704003911 Flange W704005612 Heat exchanger 1002136713 Washer 504114 NTC thermistor 848415 Coupling W702043716 Electrode W708019517 Securing plate W702035518 Lead 1002181719 Combustion cover W703010720 Burner (natural gas) W702040320 Burner (LPG) W702040421 Burner coupling W702041622 Nipple 1002066823 Flow restrictor 943024 Inlet pipe 1002066625 DHW flow switch 1002033026 Gas valve 1002102127 Gas valve outlet pipe 1002066728 Outlet pipe 1002066429 High limit thermostat 1002123530 1/2” bsp locknut 427431 Screw M4 x 7mm 508632 Screw 6,5mm x 2,9mm 507733 Fibre washer 502634 Fibre washer 502335 1/2” bsp locknut W5C17036 Spring clip W701022337 Screw 6mm x 3,5mm W127G38 Screw 38mm x 4,2mm 1002176539 Screw 9mm x 4,2mm W16540 Screw 7mm x 4,8mm W74N41 Screw 9,5mm x 3,9mm W95A42 1/8” bsp locknut 480743 Screw 3,9mm x 19mm W114A44 Flow restrictor 1466

AB

Tav. 1

1

2

4

3

438

5

6

42

7

39

9

41

40

10

11

12

39

13

14

16

37

17

1819

1538

20

36

21

35

33

27

3422

3323

24

33

25

30

34

2632

29

28

33

31

39

3422

30

44

45

4847

46

49

45

50

34

25

SECTION 10 L.P.G. INSTRUCTIONS

10.3 GAS SUPPLYThe gas supply must be connected to theappliance by a competent LPG installer and mustbe of sufficient size to supply the appliance at itsmaximum output.An existing supply must be checked to ensurethat it is of adequate size to deal with the maximumrated input of this and any other appliances thatit serves.

10.4 GAS SUPPLY INSTALLATIONThe entire installation, including the meter, mustbe purged and checked for gas soundness.

10.5 CHECKING AND ADJUSTING BURNERPRESSURE (see fig. 17)Although the burner pressure is factory set, it isnecessary to check it during servicing or if the gasvalve has been removed. Isolate the appliancefrom the electrical supply and attach a suitablemanometer to the gas valve outlet test nipple.Remove the compensator tube.

10.5.1 SETTING THE MAXIMUM BURNERPRESSURELight the appliance as described in 5.6 andcompare the reading on the manometer with thevalue described in 2.2. If adjustement is required,remove the protective cap from the gas valvemodulating coil assembly and turn the outer(10mm) nut clockwise to increase, or counter-clockwise to decrease the burner pressure.

NOTEYou should ensure that one or two outlets areopen during the above procedure. This willensure that the output of the appliance (burnerpressure) is not compromised due to a highoutlet temperature.

For details of converting an appliance to LPG please refer to the instructions supplied with the relevant conversion kit.

10.5.2 SETTING THE MINIMUM BURNERPRESSUREOnce the maximum burner pressure has beenchecked and/or adjusted, remove one of the greywires from the modulating coil. Compare thereading on the manometer with the valuedescribed in 2.2. If adjustement is required, turnthe inner (red) cross-head screw clockwise toincrease, or counter-clockwise to decrease theburner pressure, whilst ensuring that the outer(10mm) nut does not move. When checking and/or adjustement has been completed, isolate theappliance from the electrical supply, replace theprotective cap, refit the compensator tube, refitthe grey wire to the modulating coil, remove themanometer, and tighten the outlet test nipple.

IMPORTANT, A GAS SOUNDNESS CHECKMUST BE CARRIED OUT.

10.1 TECHNICAL DATA

10.2 RELATED DOCUMENTS

BS 5440

BS 5440

BS 5546

BS 6891BS 5482

PART 2

PART 1

PART 1

FLUES

FLUES & VENTILATION

INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

LOW PRESSURE INSTALLATION PIPESDOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS

Inlet pressure (LPG)Maximum burner pressureMinimum burner pressureGas rateInjector size

37 mbar36 mbar3,0 mbar1,33m3/h15 x 0,77mm

1 .dE - 40/81 - 03222001 .doC

Registered address:Vokèra Ltd

Borderlake HouseUnit 7 Riverside Industrial Estate

London ColneyHerts AL2 1HG

[email protected]

www.vokera.co.ukwww.vokera.ie

Sales, General EnquiresT 0844 391 0999F 0844 391 0998

Vokèra IrelandWest Court, Callan

Co KilkennyT 056 7755057F 056 7755060

Vokèra Limited reserve the right to changespecification without prior notice

Consumers statutory rights are not affected.

A Riello Group Company.Company Reg No: 1047779

Documents

Installation & Servicing Instructions - FREE BOILER MANUALS · Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER Vokèra is a licensed member of the