VOKERA Compact A Installation & Servicing Instructions Manual Download

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Installation
& Servicing
Instructions

THESE INSTRUCTIONS
TO BE RETAINED
BY USER

Compact

Summary of Contents for Compact A

Page 1: ...Installation Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER Compact ...

Page 2: ...5 5 Filling the hot water system 16 5 6 Pre operation checks 16 5 7 Initial lighting 16 5 8 Checking burner pressures 16 5 9 Final flushing of the heating system 17 5 9 1 Inhibtors 17 5 10 Setting the flow temperature 17 5 11 Setting the system design pressure 17 5 12 Regulating the central heating system 17 5 13 Regulating the domestic hot water 17 5 14 Final checks 17 5 15 Instructing the user 1...

Page 3: ...e combined central heating and domestic hot water boilers which by design incorporates full sequence electronic ignition circulating pump expansion vessel safety valve pressure gauge automatic by pass and mechanical time clock Compactisproducedasaroomsealedappliance suitable for wall mounting applications only Compact is provided with a fan powered flue outlet with an annular co axial combustion a...

Page 4: ...s a demand for domestic hot water the domestic hot water flow switch is proved by the flow of water through the appliance this allows the fan to run the fan proves the differen tial air pressure switch which in turn allows an ignition sequence to begin Ignition is sensed by the electronic circuitry to ensure flame stability at the burner Once successful ignition has been achieved the appli ance wi...

Page 5: ...r 1 5 mbar 1 3 mbar Gross rate maximum 2 78 m3 h 3 28 m3 h Injectors size 12 x 1 35 mm 14 x 1 35 mm 2 4 Expansion vessel Capacity 8 litres 8 litres Maximum system volume 76 litres 76 litres Pre charge pressure 1 0 bar 1 0 bar 2 5 Dimensions Height 740 mm 740 mm Width 400 mm 450 mm Depth 328 mm 328 mm Dry weight 34 kg 37 kg 2 6 Clearances Left side 50 mm 50 mm Right side 12 mm 12 mm Top 150 mm from...

Page 6: ...m 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 or boundary 300 mm I Above ground roof or balcony level 300 mm J From a surface or boundary facing the terminal 600 mm K From a terminal facing a terminal 1200 mm L Fr...

Page 7: ...ied by the gas supplier must be checked to ensure that it is of adequate size to deal with the maximum rated input of all the appliances that it serves Installation pipes must be fitted in accordance with BS 6891 Pipe work from the meter to the appliance must be of adequate size Pipes of a smaller size than the appliance gas inlet connection must not be used The installation must be tested for sou...

Page 8: ... carried naturally to air release points and that water flows naturally to drain cocks Except where providing useful heat pipes should be insulated to avoid heat loss and in particular to avoidthepossibilityoffreezing Particularattention shouldbepaidtopipespassingthroughventilated areas such as under floors loft space and void areas 3 6 2 AUTOMATIC BY PASS The appliance has a built in automatic by...

Page 9: ...on of a safe and satisfactory flue and termination The location must also permit an adequate air supply for combustion purposes and an adequate space for servicing and air circulation around the appliance Where the installation of the appliance will be in an unusual location special procedures may be necessary refer to I S 813 for detailed guidance on this aspect A compartment used to enclose the ...

Page 10: ... be from an independent make up vessel or tank mounted in a position at least 1 metre above the highest point in the system and at least 5 metres above the boiler fig 5 The cold feed from the make up vessel or tank must be fitted with an approved non return valve and stopcock for isolation purposes The feed pipe should be connected to the return pipe as close to the boiler as possible 3A 6 8 FREQU...

Page 11: ... both horizontal and vertical flue applications to be considered alternatively the Vokera twin flue system can be utilised if longer flue runs are required 4 5 1 CONCENTRIC HORIZONTAL FLUE For concentric vertical flue see section 4 5 2 For twin flue applications see section 4 5 3 The appliance flue outlet elbow can be rotated through 360º on its vertical axis In addition the flue may be extended f...

Page 12: ...pipe before connection of the 90º bend Insert the flue restrictor ring supplied with instruction pack into the appliance flue gas outlet if the total flue length is less than 1 0 metre If the horizontal flue kit 2359029 requires to be cut to the correct size dimension Y you must ensure that the inner 60 mm pipe stands proud of the outer 100 mm pipe by 7 5 mm fig 8B Ensure any burrs are filed or re...

Page 13: ...use a suitable extension Insert the flue restrictor ring into the appliance flue outlet in accordance with the table in section 4 4 2 Connect the vertical flue assembly to the boiler flue spigot using the 60 mm 100 mm clips gaskets screws supplied ensuringthecorrect seal is made The flue support bracket supplied with the vertical flue kit can now be fitted Iftheverticalfluerequiresextension soradd...

Page 14: ...drain Consideration must also be given to the fact that there is the possibility of a small amount of condensate dripping from the terminal Ensure that the entire flue system is adequately supported use at least one bracket for each extension Extreme care must be taken to ensure that no debris is allowed to enter the flue system at any time As the exhaust outlet pipe can reach very high temperatur...

Page 15: ...ng and or roof Depending on site conditions it may be preferable to install the terminal assembly prior to fitting the twin flue pipes Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside ensuring that the collar on the flue terminal fits over the flashing Push fit the twin flue pipes onto the concentric to twin converter ...

Page 16: ...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 If this method of connection is unsuitable please refer to section 8 A qualified electrician should connect the electrical supply to the appliance The electrical supply must be as specified in section 3 7 3 7A A q...

Page 17: ... cable anchorage Connect the supply cable wires earth live and neutral to their corresponding terminals on the terminal strip Ensure that the EARTH wire is left slightly longer that the others this will prevent strain on the EARTH wire should the cable become taut The securing screw on the cable anchorage should now be tightened This must be done before the control fascia is re fitted in the uprig...

Page 18: ...lves from the meter to the appliance are open and the supply pipe has been properly purged SECTION 5 COMMISSIONING Ensure the proper electrical checks have been carriedout section7 11 particularlycontinuity polarity and resistance to earth Ensure the 3 amp fuse supplied with the appliance has been fitted Ensure the system has been filled aired and the pressure set to 1bar Ensure the flue has been ...

Page 19: ...sonable temperature at the outlet The outlet temperature can also be adjusted via the DHW temperature selector If the required outlet temperature cannot be obtained by rotating the DHW temperature selector to its maximum setting the adjustable stopcock should be used to limit the available flow rate at the outlet Slowly turn the adjustable stopcock clockwise until a satisfactory temperature is obt...

Page 20: ...rs of reliable trouble free service the life span of components will be determined by fac tors such as operating conditions and usage Should the appliance develop a fault the fault finding section will assist in determining which component is malfunctioning 6 4 MAIN HEAT EXCHANGER de scaling The main heat exchanger may when operating under certain conditions become affected by scaling Evidence of ...

Page 21: ...the domestic water flow switch disconnect and remove inlet pipe between the domestic water flow switch and the heat exchanger remove locking pin from the domestic water flow switch the switch can now be removed from the appliance Replace in the reverse order Fig 17 AAV Fig 18 WATER PRESSURE SWITCH 6 11 PRESSURE GAUGE fig 1 Carry out component removal procedure as de scribed in 6 5 Remove pressure ...

Page 22: ...r Check and adjust burner pressure settings WARNING A GAS SOUND NESS CHECK MUST BE CARRIED OUT Fig 22 6 17 BURNER INJECTORS AND SPARK SENSE ELECTRODE fig 24 25 Carry out component removal procedure as de scribed in 6 5 Remove outer combustion cover by un clipping the two retaining clips located at the base of the combustion cover gently pull the cover towards you before lifting and disengaging it ...

Page 23: ...on taking care to ensure they are replaced correctly 6 20 AIR PRESSURE SWITCH fig 1 24 28 Carry out component removal procedure as de scribed in section 6 5 Removeoutercombustioncoverbyun clippingthe two retaining clips located at the base of the combustion cover gently pull the cover towards you before lifting and disengaging it from the top retaining lugs Locate and remove the two screws holding...

Page 24: ...f the primary thermistor exceeds 55 ºC 7 4 HEATING MODE Withallcontrolscallingforheat thepumpandfan will run When the fan runs it proves the air SECTION 7 CHECKS ADJUSTMENTS AND FAULT FINDING pressure switch The air pressure switch delivers current to the PCB and enables an ignition sequence to begin The ignition sequence begins with the energising of the gas valve and a simultaneous sparking at t...

Page 25: ... the reading should be 10 2 mbar Using a small screwdriver gently rotate the P5 potentiometer if adjustment is necessary To check and or adjust the minimum heating gas pressure slowly rotate the heating temperature selector until the burner pressure drops to minimum should be 1 9 mbar Using a small screwdriver gently rotate the P4 potentiometer if adjustment is necessary Isolate the appliance from...

Page 26: ... from the electrical supply and using a suitable multi meter carry out a resistance test Connect test leads between the Live Earthconnectionsattheapplianceterminal strip fig 14 If the meter reads other than infinity there is a fault which must be isolated carry out a detailed continuity check to identify the location of the fault IMPORTANT These series of checks must be carried out before attempti...

Page 27: ...N8 5 ON PCB NO NO YES MADE A LINK BETWEEN BLACK BLACK WIRES AT BOILER TERMINAL STRIP AND CLOSE THE TIMER CONTACT SWITCH ON BOILER AND SELECT MODE TO WINTER C H THERMOSTAT AT MAX YES LOOSE THE PUMP ACTING WITH A SCREWDRIVER ON THE IMPELLER RESTART THE TEST NO NO NO NO IS ROOM THERMOSTAT INPUT LINKED MADE A LINK BETWEEN THE ROOM THERMOSTAT INPUT CHECK IDRAULIC CIRCUIT WATER PRESSURE SWITCH IS OK NO ...

Page 28: ...Vdc BETWEEN TERMINALS CN8 7 CN8 8 ON PCB NO YES NO CHECK WIRING AND CONNECTIONS NO DO THE AIR FLOW SWTCH TURN ON CHECK WIRING AND CONNECTIONS AIR FLOW SWITCH AND CONTROL BOARD YES NO ARE THE VENTURI TUBE AND THE SILICONE AIR TUBES CLEAN CHECK CLEAN THE VENTURI TUBE AND SILICONE AIR TUBES IS THE AIR DP 11 mmCH2O CHECK THE FAN AND OR FLUE GAS TUBE CHECK REPLACE AIR FLOW SWITCH NO YES YES REPLACE THE...

Page 29: ...UIT NO RECHECK SUPPLY FUSE CONNECTORS TO BOILER TERMINALS MAINS PRESENT BETWEEN BLUE BROWN WIRES AT BOILER TERMINAL STRIP NO REPLACE WIRING OR CONNECTIONS TERMINAL STRIP AND CONTROL BOARD YES YELLOW LED BLINKS CHIMNEY SWEEPER CYCLE RESET AND RESTART TEST NO IS THERE 0 VCC BETWEEN TERMINALS CN9 1 CN9 2 ON PCB IS THERE 24 Vdc BETWEEN TERMINALS CN8 4 CN8 7 ON PCB IS THERE 24 Vdc BETWEEN TERMINALS CN8...

Page 30: ...UMMER DHW THERMOSTAT AT MAX START YES SWITCH DHW THERMOSTAT AT MIN DO BURNER AND FAN SWITCH OFF IS TEMPERATURE 40 C WAIT D H W TEMPERATURE 40 C REPLACE CONTROL BOARD YES NO YES NO IS THERE 24 Vdc BETWEEN TERMINALS CN9 7 CN9 8 ON PCB REPLACE CONTROL BOARD YES CHECK WIRING AND CONNECTIONS OR DHW SWITCH YES NO IS THERE 0 Vdc BETWEEN TERMINALS CN9 7 CN9 8 ON PCB NO WAIT TILL THE VOLTAGE BETWEEN TERMIN...

Page 31: ...H OFF TURN OFF TAP SWITCH DHW THERMOSTAT AT MAX DO BURNER AND FAN SWITCH ON IS TEMPERATURE 60 C WAIT D H W TEMPERATURE 60 C REPLACE CONTROL BOARD YES CHECK WIRING AND CONNECTION OR CONTROL BOARD REPLACE DHW FLOW SWITCH IS DHW FLOW SWITCH OK YES YES NO NO YES NO B D H W ...

Page 32: ...ITCH ON BOILER AND SELECT MODE TO WINTER C H THERMOSTAT AT MAX START RESTART THE TEST NO NO YES REPLACE WIRE AND CONNECTIONS REPLACE CONTROL BOARD REPLACE MODULATOR COIL IS THE RESISTENCE OF MODULATOR COIL ABOUT 70 80 OHM IS THERE A VOLTAGE 8 VDC BETWEEN TERMINALS CN9 3 CN9 4 ON PCB YES C IS VOLTAGE ACROSS TERMINALS OF MODULATOR COIL 10 VDC SWITCH CH THERMOSTAT AT MIN NO YES NO WAIT TILL THE VOLTA...

Page 33: ... SWITCH ON IS WATER FLOW TEMPERATURE 80 C WAIT WATER FLOW TEMPERATURE 80 C NO YES REPLACE CONTROL BOARD REMOVE JUMPER IS TIMER JUMPER ON RESTART THE TEST DO BURNER AND FAN SWITCH ON OPEN THE TIMER CONTACT REPLACE CONTROL BOARD DO BURNER AND FAN SWITCH OFF DO PUMP SWITCH OFF END REPLACE CONTROL BOARD YES YES YES NO NO NO NO NO NO YES YES YES WAIT 30 SECS NO IS C H NTC OK REPLACE C H NTC REPLACE CON...

Page 34: ...ppliance terminal strip if required Carry out the electrical checks as described in section 7 11 prior to refitting the PCB cover and appliance casing 8 2 CONNECTION OF AN EXTERNAL TIME CLOCK Should the integral time clock be unsuitable additional or alternative controls must be connectedtotheapplianceterminalstripasshown in fig 29 29A NOTE Guidance on the recommended practice for the installation...

Page 35: ...C B Burner control board CP08X Boiler control board JP2 Setting timer JP3 Natural gas or L P G selector JP4 Jumper disable enable DHW absolut thermostat P1 Domestic hot water temperature control P2 Central heating temperature control P3 Off summer winter selector P4 P5 Setting trimmer F External fuse 2 A F on 230 V circuit F2 CP08X Fuse 2 A F on 230 V circuit RL1 Ignition relay RL2 Fun relay RL4 P...

Page 36: ...34 Compact NOTE L N E CONNECTION IS ADVISABLE FUNCTIONAL DIAGRAM Fig 31 ...

Page 37: ...174 10022174 20 Printed Circuit Board 10023537 10023537 21 Led Light Guide 10023816 10023816 26 Instrumental panel 10023933 10023933 27 Knob 10023937 10023937 28 Knob 10023936 10023936 31 Case 10023822 10023883 33 Plastic Trade Mark Label 1979 1979 49 Converter 10023935 10023935 76 Timer 10023938 10023938 90 3 A fuse 3478 3478 226 Edge clip 5128 5128 270 Transformer 10021272 10021272 300 Wiring ha...

Page 38: ...2499 24 Flow governor 8009 8009 25 Pipe 10020714 10023950 26 DHW actuator 10022349 10022349 27 Heating cock 1789 1789 28 Connection 1790 1790 30 Water supplu stop cock 7099 7099 31 Venting plugs kit 01005137 01005137 36 Pipe 10020612 10023949 63 Pipe 10020898 10020898 201 Washer 5026 5026 285 NTC sensor 8484 8484 288 O ring 6898 6898 289 Clip 2223 2223 290 Clip 2165 2165 299 Washer 10022726 100227...

Page 39: ...lexible pipe 2164 2164 3 Pump 2225 2225 7 Pipe 10022000 10023947 8 Heat exchanger 10021419 10023661 9 Pipe 10022002 10023948 10 Automatic air vent bottle 0439 0439 12 Washer 2226 2226 201 Washer 5026 5026 202 Washer 5041 5041 285 NTC senspr 8484 8484 287 High limit thermostat 2258 2258 289 Clip 2223 2223 290 Clip 2165 2165 ...

Page 40: ...2 3 Main burner injector manifold 10023800 10023903 4 Burner 10023798 10023901 5 Spark electrode 10021398 10021398 12 Pipe 10023996 10023996 13 Gas valve 10021021 10021021 15 Gas cock 10020897 10020897 16 Cover assembly 10021570 10023928 18 Glass 10021558 10021558 27 Air box hole cap 8084 10023805 52 Burner flange 10023997 53 Nut 2233 2233 200 Washer 5023 5023 295 Silicone tube 1457 1457 LPG conve...

Page 41: ...insulating panel 2231 2231 4 Front insulating panel 2232 10023910 10 Fan 10020793 10023907 12 Connection 2237 2237 20 Fumes testing connection pipe 10020627 10020627 25 Pressure diff switch 8195 10023908 28 Stop clip 10020626 10020626 212 Screw 5080 5080 295 Silicone tube 1457 1457 300 Wiring harnes 10024067 10024067 ...

Page 42: ...ressure Heating 6 5 mbar 6 5 mbar Jumper tag for LPG Inserted across JP3 Inserted across JP3 10 5 2 SETTING THE MINIMUM DHW GAS PRESSURE fig 15 23 After carrying out section 10 5 1 disconnect one of the black wires attached to the modulator coil The burner will now operate at minimum power Observethemanometer thereadingforCompact 24 should be 5 1 mbar for Compact 28 the reading should be 4 8 mbar ...

Page 43: ... 210 mm to x to give you dimension y Push both the inner and outer concentric flue pipes together until the total length of the flue assem bly is equal to dimension y Secure the flue assembly in place by using the screw provided C Take the large rubber gasket and secure it firmly over the appliance flue spigot D Pass the as sembly through the wall mounting bracket and wall leaving 25 mm proud of t...

Page 44: ...42 281460 Technical Advice Tel 0141 945 6810 Spare Parts Tel 0141 945 68 0 After Sales Service Tel 0870 333 0220 Vokèra Ireland West Court Callan Co Kilkenny Tel 056 55057 Fax 056 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 MARK ...

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