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VOKERA Syntesi e, Installation & Servicing Instructions Manual

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VOKERA Syntesi e Installation & Servicing Instructions Manual Download Page 3

Supplied By www.heating spares.co  Tel. 0161 620 6677

1

The Syntesi range of appliances is comprised of 3 models
of high-efficiency combination boiler with outputs to
heating & DHW of 24, 28, & 34kW respectively. Each
appliance – by design – incorporates electronic ignition,
circulating pump, expansion vessel, safety valve, pressure
gauge, and automatic by-pass.

The Syntesi range is produced as room sealed, category
II2H3+ appliances, suitable for internal wall mounting
applications only. They are provided with a fan powered
flue outlet with an annular co-axial combustion air intake

INTRODUCTION

that can be rotated – horizontally – through 360 degrees
for various horizontal or vertical applications. The Syntesi
range can also be used with the Vokera twin flue system.

The Syntesi range is approved for use with C12 & C32
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.

Fig. 1

Fig.1 General Layout

1

Safety Valve

2

Pressure Switch

3

Diverter Valve Motor

4

Domestic Heat Exchanger

5

Pump

6

Automatic Air Release Valve

7

Main Burner

8

Electrode

9

Main Heat Exchanger

10

Latent Heat Collector

11

Condense Sensor

12

Flue Gas Analysis Test Point

13

Flue Outlet

14

Air Intake

15

Differential Analog Pressure Switch

16

Silicone Pressure Tube

17

Silicone Negative Pressure Tube

18

Fan Assembly

19

Combustion Chamber

20

Burner Temperature Control

21

Expansion Vessel

22

Transformer

23

Gas Valve

24

Modulator Coil

25

Condense Trap

26

Domestic Hot Water Flow Switch

27

Hot Water Temperature Control

28

Mode Selector Switch

29

Status LED

30

Temperature Indicator

31

DHW Request LED

32

Central Heating Temperature Control

33

Combustion Switch

34

Timeclock Aperture (optional)

35

Pressure Gauge

6

9

11

12

13

14

19

22

24

15

16

17

23

18

1

2

3

4

5

7

8

10

20

21

25

26

35

34

33

27

28

30

31

29

32

Summary of Contents for Syntesi e

Page 1: ...Supplied By www heating spares co Tel 0161 620 6677 Installation Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER ...

Page 2: ...system 18 5 8 1 Inhibtors 18 5 9 Setting the boiler operating temperature 18 5 9 1 Setting the domestic hot water temperature 18 5 10 Setting the system design pressure 18 5 11 Regulating the hot water 18 5 11 1 Changing the flow restrictor 18 5 11 2 Regulating the central heating system 18 5 12 Final checks 18 5 13 Instructing the user 19 Servicing instructions Page 6 1 General 19 6 2 Routine ann...

Page 3: ...e appliances are designed for use with a sealed system only consequently they are not intended for use on open vented systems Fig 1 Fig 1 General Layout 1 Safety Valve 2 Pressure Switch 3 Diverter Valve Motor 4 Domestic Heat Exchanger 5 Pump 6 Automatic Air Release Valve 7 Main Burner 8 Electrode 9 Main Heat Exchanger 10 Latent Heat Collector 11 Condense Sensor 12 Flue Gas Analysis Test Point 13 F...

Page 4: ...t for heat has been satisfied the appliance pump and fan may continue to operate to dissipate any residual heat within the appliance 1 4 MODE OF OPERATION DHW When there is a request for DHW via a hot water outlet or tap the pump and fan are started the fan speed will modulate until the correct signal voltage is received at the control PCB At this point an ignition sequence is enabled During DHW r...

Page 5: ...ximum gas rate 2 65 Sm3 h 3 07 Sm3 h 3 75 Sm3 h Minimum gas rate 1 05 Sm3 h 1 05 Sm3 h 1 05 Sm3 h Injector size quantity 12 x 1 35 mm 14 x 1 35 mm 16 x 1 35 mm 2 4 Expansion vessel Capacity 8 litres 10 litres Maximum system volume 76 litres 91 litres Pre charge pressure 1 0 bar 2 5 Dimensions Height 820mm Width 400mm 450mm 500mm Depth 350mm Dry weight kg 44 0 45 0 48 0 2 6 Clearances Sides 12mm To...

Page 6: ...00 1200 1300 Syntesi 35 Syntesi 25 29 Appliance Key Location Minimum distance A Below an opening window air brik etc 300 mm B Above an opening window air brik etc 300 mm C To the side of an opening window air brik etc 300 mm D Below gutter drain pipe etc 75 mm E Below eaves 200 mm F Below balcony car port roof etc 200 mm G To the side of a soil drain pipe etc 150 mm H From internal external corner...

Page 7: ...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...

Page 8: ...LING POINT A method for initial filling of the system and replacing water lost during servicing etc has been provided This method of filling complies with the current Water Supply Water Fittings Regulations 1999 and Water Bylaws 2000 Scotland 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 lea...

Page 9: ...r 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 SECTION 3A GENERAL REQUIREMENTS EIRE 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 si...

Page 10: ... 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 pressu...

Page 11: ... 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 carefully mark the position of the combined fixing jig and wall mounting bracket see fig 6A and using the template supplied mark the position of the flue hole ...

Page 12: ...lue 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 The 60mm M F adaptor supplied with the flue kit should be discarded NOTE Fit the internal trim to the flue assembly prior to connecting the flue pipe to the bend You must ensure that the entire flue system i...

Page 13: ...225735 90 bend N A 0225760 Wall bracket 4 N A Reduction for bends Using the dimensions given in fig 9 as a reference mark and cut a 115mm hole in the ceiling and or roof 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 terminal fits over the flashing The fixing holes for the wall mo...

Page 14: ...t pipe bend using the screws provided The twin flue pipes extensions and accessories can now 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 NOTE When cutting an extension to the required length you must ensure that the excess is cut from the plain end of the extension see fig 8 Remove any bur...

Page 15: ...d connected 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 Fig 12 4 5 3 3 VERTICAL TERMINATION see fig 13 The twin flue system must be converted to the dedicated concentric flue kit for termination The vertical terminal is supplied with a built in converter box and ca...

Page 16: ...he inlet of the valve and tighten both nuts 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 RETURN see fig 6A 14 The appliance is supplied with 22mm service valves for the flow and return connections connect a 22mm pipe to the inlet of each valve and tighten both nuts NOTE Depending on system requirements i...

Page 17: ... THE APPLIANCE The supply cable from the isolator to the appliance 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 press the controls cover to release the controls cover catch l...

Page 18: ...ith the clock using the clock wiring harness supplied in the accessory pack connect the 4 wires to the clock as shown in fig 16 Fig 16 Fig 17 remove the clock aperture plate from the appliance remove the push out blanking disc from the clock aperture plate fig 17 secure the clock to the aperture plate using the screws provided with the clock fig 17 refit the clock aperture plate ensuring the clock...

Page 19: ...pcock to the normal operating position fig 18 slowly open each outlet until air has been expelled and clear water is discharged Check pipe work etc for water soundness 5 6 PRE OPERATION CHECKS Before attempting the initial lighting of the appliance the following checks must be carried out ensure all gas service valves from the meter to the appliance are open and the supply pipe has been properly p...

Page 20: ...he appliance is fitted with a flow rate restrictor that limits the maximum flow rate that can be drawn through the appliance Syntesi 25 8 litre 9 litre Orange Blue Fitted Spare Syntesi 29 9 litre 10 litre 11 litre Orange Blue Beige Spare Fitted Spare Syntesi 35 11 litre 12 litre 13 litre Beige Red Olive Spare Fitted Spare The restrictor eliminates the need to manually adjust the DHW flow rate Howe...

Page 21: ...ce develop a fault the fault finding section will assist in determining which component is malfunctioning 6 4 COMPONENT REMOVAL PROCEDURE TTo 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 ...

Page 22: ...e thermistor and sealing washer 1 2 from the main heat exchanger Replace in the reverse order 6 6 SAFETY VALVE see fig 21 Carry out component removal procedure as described in 6 4 Disconnect the outlet pipe from the safety valve remove safety valve locking screw 1 from the heating manifold Replace in the reverse order 6 7 AUTOMATIC AIR RELEASE VALVE see fig 20 AAV Carry out component removal proce...

Page 23: ...and remove the PCB securing screws 2 3 remove the required PCB 4 5 6 Replace in the reverse order Fig 24 Fig 25 NOTE Ensure that any replacement PCB has the correct Jumper Tag configuration see section 8 6 13 GAS VALVE see fig 27 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 Slack...

Page 24: ...l the cover towards you before lifting and disengaging Disconnect the electrode lead and burner thermostat from their respective connectors Ease the electrode sealing grommet from its seating 4 Remove the retaining screw 6 for the burner thermostat and remove the thermostat 7 Fig 29 Locate and remove the four screws which secure the burner in position 1 gently ease the burner out of its location O...

Page 25: ...ation Locate and remove the four screws that secure the fan to the flue hood Remove the fan to flue elbow Replace in the reverse order Ensure all seals are in good condition taking care to ensure they are replaced correctly 6 17 MAIN HEAT EXCHANGER see fig 28 31 Carry out component removal procedure as described in 6 4 Fig 28 unclip and remove the air chamber cover gently pull the cover towards yo...

Page 26: ...ing from its seating taking care not to lose the float contained within the housing Replace in the reverse order ensuring that the housing is firmly inserted onto its seating Ensure all seals are in good condition taking care to ensure they are replaced correctly 6 21 DHW HEAT EXCHANGER Carry out component removal procedure as described in 6 4 Locate and remove the screws 1 that secure the heat ex...

Page 27: ...N VESSEL REMOVAL with sufficient clearance above Carry out component removal procedure as described in 6 4 Disconnect the flue from the appliance Disconnect the flexible expansion pipe from the vessel fig 39 Locate and remove the four screws that secure the vessel top holding plate remove the plate The expansion vessel can now be removed Replace in the reverse order Ensure all seals are in good co...

Page 28: ... DISMANTLING THE LATENT HEAT COLLECTOR see fig 42 During routine servicing or maintenance there is no requirement to remove or dismantle the collector however should it be deemed necessary to dismantle the collector all seals should be discarded and replaced with new ones 6 29 CONDENSE TRAP REMOVAL see fig 43 Carry out component removal procedure as described in 6 4 Disconnect the flexible outlet ...

Page 29: ...ting or HW Should the temperature of the primary thermistor drop below 7 C the valve actuator will motor to the heating position and the pump will be activated for approximately 20 minutes Should the temperature of the primary thermistor excee 10 C during this period the cycle will be aborted If the temperature drops below 4 C the boiler will operate on minimum power until the temperature of the p...

Page 30: ...be enabled When the request for heating has been satisfied the appliance fan may continue to operate to dissipate any residual heat from within the appliance 7 3 CHECKINGAND ADJUSTING BURNER PRES SURE see fig 19 Although the burner pressure is factory set it is necessary to check it during servicing or if the gas valve has been removed Isolate the appliance from the electrical supply and attach a ...

Page 31: ...minal strip fig 16 The meter should read approximately 230V ac Iff so proceed to next stage If not see 7 7 4 connect test leads between the Neutral Earth connections at the appliance terminal strip fig 16 The meter should read approximately 0 15Vac If so polarity is correct If not see 7 7 4 7 7 4 REVERSED POLARITY OR SUPPLY FAULT Repeat the above tests at the appliance isolator if testing reveals ...

Page 32: ...propriate code is shown on the display accompanied by a flashing red LED To reset the boiler slowly turn the mode selector switch to the reset position then back to the on position If the boiler does not reset refer to the following section and the detailed faultfinding flowcharts overleaf FAULT CODE 01 Fault code 01 appears when the burner has failed to ignite or the flame supervision system has ...

Page 33: ...R TO DHW POSITION START TEST A CHECKING OPERATION OF ELECTRONIC CONTROL BOARD AT START UP VOKERA LINEA PLUS AG Rev 1 08 03 2000 REPLACE PCB MAINS ON 3 WAY VALVE BETWEEN TERMINALS M11 1 M11 3 ON PCB CHECK OR REPLACE WIRING OR CONNECTIONS AND 3 WAY VALVE IS THE 3 WAY VALVE IN DHW POSITION IS THERE 5 Vdc BETWEEN TERMINALS M5 5 M5 6 ON PCB CHECK WIRING AND CONNECTIONS OR DHW FLOW SWITCH REPLACE CONTRO...

Page 34: ...Vdc BETWEEN TERMINALS M5 3 ON PCB RED WIRE ON HIGH LIMIT THERMOSTAT IS THERE 24 Vdc BETWEEN TERMINALS M5 3 AND M3 4 ON PCB CHECK WIRING AND CONNECTIONS RESET THE HIGH LIMIT THERMOSTAT GREEN LED LIGHT RESTART THE TEST REPLACE THE CONTROL BOARD CHECK WIRING AND CONNECTIONS REPLACE THE CONTROL BOARD IS THERE 24 Vdc BETWEEN TERMINALS M5 3 AND M3 5 ON PCB CHECK COMBUSTION AND CHECK OR REPLACE BURNER TH...

Page 35: ... Vdc BETWEEN TERMINALS M9 1 M9 2 ON CONTROL BOARD CHECK AND OR REPLACE WIRING OR CONNECTIONS WITH DISPLAY BOARD 5 Vdc BETWEEN TERMINALS M2 1 M2 2 ON DISPLAY BOARD REPLACE DIGITS BOARD FAULT CODE 01 SHOWING SWITCH ON OFF SELECTOR TO OFF POSITION SWITCH MODE SELECTOR TO DHW POSITION GREEN LED LIGHT RESTART THE TEST IGNITION CONTROL OK REPLACE CONTROL BOARD REPLACE IGNITION CONTROL FAULT CODE 02 SHOW...

Page 36: ... SWITCH OFF IS WATER FLOW TEMPERATURE 40 C WAIT WATER FLOW TEMPERATURE 40 C REPLACE CONTROL BOARD TURN DHW THERMOSTAT AT MAX B IS THERE A VOLTAGE 4 Vdc BETWEEN TERMINALS M3 10 M3 11 ON PCB CHECK FAN WIRING AND CONNECTIONS DIFFERENTIAL ANALOG PRESSURE SWITCH AND CONTROL BOARD IS FAN ON CHECK FLUE VENTURI TUBE IS D A P S OK REPLACE DIFFERENTIAL ANALOG PRESSURE SWITCH VOKERA LINEA PLUS AG Rev 1 08 03...

Page 37: ...1 1 M11 2 ON CONTROL BOARD REPLACE CONTROL BOARD C TURN CH THERMOSTAT TO MIN DO BURNER AND FAN SWITCH OFF IS WATER FLOW TEMPERATURE 40 C WAIT WATER FLOW TEMPERATURE 40 C REPLACE CONTROL BOARD TURN CH THERMOSTAT AT MAX IS THERE A VOLTAGE 4 Vdc BETWEEN TERMINALS M3 10 M3 11 ON PCB CHECK FAN WIRING AND CONNECTIONS DIFFERENTIAL ANALOG PRESSURE SWITCH AND CONTROL BOARD IS FAN ON CHECK FLUE VENTURI TUBE...

Page 38: ...K SENSING ELECTRODE AND LEAD END LOCKOUT AFTER IGNITION REPLACE GAS VALVE CHECK GAS GAS VALVE OK IGNITION SPARK AT ELECTRODE IS THERE MAIN BETWEEN TERMINALS L N ON IGNITION CONTROL CHECK SPARK ELECTRODE AND LEAD OR REPLACE CHECK WIRING AND CONNECTIONS CHECK WIRING AND CONNECTIONS CHECK WIRING AND CONNECTIONS IS THERE A VOLTAGE 0 5 Vdc BETWEEN TERMINALS M3 11 ON PCB GRAY WIRE ON D A P SWITCH CHECK ...

Page 39: ...ECK IF THE PUMP IS ON 3a SPEED A3 CHECK THE WIRING AND OR THE CONTROL BOARD CHECK REPLACE THE BOILER FLOW SWITCH NO YES NO YES NO YES NO YES NO YES NO YES FAULT CODE SHOWING 04 FAULT CODE SHOWING 06 FAULT CODE SHOWING 07 FAULT CODE SHOWING 08 CHECK FLOW NTC SENSOR OR CONNECTION CHECK COMBUSTION AND BURNER THERMISTOR OR CONNECTION YES NO FAULT CODE SHOWING d1 YES CHECK CONDENSATE LEVEL SENSOR OR WI...

Page 40: ...HE TEST C1 DO BURNER AND FAN SWITCH ON REMOVE THE LINK BETWEEN PIN M16 TA AND M16 TA ON CONTROL BOARD WAIT 30 SEC END DO BURNER FAN AND PUMP SWITCH OFF C IS THERE A VOLTAGE 1 Vdc BETWEEN TERMINALS M3 10 M3 11 ON PCB CHECK FAN WIRING AND CONNECTIONS DIFFERENTIAL ANALOG PRESSURE SWITCH AND CONTROL BOARD IS FAN ON CHECK FLUE VENTURI IS D A P S OK REPLACE DIFFERENTIAL ANALOG PRESSURE SWITCH IS THERE A...

Page 41: ...05 can be used in 3 modes Boiler only control whereby the RC05 controls only the functions of the appliance Heating DHW temperature reset function fault code display etc Boiler control with room thermostat function whereby the RC05 controls the functions of the appliance Heating DHW temperature reset function fault code display etc and also functions as a room thermostat Boiler control with progra...

Page 42: ...o basic voltage free time clock Fig 49 Basic wiring with link between TA TA no controls fitted Appliance wired to programmable room thermostat Appliance wired to basic voltage free time clock and room thermostat red black black blue white red red black black blue white red ...

Page 43: ...nse electrode OPE Gas valve solenoids B C B ACF02X Burner control board B E B Boiler control board S B Secondary board JP6 Pre heating jumper JP7 Room thermostat or remote control jumper JP8 Natural gas or L P G selector JP9 Timer on off selector PT1 S B Selection of 0 reset winter summer PT2 Central heating temperature control PT3 DHW temperature control DS1 DS2 Temperature alarm display TA1 Comb...

Page 44: ...Supplied By www heating spares co Tel 0161 620 6677 42 NOTE L N E CONNECTION IS ADVISABLE CONTROL SWITCHING OF TIME CLOCK AND ROOM THERMOSTAT IS 230 V a c WIRING DIAGRAM Syntesi 25 Syntesi 35 Syntesi 29 ...

Page 45: ... R10021951 R10022015 R10022029 31 Case R1880 R1922 R2062 38 Printed Circuit Board R10024558 R10024558 R10024558 39 Spring R1862 R1862 R1862 40 Door panel R10024508 R10024508 R10024508 43 Push push cover R1864 R1864 R1864 48 Led Light Guide R1858 R1858 R1858 49 Hole cap R8654 R8654 R8654 50 Pin R1867 R1867 R1867 51 Hole cover R1861 R1861 R1861 52 Selector knob kit R01005073 R01005073 R01005073 53 C...

Page 46: ...www heating spares co Tel 0161 620 6677 44 24 201 26 40 7 201 201 2 292 4 202 285 22 277 31 3 41 292 1 9 37 248 200 10 17 202 16 19 18 353 366 353 366 351 328 351 328 351 328 365 28 27 64 61 35 30 34 62 11 400 401 ...

Page 47: ...k R10023567 R10023567 R10023567 31 Venting plugs kit R01005137 R01005137 R01005137 34 Heating cock R10023566 R10023566 R10023566 35 Flexible pipe R10023570 R10023570 R10023570 37 Pipe R1631 R1631 R10023211 40 Pipe R10022125 R10022125 R10023210 41 Connection R2903 R2903 R2903 61 Non return valve R10023569 R10023569 R10023569 62 Filling cock R10023568 R10023568 R10023568 64 Pipe R10023643 R10023643 ...

Page 48: ...13 R10024131 R10024520 50 Siphon plug R10024133 R10024133 R10024133 200 Washer 24 x 17 R5023 R5023 R5023 201 Washer 18 5 x 11 R5026 R5026 R5026 202 Washer R5041 R5041 R5041 277 Screw M4 R6903 R6903 R6903 285 Sensor R8484 R8484 R8484 287 Limit thermostat R2258 R2258 R2258 288 O Ring R6898 R6898 R6898 289 Clip R2223 R2223 R2223 290 Clip R2165 R2165 R2165 370 O Ring R10023533 R10023533 R10023533 371 ...

Page 49: ...Gas pipe R1839 R1839 R1839 13 Gas valve R10025074 R10025074 R10025074 14 Gas pipe R1840 R1840 R1840 15 Gas cock R1787 R1787 R1787 16 Air box cover R10020216 R10020217 R10020430 17 Washer R5072 R5072 R5072 18 Glass R3139 R3139 R3139 19 Glass flange R4007 R4007 R4007 21 Washer R5905 R5905 R5905 200 Washer R5023 R5023 R5023 328 Clip R1890 R1890 R1890 332 Thermostat R2600 R2600 R2600 351 Nut R1823 R18...

Page 50: ...mbly R10024310 R10024125 R10024473 10 Fan R10024035 R10024035 R10024035 13 Venturi and pressure tube kit R01005293 R01005293 R01005293 16 Clamp for tube R10024126 R10024126 R10024126 19 Fan flue connection R10024137 R10024137 R10024137 20 Block with combustion analysis check R8085 R8085 R8085 23 Brass cap R8086 R8086 R8086 25 Pressure differential switch R2677 R2677 R2677 295 Silicone tube R1457 R...

Page 51: ...ncrease or counter clockwise to decrease the burner pressure 10 6 2 SETTING THE MIMIMUM BURNER PRESSURE see fig 45 Once the maximum burner pressure has been checked and or adjusted remove one of the grey wires from the modulating coil Compare the reading on the manometer with the value described in 10 2 If adjustment is required turn the inner red crosshead screw clockwise to increase or counter c...

Page 52: ...uk Sales Technical Advice General Enquiries Tel 0870 333 0520 Fax 01442 281403 After Sales Service Tel 0870 333 0220 Vokèra Ireland West Court Callan Co Kilkenny Tel 05677 55057 Fax 05677 55060 Vokèra Ltd reserve the right to change the specifications without prior notice Consumers statutory rights are not affected A Riello Group Company energizing home heating Vokèra supports Benchmark COLLECTIVE...

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