Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER
Contents Design principles & operating sequence 1.1 1.2 1.3 1.4 Principle components Mode of operation (at rest) Mode of operation (heating or hot water request) Safety devices Technical data 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 Central heating Gas pressure Expansion vessel Dimensions Clearances Connections Electrical Flue details Efficiency Adjusting operating parameters Emissions Pump duty General requirements (UK) 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.
INTRODUCTION The Pinnacle range of boilers are central heating condensing boiler, which – by design – incorporates full sequence electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge and automatic bypass. Pinnacle is produced as a room sealed, category C1, C3, C6 appliance, suitable for wall mounting applications only.
SECTION 1 1.1 DESIGN PRINCIPLES AND OPERATING SEQUENCE PRINCIPLE COMPONENTS A fully integrated electronic control board featuring differential temperature control, continuous air/gas modulation, anti-cycle control, pump over-run, self-diagnostic fault indicator, electronic ignition with flame supervision & appliance frost protection ● Cast aluminium mono-block heat exchanger ● Low Nox burner with pre-mix ● Two-stage gas valve ● Pump ● Expansion vessel ● Pressure gauge ● Safety valve ● ● 1.2 1.3 1.
SECTION 2 TECHNICAL DATA 2.1 Central heating Heat input (gross) Maximum heat output 60/80°C (return & flow temperature) Maximum heat output 30/50°C (return & flow temperature) Minimum heat output 60/80°C (return & flow temperature) Minimum heat output 30/50°C (return & flow temperature) Minimum working pressure Maximum working pressure Minimum flow rate 2.2 Gas pressure Inlet pressure (G20) Maximum gas rate Minimum gas rate Injector size 2.
7 6,5 6 ) 5,5 5 4,5 ( 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 20 ºC temperature differential. Water pressure (mH20) 2.12 4 3,5 3 2,5 2 1,5 1 0,5 0 0 100 200 Fig. 3 SECTION 3 Key A B C D E F G H I J K L M N P Q Fig.
This appliance must be installed by a competent person in accordance with the Gas Safety (Installation & Use) Regulations. 3.1 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. wiring regulations, the bylaws of the local water undertaking, the Building Standards (Scotland) Regulation and Building Standards (Northern Ireland) Regulations.
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. Except where providing useful heat, pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing.
*Fernox and Sentinel manufacture products that have proved suitable for use with Vokera appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our appliances. CH return valve Gas cock CH flow valve Fig. 6 CONDENSATE TRAP RETURN FLOW GAS Fig.
SECTION 3A GENERAL REQUIREMENTS (EIRE) This appliance must be installed by a competent person in accordance with and defined by, the Standard Specification (Domestic Gas Installations) Declaration (I.S. 813). 3A.1 RELATED DOCUMENTS The installation of this boiler must be in accordance with the relevant requirements of the local building regulations, the current ETCI National Rules for Electrical Installations, and the bylaws of the local water undertaking.
3A.6.4 AIR RELEASE POINTS These must be positioned at the highest points in the system where air is likely to be trapped. They should be used to expel trapped air and allow complete filling of the system. 3A.6.5 EXPANSION VESSEL The appliance has an integral expansion vessel to accommodate the increased volume of water when the system is heated.
SECTION 4 4.1 4.2 4.3 4.4 4.5 4.5.1 10 INSTALLATION DELIVERY Due to the weight of the appliance it may be necessary for two people to lift and attach the appliance to its mounting. The appliance is contained within a heavy-duty cardboard carton. Lay the carton on the floor with the writing the correct way up.
NOTE When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (fig. 7 & 7B). Remove any burrs, and check that all seals are located properly. 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 will provide satisfactory weatherproofing. The interior and exterior trim can now be fitted.
Using the dimensions given in fig. 8 as a reference, mark and cut a 105 mm hole in the ceiling and/or roof. IMPORTANT You must ensure that the terminal is at least 300 mm from any structure or surface (fig. 8). The vertical flue terminal is 1.0 metre in length and cannot be cut; therefore it may be necessary to adjust the height of the appliance to suit or use a suitable extension. Ensure that any horizontal sections of the flue system have a 1º fall back to the boiler (17 mm per 1000 mm).
connects to the exhaust connection on the concentric to twin converter. If necessary cut the plain ends (male) of the twin flue pipes to allow connection to the concentric to twin converter. NOTE Before cutting twin flue pipes ensure allowances have been made for connection onto the previous piece and onto the concentric to twin converter. The last twin flue pipes must be pushed 50 mm onto the male spigots of the concentric to twin converter.
(condensate outlet pipe) is connected to the outlet of the trap. The flexible pipe must be connected to a plastic waste pipe only. The plastic waste pipe must have a minimum of a 3º fall towards the drain. Any external run of pipe should be insulated to prevent the risk of freezing. CONNECTING THE CONDENSATE OUTLET Gently pull the condensate outlet pipe down from its location inside the boiler until approximately 250 mm protrudes from the underside of the boiler.
4.10 CASING REMOVAL Lower the front control panel as described in section 4.9.1. ● Locate and remove the 2 screws that secure the controls fascia to the appliance casing (fig. 13A) ● locate and remove the 2 screws that secure the casing to the back frame of the boiler (fig. 15) ● gently pull one side of the casing then the other to disengage it from the retaining clips ● lift the casing upward to disengage it from the top locating hooks and then remove ● store the casing and screws safely until required.
SECTION 5 COMMISSIONING 5.1 GAS SUPPLY INSTALLATION Inspect the entire installation including the gas meter, test for soundness and purge. 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. 5.3 INITIAL FILLING OF THE SYSTEM 5.3.1.
Step number 1 2 3 4 5 6 7 Information displayed Temperature at flow sensor Temperature at return sensor Unused Unused Unused Required temperature (as set at parameter 4) Temperature rise of flow sensor (measured in °C per second) Temperature rise of return sensor (measured in °C per second) Unused Unused 8 9 A ● Press the mode in the display. Press the + Press the S button until the appropriate step ● number is shown in the left side of the display.
SECTION 6 6.1 6.2 SERVICING INSTRUCTIONS GENERAL To ensure the continued safe and efficient operation of the appliance, it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation conditions, but in general, once per year should be adequate. It is the law that any servicing work is carried out by competent person such as a Vokera engineer, an approved service agent, British Gas or other CORGI registered personnel.
6.9 NTC THERMISTORS (temperature sensors) Carry out component removal procedure as described in section 6.4. Flow & return sensors (fig. 1 & 18) Pull back protective boot and remove the 2 spade connectors. Slacken and remove the 2 securing screws. Replace in the reverse order. Screw Fig. 20 6.12 Fig. 18 6.10 FAN (fig. 20A) Carry out component removal procedure as described in section 6.4. Unclip and remove the air chamber cover. Disconnect the electrical plug from the fan.
6.14 ELECTRODE (fig. 21 & 22) Carry out component removal procedure as described in section 6.4. Unclip and remove the air chamber cover. Remove the electrode lead. Remove the 2 screws that secure the electrode to the combustion cover, and gently withdraw the electrode. Replace in the reverse order ensuring that the electrode seal is in good condition, and that the combustion cover insulation board is undisturbed. Inlet connection Pressure switch connection Outlet connection All dimensions in mm. Fig.
8 7 1 6 5 2 1 2 3 4 5 6 7 8 Hydraulic manifold Safety valve locking screw Pressure gauge locking screw Safety valve Expansion pipe Bleed/drain nipple Automatic bypass Expansion pipe locking screw 3 4 Fig. 27 side. Replace in the reverse order, ensuring that all seals and insulation panels are undamaged and in good condition. 6.20 screws EXPANSION VESSEL (fig.
SECTION 7 7.1 CHECKS, ADJUSTMENTS AND FAULT FINDING CHECKING APPLIANCE OPERATION When carrying out any repairs or servicing to the appliance, the relevant commissioning and/or set-up 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 7.2.
Service parameters must only be changed or adjusted by qualified service personnel Parameter Description Range 5 6 7 8 9 10 11 12 13 Minimum setting for flow sensor Unused Unused Unused Unused Unused Unused Unused Maximum fan speed for heating (hundreds) Maximum fan speed (units) Unused Unused Minimum fan speed (hundreds) Minimum fan speed (units) Ignition fan speed Pump over-run Unused Set point drop before re-lighting (heating) Set point overshoot before burner off (heating) Unused Unused Unused Unuse
Maximum screw Minimum screw Fig. 30 7.5 1ST DIGIT STATUS CODE When the boiler is operating normally (without fault), the first digit of the display shows the current status of the boiler whilst the right side will show the relevant temperature. Status Standby Purge Ignition Burner on Waiting for fan Built-in delay Pump over-run Temporary fault condition Combustion test at maximum output Combustion test at minimum output Anti seizing cycle Manual operation of fan 7.6 7.
7.10 EXTERNAL FAULTS Before carrying out any fault-finding or component replacement, ensure the fault is not attributable to any aspect of the installation. For example, external wiring fault, service valves closed, gas supply turned off, etc. The table below may assist in identifying some common installation faults. Fault code displayed E 02 b/E 18 E 36 7.
7.12.
7.12.
7.12.
7.12.
7.12.
SECTION 8 8.1 8.2 WIRING DIAGRAMS INSTALLATION OF VOKERA TIMECLOCK (part n° 201 or 202) The Vokera time clock (part no. 201 & 202) can be installed using the following procedure: • Isolate the appliance from the electrical supply and remove the casing as described in 4.9.1. • Gain access to the electrical input board as detailed in 4.9.2. • Remove the square blanking plate from the clock aperture of the control panel. • Connect the wires to the clock as shown in fig. 31.
“Y” plan system Room thermostat contact rated at 230V Fig.
NOTE. L-N-E CONNECTION MUST NOT BE INTERCHANGED FUNCTIONAL DIAGRAM Fig. 33 Key R.T. F P S1 S2 BE05 MCBA L1 L2 (V) Room thermostat Fan Pump Flow thermistor (NTC) Return thermistor (NTC) Connection board Control board N/A Led OK L2 (R) L3 F1 F3 S/S.E. OPE P.S.
NOTE. L-N-E CONNECTION MUST NOT BE INTERCHANGED CONTROL SWITCHING OF TIME CLOCK AND ROOM THERMOSTAT RATED AT 230V.a.c. FUNCTIONAL DIAGRAM Fig.
PCB Input PCB Input PCB Input PCB Input PCB Input PCB Input PCB PLUG or CONNECTION M2 M3 M4 M5 M7 F1 DESIGNATION Incoming 230V supply 230V supply to main PCB 230V clock supply Low voltage connector (to main PCB) Low voltage connector (heat request) 2AF fuse PCB Main PCB Main PCB PLUG or CONNECTION X1 X2 Main PCB Main PCB Main PCB Main PCB Main PCB Main PCB Main PCB X3 X7 X8 X10 F1 F2 F3 DESIGNATION Incoming 230V supply & pump connection Fan connection, condense pressure switch connection, gas valve c
SECTION 9 EXPLODED DIAGRAMS 90 100 31 16 17 20 1 67 74 260 226 101 18 16 48 261 75 21 15 99 80 43 26 300 13 50 49 39 301 12 40 POS.
3 7 52 9 31 277 22 23 353 27 27 353 POS.
16 310 34 8 9 200 12 338 1 200 10 201 2 200 2 316 253 338 369 200 200 27 6 291 310 370 36 371 3 398 25 26 291 5 288 POS.
40 4 40 35 17 3 5 200 24 12 23 256 2 200 13 27 21 200 295 41 39 14 200 351 15 16 1 1 POS.
23 20 22 2 6 5 4 14 11 13 341 321 10 40 POS.
SECTION 10 L.P.G. INSTRUCTIONS For details of converting boilers to LPG please refer to the instructions supplied with the relevant conversion kit. 10.1 TECHNICAL DATA 16 Inlet pressure 37 mbar Gas rate (max.) 2.49 l/per hr. Gas rate (min.) 0.72 l/per hr. Injector size Single injector with six 1.6 mm holes CO2 level (cover off) 9,80% Maximum fan speed for heating 4.100RPM* Minimum fan speed 1.400RPM* Soft-light 3.900RPM* NOx (max) 40 ppm NOx (min) 20 ppm CO (max) 50 ppm CO (min) 50 ppm 26 37 mbar 4.
Cod. 10023766 - 39/03 - Ed. 2 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.
