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  4. Compact 24
  5. Installation & Servicing Instructions Manual

VOKERA Compact 24 Installation & Servicing Instructions Manual

Summary of Compact 24

  • Page 1

    Installation & servicing instructions these instructions to be retained by user compact.

  • Page 2

    Contents design principles and operating sequence page 1.1 principle components 2 1.2 central heating mode 2 1.3 hot water mode 2 1.4 safety devices 2 1.5 frost protection 2 technical data page 2.1 central heating 3 2.2 domestic hot water 3 2.3 gas pressure 3 2.4 expansion vessel 3 2.5 dimensions 3 ...

  • Page 3

    1 compact introduction fig.1 general layout 1 flue analysis test point 2 pressure tube negative 3 fan assembly 4 heat exchanger 5 secondary thermistor 6 combustion chamber 7 burner 8 expansion vessel 9 water pressure switch 10 domestic hot water flow switch 11 gas valve 12 timeclock 13 ch position 1...

  • Page 4

    2 compact section 1 design principles and operating sequence fig. 2 1.1 principle components ● a fully integrated, electronic control board fea- turing mode selection switch, full sequence- electronic ignition, temperature control system, and appliance status indicator. ● a bi-thermal gas to water h...

  • Page 5

    3 compact section 2 technical data ref. Condition 15 ° c , 1013,25 mbar, dry gas note: l.P.G. Data refer to section 10 compact 24 compact 28 2.1 central heating heat input (kw) 26.3 31.0 heat output (maximum) kw 24.0 28.0 heat output (minimum) kw 9.4 10.5 minimum working pressure 0,5 bar 0,5 bar max...

  • Page 6

    4 compact 2.11 pump duty fig. 3 shows the flow rate available – after allowing for pressure loss through the appliance – against system pressure loss. When using this graph apply only the pressure loss of the system. The graph is based on a 20 ºc temperature differential. Fig. 3 fig. 4 water pressur...

  • Page 7

    5 compact 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 loca...

  • Page 8

    6 compact fig. 5a 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 least 1 metre above the highest point in the system and at least 5 metres above the boiler (fig. 5a). The cold feed from the mak...

  • Page 9

    7 compact fig. 6 3.9 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. 3.10 timber framed building if the appliance is to be fitted in a timber framed building, it should be fitted in accordance ...

  • Page 10

    8 compact 3a.5 air supply the following notes are intended for general guidance only. This appliance is a room-sealed, fan-flued boiler, consequently it does not require a permanent air vent for combustion air supply. When installed in a cupboard or compartment, ventilation for cooling purposes is a...

  • Page 11

    9 compact section 4 installation 4.1 delivery the appliance is delivered in a heavy-duty card- board carton. Lay the carton on the floor with the writing the correct way up. 4.2 contents contained within the carton is: ● the boiler ● the wall mounting bracket ● an accessories pack containing service...

  • Page 12

    10 compact carefully measure the distance from the centre of the appliance flue outlet to the face of the outside wall (dimension ‘x’, fig. 8). Add 50 mm to dimension ‘x’ to give the overall flue length (dimension ‘y’). Using the complete telescopic flue assembly adjust the length to suit dimension ...

  • Page 13

    11 compact fig. 9 465 mm 300 mm min. 150 mm note when cutting the horizontal flue terminal or an extension to the required length, you must ensure that the excess is cut from the plain end of the terminal or extension, and that the inner (60 mm) pipe is 7.5 mm longer than outer (100 mm) pipe (fig. 8...

  • Page 14

    12 compact 4.5.3.2 installation of condensate drain kit (fig. 10b) the condensate drain kit must be fitted within 1 metre of the appliance flue outlet. It is recommended that the condensate drain kit should be fitted in the vertical plane, however it can be fitted horizontally with care. ● fit the f...

  • Page 15

    13 compact 4.5.3.3 horizontal termination (fig. 11) the twin flue system must be converted to the dedicated concentric flue kit for termination. ● the horizontal terminal is supplied with a built- in converter box and cannot be shortened. ● a 130 mm hole is required for the passage of the concentric...

  • Page 16

    14 compact 4.6.2 flow & return (fig. 6) the appliance is supplied with 22 mm service valves for the heating connections, connect 22 mm pipe to the inlet of each valve and tighten both nuts. 4.6.3 safety valve (fig. 6) the appliance is supplied with a 15 mm compres- sion coupling. Connect a 15 mm pip...

  • Page 17

    15 compact 4.7.3 connecting the mains (230v) input (fig. 14) the appliance comes with a factory fitted main electrical supply cable. If it’s necessary to change the main electrical cable, proceed as follow. Open the terminal strip cover. Pass the cable through the cable anchorage. Connect the supply...

  • Page 18

    16 compact 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 installa- tion of the...

  • Page 19

    17 compact 5.9 final flushing of the heating system the system shall be flushed in accordance with bs 7593. If a cleanser is to be used, it shall be from a reputable manufacturer* and shall be administered in strict accordance with the manufacturers instructions. *both sentinel and fernox manufactur...

  • Page 20

    18 compact section 6 servicing instructions 6.1 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, o...

  • Page 21

    19 compact fig. 19 fig. 20 6.8 automatic air release valve (aav, fig. 17) carry out component removal procedure as de- scribed in 6.5. Remove the locking pins at the pump outlet, and the flow & return connection of the heat ex- changer, disconnect both pipes from the heat exchanger, and remove the r...

  • Page 22

    20 compact 6.14 printed circuit board (pcb, fig. 22) carry out component removal procedure as de- scribed in section 6.5. Remove the pcb cover, after carefully taking note off all wiring connections, disconnect all wiring from the pcb, locate and remove the pcb securing screws, remove pcb. Replace i...

  • Page 23

    21 compact fig. 26 fig. 27 6.18 flue fan (fig. 24 & 28) carry out component removal procedure as de- scribed in section 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 disengag...

  • Page 24

    22 compact 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 t...

  • Page 25

    23 compact 7.6.1 setting the maximum dhw gas pressure (fig. 15 & 23) isolate the appliance from the electrical supply, remove the appliance casing as described in section 4.7.1. ● attach a manometer to the outlet test point of the gas valve. ● remove the protective cover from the gas valve modulator...

  • Page 26

    24 compact 7.11 electrical checks any electrical checks must be carried out by a suitably qualified person. 7.11.1 earth continuity test isolate the appliance from the electrical supply, and using a suitable multi-meter carry out a resistance test. Connect test leads between an appliance earth point...

  • Page 27

    25 compact 7.12.1 fault finding test ‘a’: checking operation of electronic control board at start up mains on fan replace fan yes no yes replace wiring or connections mains on pump replace pump no yes yes yes no no a1 a check &/or replace wiring and connections mains on fan connector cn4.1 & cn4.2 o...

  • Page 28

    26 compact 7.12.2 fault finding test ‘a’ yes no no mains on e.V.G. No yes no no yes yes yes no is there 24 vdc between terminals cn8.4 & cn8.5 on pcb a replace sensing/spark electrode and lead replace pcb sensing spark electrode and lead ok chek sensing/spark electrode and lead end lockout ignition ...

  • Page 29

    27 compact 7.12.3 fault finding test ‘a1’ no yes a1 replace control board fuse ok check fuse f1 on control board red led blinks mains present between terminals cn1.2 &cn1.3 m2.2 on control yes no restart the test replace fuse no no replace control board red led light yes yes switch on/off selector o...

  • Page 30

    28 compact 7.12.4 fault finding test ‘b’: check control in dhw mode no no no no no yes yes yes is voltage across terminals of modulator coil > 10 vdc replace wire and connections replace control board replace modulator coil is the resistence of modulator coil about 70/80 ohm is there a voltage >10 v...

  • Page 31

    29 compact 7.12.5 test ‘b’ cont’d no end do burner, fan and pump switch off turn off tap switch dhw thermostat at max. Do burner and fan switch on is temperature >60 ˚c wait d.H.W. Temperature replace control board yes check wiring and connection or control board replace dhw flow switch is dhw flow ...

  • Page 32

    30 compact 7.12.6 fault finding test ‘c’: check control in c/h mode no yes no yes yes no yes no replace control board replace control board remove jumper is timer jumper on is voltage across terminals of modulator coil >10 vdc is voltage across terminals of modulator coil check boiler startup test a...

  • Page 33

    31 compact 7.12.7 test ‘c’ cont’d yes wait 3 min. C no do burner and fan switch off is water flow temperature >40 ˚c wait water flow temperature >40 ˚c replace control board switch ch thermostat at max. Do burner and fan switch on is water flow temperature >80 ˚c wait water flow temperature no yes r...

  • Page 34

    32 compact section 8 wiring diagrams fig. 29 fig. 29a 8.1 connection of a room thermostat (fig. 29 & 29a) isolate the appliance from the electrical supply. Remove the appliance casing and pcb cover. Connect the room thermostat as shown in diagram fig. 29. A neutral supply can be taken from the appli...

  • Page 35

    33 compact functional diagram note: l-n-e connection is advisable key r.T. Room thermostat s.F.S. Domestic hot water flow switch p.S. Pressure switch p.D.S. Differential pressure switch h.L. High limit thermostat s.R. Heat thermistor s.S. Domestic hot water thermistor mod modulator f fan p pump sp/s...

  • Page 36

    34 compact note: l-n-e connection is advisable functional diagram fig. 31.

  • Page 37

    35 compact section 9 exploded diagrams 270 13 26 20 12 21 27 28 27 226 18 19 76 49 33 31 226 90 1 300 301 302 pos. Description 24 28 1 frame assembly 01005259 01005260 12 quick primer pressure gauge 10024019 10024019 13 pin 10023044 10023044 18 cover 10023812 10023812 19 ignition module 10022174 100...

  • Page 38

    36 compact 27 28 351 30 27 353 26 3 2 7 288 288 288 300 303 289 289 22 289 303 289 31 289 290 23 201 299 285 36 25 201 353 63 24 pos. Description 24 28 2 connection 10022658 10022658 3 pressure switch 2044 2044 7 by-pass valve 2047 2047 22 safety valve 1806 1806 23 connection 10022499 10022499 24 fl...

  • Page 39

    37 compact 1 2 201 7 9 3 289 12 8 289 290 289 290 285 202 287 10 12 pos. Description 24 28 1 expansion vessel 2204 2204 2 flexible 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 222...

  • Page 40

    38 compact 18 16 5 4 3 200 15 200 13 295 12 200 1 52 27 53 200 2 14 53 27 1 2 18 16 24 csi pos. Description 24 28 1 roomsealed chamber 10023931 10023945 2 clip 0442 0442 3 main burner injector manifold 10023799 10023902 3 main burner injector manifold 10023800 10023903 4 burner 10023798 10023901 5 s...

  • Page 41

    39 compact 4 25 212 2 3 12 28 20 295 10 300 3 pos. Description 24 28 2 back insulating panel 2230 10023909 3 lateral 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....

  • Page 42

    40 compact 10.1 technical data section 10 l.P.G. Instructions 10.3 gas supply the gas supply must be connected to the appliance by a competent l.P.G. Installer and must be of sufficient size to supply the appliance at its maxi- mum output. An existing supply must be checked to ensure that it is of a...

  • Page 43

    41 compact section 11 rear flue fig. 33 fig. 34 m a x min 200 d a c b fig. 32 11.1 fitting the flue (see fig. 33) there are two telescopic flue kits for use with the option boiler. The standard telescopic flue is suitable for a wall thickness of 200 mm – 425 mm. The extended telescopic flue is suita...

  • Page 44: Energizing Home Heating

    Cod. 10023942 - 38/02 - ed. 2 vokèra ltd. 4 th floor, catherine house, boundary way, hemel hempstead, herts, hp2 7rp email: enquiries@vokera.Co.Uk web: www.Vokera.Co.Uk general enquiries - tel: 01442 281400 fax: 01442 281460 technical advice - tel: 0141 945 6810 spare parts - tel: 0141 945 68”0 afte...