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CONDEXA PRO

5

a

The boiler must not be used by children or invalid
persons without supervision.

a

Electrical devices or appliances, such as switches,
household appliances, etc. must not be used if there
is the smell of gas or unburned fuel. In this case: 

- ventilate the room by opening doors and windows;
- close the fuel stopcock;
- promptly contact 

Vokera Ltd

, your gas supplier or

other professionally qualified personnel.

a

Do not touch the boiler when barefoot or with wet
parts of the body.

a

No service or cleaning operations may be perfor-
med without first having disconnected the boiler
from the mains power supply, moving the main
system switch to "off".

a

The safety or control devices must not be adjusted
without the authorisation and written instructions
from the manufacturer of the boiler.

a

The condensate drain must not be plugged.

a

Do not pull, remove or twist the electrical cables
coming out of the boiler, even if the appliance is
disconnected from the mains power supply.

a

The ventilation openings in the room where the
appliance is installed must not be plugged or redu-
ced in size and must comply with any current stan-
dards and law applicable.

a

Do not expose the boiler to the elements. It is not
designed to operate outdoors and does not have
sufficient frost protection systems.

a

Do not switch the boiler off if the outside temperatu-
re may fall below ZERO (risk of freezing).

a

Do not leave containers and flammable substances
in the room where the boiler is installed.

a

The packaging material must not be dispersed in
the environment or left within the reach of children
as it is a potential source of hazard. It must be
disposed of according to the legislation in force.

The use of products that operate on fuel, electricity and water requires a number of fundamental safety rules to be
observed, including:

b

After having removed the packaging, check that the
material supplied is intact and complete; if this is
not the case, contact 

Vokera Ltd

.

b

The 

CONDEXA PRO

Boiler must be installed by

qualified personnel as detailed under any current
standards and law applicable and with the instruc-
tions provided by 

Vokera

in the manual supplied

with the appliance.

b

The boiler must be used for the purposes it has
been expressly manufactured. 

Vokera Ltd

declines

all contractual and extra-contractual liability for
damage caused to persons, animals or things, due
to errors in installation, control, servicing or impro-
per use.

b

In the event of water leaks, disconnect the boiler
from the mains power supply, close the water sup-
ply and promptly notify 

Vokera Ltd

or other profes-

sionally qualified personnel.

b

Periodically check that the condensate drain is free
of blockages.

b

Periodically check that the operating pressure of
the water circuit when cold is 

1.5 bar

and less than

the maximum limit specified for the appliance. If this
is not the case, contact 

Vokera Ltd

or other profes-

sionally qualified personnel.

b

If the boiler is not used for an extended period, the
following minimum operations must be completed: 

- move the main system switch to "off"
- close the fuel cock and the water cocks on the cen-

tral heating system

- empty the central heating system if there is the risk

of frost.

b

Servicing must be performed on the boiler at least
once a year.

b

This manual is an integral part of the boiler and as a
consequence must be kept with care. If the manual
is damaged or lost, contact 

Vokera Ltd

for another

copy.

GENERAL WARNINGS 

FUNDAMENTAL SAFETY RULES

Summary of Contents for CONDEXA PRO 100 S

Page 1: ...HESE INSTRUCTIONS TO BE RETAINED BY USER Vok ra is a licensed member of the Benchmark scheme which aims to improve the standards of installation and commissioning of domestic hot water systems in the...

Page 2: ...5 12867 0 CONDEXA PRO 100 S Natural gas LPG 50 37685 12868 7 The Vokera CONDEXA PRO boilers comply with Gas Appliances Directive 90 396 EEC Boiler Efficiency Directive 92 42 EEC Electromagnetic Compat...

Page 3: ...lies providing the boiler has been correctly installed operated and com missioned by qualified personnel The manufacturer is not liable for any damage caused by the incorrect layout or installation of...

Page 4: ...Electrical connections 33 Installing the outside probe 35 Filling and emptying the systems 36 Preparing for first start up 38 TECHNICAL Starting for the first time pag 39 Checks during and after first...

Page 5: ...disposed of according to the legislation in force The use of products that operate on fuel electricity and water requires a number of fundamental safety rules to be observed including bAfter having r...

Page 6: ...lue gas temperatures 80 C In addi tion the float in the drain trap prevents the flue gas from passing through the condensate drain Fan safety device a Hall effect sensor constantly moni tors the rotat...

Page 7: ...i fications Packaging label This shows the code the serial number and the barcode 1 2 Gas label This is applied on the side of the frame and describes the type of fuel used by the boiler and the count...

Page 8: ...tat 8 SECOND combustion chamber models 100 M and 100 S 9 Return probe 10 Condensate collection drain trap 11 Control panel 90 rotation 12 Gas supply CONDEXA PRO 50 M CONDEXA PRO 100 M 100 S 13 Central...

Page 9: ...88 30 kW Useful heat output 50 30 C 48 5 96 8 96 8 kW Useful efficiency ref NHV 80 C 60 C 98 2 kW Useful efficiency ref NHV 50 C 30 C 107 7 Useful efficiency at 30 ref NHV 50 C 30 C 108 7 Losses throu...

Page 10: ...C1 9 0 Pressure drop mbar Flow rate l h 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 250 500 750 1000 1250 1500 1750 2000 2250 3000 2500 2750 1 Fan 2 Gas valve 3 Automatic vent valve 4 Burner...

Page 11: ...h distribution pumps Boiler discharge head 7 mWC Boiler flow rate 2 m3 h for each heating unit Also consider the pressure drops in the individual circuit PB PZ1 PZ2 V2 V2 THE CONDEXA PRO Boiler does n...

Page 12: ...Boiler discharge head 7 mWC Boiler flow rate 2 m3 h for each heating unit Recommended p 50 M TYPE A 100M S TYPE B 100M 100S TYPE C PB PZ1 PZ2 V2 V2 With this configuration the pump in the low temperat...

Page 13: ...4 5 6 7 8 9 800 Flow rate m h Pump TYPE B 0 I II 100 200 300 400 500 600 700 0 2 4 6 8 10 12 14 16 20 1100 18 800 900 1000 Residual head mbar Flow rate m h Pump TYPE C 0 I II 100 200 300 400 500 600...

Page 14: ...tral pump 3 J4 1 J2 J9 J8 J10 R4 2 4 3 J3 J6 J5 J7 F1 Fuse 3 15 A 1 R6 R5 MC R3 R2 1 5 6 3 4 2 On Max valve 2 3 Alarm Common 2 1 J12 2 BUS J14 1 R1 4 3 T1 Ebus remote cont 24V remote cont Common 8 9 A...

Page 15: ...W pump PZ1 Pump in zone 1 high temperature PZ2 Pump in zone 2 low temperature VM Mixing valve CR Remote control accessory IA Analogue input SB DHW probe SZ1 Probe in zone 1 SZ2 Probe in zone 2 SE Outs...

Page 16: ...a m v n g b m 4 7 8 a 4 J11 3 1 3 4 2 2 J1 7 5 6 6 5 a m m 5 J6 J14 J2 1 2 3 J15 gv a m gv gv gv a m 3 m a gv gv 230V 50Hz SLAVE 1 EA ER IG1 TS SM SR SF J10 J17 VG a 13 m PD m a 6 C to main earth pole...

Page 17: ...m PD VG m a 6 C Line Neutral Earth Earth Earth Gas Valve Safety thermostat Diff pressure switch Hall sensor common Blower Hall sensor imput Blower Hall sensor power Flue gas NTC Return NTC Outlet NTC...

Page 18: ...g mode 3 Reset button Master 4 Boiler lockout signal 5 Button for selecting the parameters 6 Display 7 Save button 8 Button to increase values 9 Button to decrease values 10 SECOND heating unit switch...

Page 19: ...wo way valve When the last burner has shut down the valve closes only when there is no demand from the room thermostat The cascading function to manage the output delive red by the system the minimum...

Page 20: ...decimal point after the 1st digit on the left flashes Demand from the 2nd circuit The two digits on the right display the outlet temperature T1 E g T1 80 C READOUT MODE TEMPERATURE VALUES AND OPERATI...

Page 21: ...cuit DHW temperature T3 Outlet temperature in the second circuit or low temperature circuit T6 To change the corresponding set points Press MODE the corresponding value will be displayed and the two d...

Page 22: ...unit in the system addresses from 1 to 60 Operation Display 1 The boiler is operating with the high temperature circuit at 80 C 2 Press MODE for 5 seconds The display indicates that the values and the...

Page 23: ...second and third digit will flash 3 Use and to enter the first number in the password on the centre digit E g password X2 4 Press MEMO to save the second number in the password 5 Use and to enter the...

Page 24: ...ROR MODE The display starts flashing when there is a fault on any of the heating units Proceed as follows to identify the faults PERMANENT LOCKOUT In the event where the burners are in permanent locko...

Page 25: ...cate Water pressure test certificate Spare parts catalogue Outside probe Kit for conversion from natural gas to LPG Assembly template bThe Installation and operation manual is an integral part of the...

Page 26: ...compliance with any current standards and low applicable If the combustion air is taken from outside accessories code 5037685135067 and 5037685135074 the room where the boiler is installed CONDEXA PRO...

Page 27: ...lean the system see the paragraph on Water connections page 28 The manufacturer is not liable for any damage caused by the incorrect flushing treatment and venting etc of the system The condensate dra...

Page 28: ...on MI RI GAS S MI RI GAS 1 2 The Vokera CONDEXA PRO Boilers are designed and built to be installed in central heating and domestic hot water systems The characteristics of the water fittings are as fo...

Page 29: ...ides protection against corrosion and fouling bFor additional information on the type and the use of the additives contact Vokera Ltd or a suitable additives manufacture Water connection kits To assis...

Page 30: ...in com pliance with the standards and the legislation in force as well as with local regulations The pipes used must be rigid and resistant to tempera ture condensate and mechanical stress and airtigh...

Page 31: ...diameter 50 mm Circular compartment Square compartment MAXIMUM LENGTH OF THE PIPES The maximum equivalent length of the sum of the 50 mm intake pipes and flues is 30 metres with a pressure drop of 2 m...

Page 32: ...and law applica ble install a neutraliser where required by law bSpecific pipes for condensing boilers must be used For installation follow the instructions provided with the kit Drain trap along the...

Page 33: ...g terminals For the CONDEXA PRO 100 S boiler only the Bus cable needs to be connected see the wiring diagram on page 16 To do this Move the main system switch to off Unscrew the fastening screws 1 on...

Page 34: ...thermal overload swit ch mains disconnecting switch compliant with the CEI EN standards minimum contact opening 3 mm 2 respect the connection L Line N Neutral Leave the earth wire around 2 cm longer t...

Page 35: ...cable must be separate from the power cables 230Vac The correct positioning of the outside probe is fundamental for the correct operation of the climate control function The probe must be installed ou...

Page 36: ...on the automatic vent valve valves 2 two or three turns Open the filling valve on the system until the pressure shown on the pressure gauge is 1 5 bar Close the filling valve again bThe air is vented...

Page 37: ...er fit tings Connect a plastic hose to the drain cock 4 on each heating unit and open the cock bBefore opening the drain cock 4 protect the elec trical devices underneath against water spillage Emptyi...

Page 38: ...vessel is suitably pre charged The electrical connections have been performed cor rectly bThe pumps should be connected by installing sui table contactors with manual emergency operation Check that t...

Page 39: ...es from the third boiler on To do this see the paragraph Setting the addresses for cascading configurations on page 54 Set the room thermostats in the high and low tempera ture zone to the desired tem...

Page 40: ...ied person Press SEL button twice the DHW temperature will be displayed preceded by the symbol 3 Press MODE the corresponding set point will be displayed and the two digits on the right will flash To...

Page 41: ...y pres sing RESET Type E errors which are deactivated when the causes are no longer present see ERROR MODE on page 24 and the Fault codes paragraph on page 56 When ignition is complete check that the...

Page 42: ...S SUPPLY PRESSURE Move the main system switch to off Unscrew the fastening screws 1 on the front panel 2 Pull the base of the panel 2 outwards and then upwards to release it from the frame and then re...

Page 43: ...the boiler Press MEMO to exit TEST mode Disconnect the pressure gauge and tighten the screw on the pressure test point 3 upstream of the gas valve CHECKING COMBUSTION Power up the boiler by moving th...

Page 44: ...based on the type of gas and the length of the flue L This information is managed by parameter 36 To change the settings Enter INSTALLER PROGRAMMING MODE following the procedure described on page 23 a...

Page 45: ...and will be valid after 3 seconds For a detailed description of all the parameters and the default values see page 58 The following functions can be set for central heating 1 Setpoint_T_CH_High Set p...

Page 46: ...entral heating priority parameter 16 If this is set to 0 the system works without central heating priority that is with the high temperature and low tempe rature circuit served in parallel If set to 1...

Page 47: ...sent Pre set to 0 3 DHW_Priority Domestic hot water priority parameter 9 0 Sliding priority A The purpose of the sliding priority A function is to allow the system to also serve the central heating fu...

Page 48: ...Manifold Temperature Set point Stop hysteresis The stop hysteresis can be set CH_High_mod_Hyst_off Par 20 pre set to 3 between 0 and 20 C When the attenuation in the high temperature circuit paramete...

Page 49: ...ers are off when Manifold Temperature Set point Stop hysteresis The stop hysteresis can be set CH_Low_mod_Hyst_off Par 27 pre set to 3 between 0 and 20 C When the attenuation in the low temperature ci...

Page 50: ...l_mode Cascading management parameter 33 To manage the output delivered by the system two cascading strategies are available In both cases the Master controller can only start a new burner when anothe...

Page 51: ...nd intervals Low load The low load function prevents the burners from stating and stopping when there is a low heating demand The con ditions for the activation of the Low Load function are checked on...

Page 52: ...h_high_mod_hist_on Par 19 Outlet Temp Setpoint_Ch_low Par 3 Ch_low_mod_hist_on Par 26 The burner stops when Outlet Temp Setpoint_Ch_high Par 1 Ch_high_hist_off Par 20 Outlet Temp Setpoint_Ch_low Par 3...

Page 53: ...um if D_T D_T_max burner off MANAGEMENT OF THE MIXING VALVE The mixing valve is controlled by the following parameters Mix_valve_step_open_time Par 28 pre set to 5s Mix_valve_step_close_time Par 29 pr...

Page 54: ...ve generators are connected to a master there are two blocks the first made up of four slave gene rators and the second of one slave generator Consequently the addresses should be set as follows Ident...

Page 55: ...f seven slave generators there are two blocks the first made up of four generators and the second of three Therefore two blocks need to be configured with address 1 and 2 respectively and the generato...

Page 56: ...ally If any one of these errors occurs the red LED comes on see ref 4 on page 18 N Error Description E 02 NTC1 open or not connected NTC1 outlet sensor Probe manifold not connected E 04 NTC3 OPEN Stor...

Page 57: ...Flue gas sensor error for having exceeded the max flue gas temperature with this error the fan operates at maximum speed A 20 The flame is extinguished too late after the gas valve closes A 24 Fan er...

Page 58: ...er DHW differential 13 N _bruc_DHW 1 60 60 Maximum no of burners in DHW 14 CH_type_high 0 3 1 0 Fixed temperature 1 Climate with outside probe 2 0 10 Vdc for heat output 3 0 10 Vdc for temperature 15...

Page 59: ...al_time 0 255 5 s Mixing valve delay 31 Mixing_p_hyst 0 255 2 C Hysteresis for maximum valve opening 32 Mixing_still_hyst 0 255 2 C 33 Power control mode 0 1 1 0 Minimum number of burners 1 Maximum nu...

Page 60: ...l 2 Pull the base of the panel 2 outwards and then upwards to release it from the frame and then remove it Set parameter 36 to 3 or 4 according to the length L of the flue 3 L 15 m 4 L 15 m The fan sp...

Page 61: ...ve the G20 gas label from the inside of the frame 4 6 5 6 75 5 Country of destination Type of appliance Boiler category II2H3 Gas supply pressure G20 G30 G31 20 mbar 28 30 37 mbar Manufacturer setting...

Page 62: ...decreases the CO2 value so as to achie ve a value of 9 4 for G20 and 10 7 for G30 G31 CO2 ADJUSTMENT AT MINIMUM OUTPUT Press the MODE and buttons together for 5s The boiler will operate at minimum ou...

Page 63: ...rature circuit are started the second starts the pump and the burner if after 10 minutes the temperature in the manifold 5 C a burner is started at maximum output until the temperature in the manifold...

Page 64: ...Disconnect the power supply by moving the main system switch to off Close the fuel valve Before performing any cleaning operation disconnect the power supply by moving the main system switch to off OU...

Page 65: ...o release it from the frame and then remove it Turn the control panel 3 90 C and take out the four screws 4 so as to remove the rear cover The terminal block 5 and the boards can now be accessed Maste...

Page 66: ...he Master board refer to the wiring diagram on page 14 to restore the connections Once the servicing operations have been completed reassemble the components in the reverse order Dismantling the fan R...

Page 67: ...e fan 6 to the air conveyor 9 Unscrew the four screws 10 that fasten the fan assembly 6 to the exchanger using a 10 mm socket wrench Remove the gasket 11 and remove the burner 12 Remove the electrode...

Page 68: ...65 and identify the condensate drain trap 14 Remove the safety pin 15 remove the corrugated condensate drain pipe remove the drain trap and dismantle it using the two screw caps 16 Remove the float 1...

Page 69: ...tion Flue gas circuit Smell of unburned gas Check The tightness of the joints The absence of obstructions The quality of combustion Gas valve Check that 230 Vac is present at the terminals on the gas...

Page 70: ...ontroller Check correct operation Check set temperature No water Check vent valve Check pressure in central hea ting circuit Air in the system The heat generator reaches the temperature but the centra...

Page 71: ...mp Replace the pump Check the electrical connections to the pump System expansion vessel Check efficiency Pressure in heating system circuit Check charge pressure Check pressure reducer System safety...

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Page 76: ...es vokera co uk www vokera co uk www vokera ie Sales General Enquires T 0844 391 099 F 0844 391 0998 Vok ra Ireland West Court Callan Co Kilkenny T 056 7755057 F 056 7755060 Vok ra Limited reserve the...

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