Linea Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER
Contents Design principles and operating sequence 1.1 Principle components 1.2 Mode of operation (at reset) 1.3 Mode of operation (Heating) 1.4 Mode of operation (DHW) 1.5 Safety devices 1.6 Optional accessories Technical data 2.1 Central heating 2.2 Domestic hot water 2.3 Gas pressure 2.4 Expansion vessel 2.5 Dimensions 2.6 Clearances 2.7 Connections 2.8 Electrical 2.9 Flue details (concentric) 2.9A Flue details (twin pipes) 2.10 Efficiency 2.11 Pump duty 2.12 Emissions General requirements (UK) 3.
INTRODUCTION The Linea 7 range is comprised of 3 models of combination boiler – 726, 730, 735 – with outputs to heating & DHW of 26, 30 & 35 kW respectively. Each appliance – by design – incorporates electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge, and automatic by-pass. The Linea 7 range are produced as room sealed, category II2H3+ appliances, suitable for internal wall mounting applications only.
SECTION 1 1.1 DESIGN PRINCIPLES AND OPERATING SEQUENCE PRINCIPLE COMPONENTS A fully integrated electronic control board featuring electronic temperature control, anti-cycle control, pump over-run, self-diagnostic fault indicator, full air/gas modulation. ● Low-water-content, copper heat exchanger.
SECTION 2 TECHNICAL DATA 2.1 Central heating Heat input (kW) Maximum heat output (kW) Minimum heat output (kW) Minimum working pressure Maximum working pressure Minimum flow rate 2.2 Domestic hot water Maximum input (kW) Maximum output (kW) Minimum output (kW) Flow rate (35oC rise) Maximum inlet pressure Minimum inlet pressure Minimum flow rate 2.3 Gas pressures Inlet pressure (G20) Burner pressure maximum Burner pressure minimum Maximum gas rate Minimum gas rate Injector size (quantity) 2.
SECTION 2 TECHNICAL DATA PUMP DUTY Fig. 3 shows the flow-rate available – after allowing for pressure loss through the appliance – for system requirements. When using this graph, apply only the pressure loss of the system. The graph is based on a 20oC temperature differential. 600 Water pressure (mbar) 2.11 500 400 300 200 100 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 Litres Per Hour Fig. 3 2.
SECTION 3 GENERAL REQUIREMENTS (UK) This appliance must be installed by a competent person in accordance with the Gas Safety (Installation & Use) Regulations. 3.1 3.2 RELATED DOCUMENTS The installation of this boiler must be in accordance with the relevant requirements of the Gas Safety (Installation & Use) Regulations, the local building regulations, the current I.E.E.
WATER CIRCULATION Detailed recommendations are given in BS 5449 Part 1 and BS 6798. The following notes are for general guidance only. 3.6.1 PIPEWORK It is recommended that copper tubing to BS 2871 Part 1 is used in conjunction with soldered capillary joints. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and that water flows naturally to drain cocks.
3.10 TIMBER FRAMED BUILDINGS If the appliance is to be fitted in a timber framed building, it should be fitted in accordance with the Institute of Gas Engineers publication (IGE/UP/ 7) ‘Guide for Gas Installations in Timber Frame Buildings’. 3.11 INHIBITORS Vokera recommend that a inhibitor – suitable for use with low water-content, copper heat exchangers – is used to protect the boiler and system from the effects of corrosion and/or electrolytic action.
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 soundness in accordance with I.S. 813. If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time. 3A.
3A.9 MOUNTING ON A COMBUSTIBLE SURFACE If the appliance is to be fitted on a wall of combustible material, a sheet of fireproof material must protect the wall. 3A.10 TIMBER FRAMED BUILDINGS If the appliance is to be fitted in a timber framed building, it should be fitted in accordance with I.S. 813 and local Building Regulations. The Institute of Gas Engineers publication (IGE/ UP/7) ‘Guide for Gas Installations in Timber Frame Buildings’ gives specific advice on this type of installation. 3A.
The telescopic flue kit (part no. 2359119) is suitable for a distance (dimension ’Y’) of up to 600mm. Dimension ‘Y’ is measured from the end of the terminal to the end of the outer (100mm) pipe. The internal trim should be fitted to the flue pipe before connection of the 90° bend. Reduction for additional bends Bend Reduction in maximum flue length for each bend 45° bend 0.5 metre 90° bend 1.0 metre Horizontal flue terminals and accessories Part No. Description 2359029 Standard flue kit.
Fig. 8A You must ensure that the entire flue system is properly supported and connected. Seal the flue assembly to the wall using cement or a suitable alternative that provides satisfactory weatherproofing. The exterior trim can now be fitted. 4.5.1.4 EXTENDING THE HORIZONTAL FLUE The horizontal flue system can be extended using bends and/or extensions from the Uni-Flue range (see 4.5.1). an extension or bend can be connected to the appliance flue outlet if desired (see 4.4.
● ● ● ● Ensure that the entire flue system is adequately supported, use at least one bracket for each extension. The entire flue system must be adequately insulated to maintain heat within the flue system thereby reducing the possibility of condensate production. As the exhaust outlet pipe can reach very high temperatures it must be protected to prevent persons touching the hot surface.
4.5.3.1 INSTALLATION OF TWIN ADAPTOR KIT (fig. 10) ● Insert the exhaust connection manifold onto the appliance flue outlet. ● Place the silicone seal (supplied with twin adapter kit) over the rim of the exhaust connection manifold. ● Remove the required blanking plate (located to the left and right of the appliance flue outlet) and – using the same screws – install the air baffle.
4.5.3.4 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 cannot be shortened. ● A 130mm hole is required for the passage of the concentric terminal through the ceiling and/ or roof. Depending on site conditions it may be preferable to install the terminal assembly prior to fitting the twin flue pipes.
4.6.3 COLD WATER INLET (fig. 6 & 14) The appliance is supplied with a 15mm combined stopcock and double check-valve, connect a 15mm pipe to the inlet of the stopcock and tighten both nuts. 4.6.4 HOT WATER OUTLET (fig. 6 & 14) The appliance is supplied with a 15mm outlet connection, connect a 15mm pipe to the outlet connection and tighten both nuts. 4.6.5 SAFETY VALVE (fig. 6 & 14) Connect the safety valve connection pipe between the safety valve outlet and the fixing jig.
To fit the Vokera time clock: ● Remove the appliance PCB cover. ● Remove and discard the wiring harness supplied with the clock. ● Using the clock wiring harness supplied in the accessory pack, connect the 4-wires to the clock as shown in fig 16. ● 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).
SECTION 5 COMMISSIONING 5.1 GAS SUPPLY INSTALLATION Inspect the entire installation including the gas meter, test for soundness and purge. Refer to BS 6891 for specific instruction. 5.2 THE HEATING SYSTEM The appliance contains components that may become damaged or rendered inoperable by oils and/or debris that are residual from the installation of the system, consequently it is essential that the system be flushed in accordance with the following instructions.
To lower the system pressure to the required value, pull lever on head of safety valve to release water until the required figure registers on the pressure gauge (see fig. 1). Compensator tube 5.11 Outlet test-point Protective cap Inlet test-point Fig. 19 Once the burner pressure has been checked, close the DHW outlet, isolate the appliance from the electrical supply, remove the manometer, and tighten the gas valve outlet test nipple. 5.
5.12 FINAL CHECKS ENSURE ALL TEST NIPPLES ON THE APPLIANCE GAS VALVE HAVE BEN TIGHTENED AND CHECKED FOR SOUNDNESS. ● ENSURE THE APPLIANCE FLUE SYSTEM IS FITTED CORRECTLY AND IS PROPERLY SECURED. ● ENSURE ALL PIPE WORK IS RE-CHECKED FOR SOUNDNESS. ● RE-FIT APPLIANCE CASING. ● COMPLETE APPLIANCE LOGBOOK. Complete details of the boiler, controls, installation, and commissioning in the logbook supplied with the boiler. This is an important document, which must be correctly completed and handed to the user.
6.4 COMPONENT REMOVAL PROCEDURE To remove a component, access to the interior of the appliance is essential. Isolate the appliance from the electrical supply and remove the fuse. And when necessary, close all service valves on the appliance, remove the appliance casing as described in section 4.7.1, and drain the water content from the appliance via the safety valve. Ensure some water absorbent cloths are available to catch any residual water that may drip from the appliance or removed component.
6.9 PRESSURE GAUGE fig. 23 Carry out component removal procedure as described in 6.4. Remove pressure gauge locking screw (1), located on pump base, and withdraw the pressure gauge pipe (2), locate the spring tabs on the pressure gauge body, push and hold tabs in, to enable extraction of the gauge from its location. Replace in the reverse order. 6.10 PRIMARY THERMISTOR fig. 24 Carry out component removal procedure as described in 6.4.
electrode lead and burner thermostat from their respective connectors. Ease the electrode sealing grommet from its seating (4). Remove the retaining screw for the burner thermostat and remove the thermostat FIG. 29, Locate and remove the four screws which secure the burner in position (1), gently ease the burner out of its location Once the burner has been removed, the electrode retaining screw can be can be removed. Locate the burner injectors (2) and remove (if necessary). Replace in the reverse order.
Fig. 29 Fig.
Fig. 31 6.17 6.18 MAIN HEAT EXCHANGER fig. 31 Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging. Locate and remove the six screws (2) that secure the front combustion cover, then remove the cover. Remove the air chamber side panels if necessary by unscrewing the securing screws (3). Disconnect the flow and return connections (4,5) on the heat exchanger.
6.22 Fig. 35 Fig. 33 6.20 DHW FLOW SWITCH fig. 33 Carry out component removal procedure as described in 6.4. Disconnect and remove the cold water inlet pipe (1,2) from the DHW flow switch & DHW heat exchanger. Disconnect the wiring to the DHW flow switch. Remove the locking pin (3) from the DHW flow switch and lift the DHW flow switch housing from its seating, taking care not to lose the float contained within the housing.
6.25 AUTOMATIC BYPASS fig. 38 Carry out component removal procedure as described in 6.4. Disconnect and remove the flow pipe at the heating manifold & DHW manifold (1), and at the connection to the air chamber. Using a hooked piece of wire, carefully withdraw the bypass cartridge (2). Ensure all seals are in good condition, taking care to ensure they are replaced correctly. Replace in the reverse order ensuring the cartridge is facing the correct way. Fig. 38 6.26 DHW NON-RETURN VALVE fig.
SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING 7.1 CHECKING APPLIANCE OPERATION When carrying out any repairs or servicing to the appliance, the relevant commissioning procedure must be undertaken to ensure the continued safe operation of the appliance. Particular attention should be made to ensure gas soundness, water soundness, and the electrical integrity of the appliance. 7.2 APPLIANCE MODE OF OPERATION NOTE there must be sufficient system water pressure (min. 0.
If the temperature continues to rise and exceeds the set-point by 6oC, the burner will shut down and the boiler will perform a three-minute anticycle (timer delay). A new ignition sequence will be enabled when the 3-minute anti-cycle has been performed and the temperature at the primary thermistor has dropped 6oC below the set-point. NOTES The timer delay can be de-activated by the insertion of a ‘jumper’ on the PCB or by isolating the appliance from the electrical supply for 30 seconds.
7.6.1 INSTALLATION FAULTS Symptom No ignition Protecting cap No hot water Air analysis outlet No central heating Check wiring of time clock and/or room thermostat Fault code 01 Possible causes Gas supply problem Gas line requires purging Reversed polarity Broken, internal flue joint Flow/return valves closed Stuck pump Debris in flue system Debris in flue venturi Insufficient water pressure Air in boiler Fumes analysis outlet 02 03 04 Fig. 43 7.4 7.5 7.
If 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 7.7.5 7.8 7.9 30 REVERSED POLARITY OR SUPPLY FAULT Repeat the above tests at the appliance isolator, if testing reveals correct polarity and/or supply at the isolator, re-check wiring and connections between the isolator and the appliance.
VOKERA LINEA PLUS AG START Rev. 1 08/03/2000 TEST A : CHECKING OPERATION OF ELECTRONIC CONTROL BOARD AT START UP IS THE 3 WAY VALVE IN DHW POSITION? NO NO MAINS ON 3 WAY VALVE BETWEEN TERMINALS M11.1 & M11.3 ON PCB YES NO TURN ON HOT TAP A2 CHECK &/OR REPLACE WIRING OR CONNECTIONS AND 3 WAY VALVE PUMP RUNNING BETWEEN TERMINALS M5.5 & M5.
A1 IS THERE 24 Vdc BETWEEN TERMINALS M5.3 AND M3.3 ON PCB NO YES REPLACE THE CONTROL BOARD IS THERE 24 Vdc NO BETWEEN TERMINALS M5.3 ON PCB & WHITE WIRE ON HIGH LIMIT THERMOSTAT CHECK WIRING AND CONNECTIONS YES IS THERE 24 Vdc NO BETWEEN TERMINALS M5.3 ON PCB & RED WIRE ON HIGH LIMIT THERMOSTAT YES RESET THE HIGH LIMIT THERMOSTAT IS THERE 24 Vdc BETWEEN TERMINALS M5.3 AND M3.
A2 5 Vdc BETWEEN TERMINALS M2.1 & M2.2 ON DISPLAY BOARD YES IS RED LED FLASHING FAULT CODE SHOWING 5 Vdc BETWEEN TERMINALS M9.1 & M9.2 ON CONTROL BOARD NO YES YES CHECK AND/OR REPLACE WIRING OR CONNECTIONS WITH DISPLAY BOARD NO MAINS PRESENT BETWEEN M16.L & M16.
VOKERA LINEA PLUS AG START Rev. 1 08/03/2000 TEST B : CHECK CONTROL IN DHW MODE TURN MODE SELECTOR SWITCH TO DHW. DHW STAT AT MAX. TURN ON TAP NO CHECK BOILER STARTUP: TEST A DOES BURNER LIGHT YES IS THERE A VOLTAGE >4 Vdc BETWEEN TERMINALS M3.10 & M3.11 ON PCB NO IS FAN ON? YES YES IS D.A.P.S. OK? NO CHECK FAN, WIRING AND CONNECTIONS, DIFFERENTIAL ANALOG PRESSURE SWITCH AND CONTROL BOARD NO YES TURN DHW THERMOSTAT AT MIN. DO BURNER AND FAN SWITCH OFF YES TURN DHW THERMOSTAT AT MAX.
VOKERA LINEA PLUS AG START Rev. 1 08/03/2000 SWITCH ON BOILER AND SELECT MODE TO WINTER C/H THERMOSTAT AT MAX. TEST C: CHECK CONTROL IN C/H MODE MAKE A LINK BETWEEN PIN M16.TA AND M16.TA ON CONTROL BOARD YES DOES BURNER LIGHT IS THE 3 WAY VALVE ON CH POSITION? NO YES NO CHECK BOILER STARTUP TEST A MAINS PRESENT BETWEEN M11.1 & M11.2 ON CONTROL BOARD YES IS THERE A VOLTAGE >4 Vdc BETWEEN TERMINALS M3.10 & M3.11 ON PCB CHECK &/OR REPLACE 3 WAY VALVE IS FAN ON? YES IS D.A.P.S.
A SPARK AT ELECTRODE NO IS THERE MAIN BETWEEN TERMINALS M14.1 & M14.2 ON PCB YES IGNITION NO YES NO IS THERE MAIN BETWEEN TERMINALS L & N ON IGNITION CONTROL LOCKOUT AFTER IGNITION YES END YES NO YES CHECK SENSING ELECTRODE AND LEAD YES NO CHECK WIRING AND CONNECTIONS CHECK SPARK ELECTRODE AND LEAD OR REPLACE IGNITION CONTROL SENSING ELECTRODE AND LEAD OK REPLACE IGNITION CONTROL IS THERE 0 Vdc NO BETWEEN TERMINALS M5.3 & M5.
A3 A4 FAULT CODE SHOWING 03 YES DOES THE FLOW SWITCH PIN OPERATE NO YES FAULT CODE SHOWING 04 NO YES REPLACE CONTROL BOARD DO THE BOILER FLOW SWITCH OPERATE NO CHECK AND/OR REPLACE THE DIAPHRAGM. CHECK THE CORRECT WATER DP CHECK THE WATER CIRCUIT.
C DO BURNER AND FAN SWITCH ON YES NO NO WAIT 3 MIN. IS TIMER JUMPER ON YES REPLACE CONTROL BOARD DO BURNER AND FAN SWITCH ON WAIT WATER FLOW TEMPERATURE < 80 ûC YES REMOVE JUMPER YES RESTART THE TEST NO IS THERE A VOLTAGE < 1 Vdc IS WATER FLOW TEMPERATURE >80 ûC YES NO BETWEEN TERMINALS M3.10 & M3.11 ON PCB IS THERE A VOLTAGE >4 Vdc NO BETWEEN TERMINALS M3.10 & M3.11 ON PCB REPLACE CONTROL BOARD YES IS TIMER JUMPER ON JP9 YES NO REMOVE JUMPER REMOVE THE LINK BETWEEN PIN M16.
SECTION 8 WIRING DIAGRAMS 8.1 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 programmable room thermostat, whereby the RC05 controls the functions of the appliance (Heating & DHW temperature, reset function, fault code display, etc), and also functions as a programmable room thermostat.
Fig.
FUNCTIONAL DIAGRAM NOTE: L-N-E CONNECTION IS ADVISABLE CONTROL SWITCHING OF TIME CLOCK AND ROOM THERMOSTAT IS 230 V.a.c. R.T. TS H S.F.S. P.S. H.L. S.R. S.S. MOD F P 3W SP\SE E. OPE B.C.B. B.E.B. S.B.
42 CONTROL SWITCHING OF TIME CLOCK AND ROOM THERMOSTAT IS 230 V.a.c.
SECTION 9 EXPLODED DIAGRAMS 31 1 362 226 16 17 18 20 90 48 19 6 326 26 212 38 51 43 50 400 53 52 401 12 402 POS.
40 1 24 Spare 201 201 285 26 202 37 4 292 248 2 24 200 201 7 351 41 328 9 351 31 3 277 328 351 10 22 328 365 16 11 18 15 19 202 353 17 366 353 30 64 366 28 62 61 27 34 400 35 401 44 Linea
POS.
200 202 8 285 287 9 1 200 201 7 2 284 2 735 200 7 3 5 28 4 290 200 288 6 200 11 10 6 POS.
6 21 2 21 2 21 7 21 735 9 4 3 1 332 5 12 735 200 13 351 10 328 15 200 400 14 17 18 19 16 401 POS.
25 23 19 20 295 17 16 12 300 10 301 7 1 4 2 3 212 3 POS.
SECTION 10 LPG INSTRUCTIONS 10.1 RELATED DOCUMENTS BS 6798 BS 5449 INSTALLATION OF BOILERS OF RATED NOT EXCEEDING 60kW PART 1 BS 5546 FORCED CIRCULATION OF HOT WATER SYSTEMS INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES BS 5440 PART 1 FLUES BS 5482 PART 1 DOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS 10.2 Gas Pressures Inlet pressure (G31) Burner pressure maximum Burner pressure minimum Maximum gas rate Minimum gas rate Injector size (quantity) 10.3 726 4.
Cod. 10024467 - 49/03 - Ed. 3 energizing home heating Vokèra Ltd. 4th Floor, Catherine House, Boundary Way, Hemel Hempstead, Herts, HP2 7RP Email: enquiries@vokera.co.uk Web: www.vokera.co.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.
