1. DL manuals
  2. VOKERA
  3. Boiler
  4. Linea Max HE
  5. Installation & Servicing Instructions Manual

VOKERA Linea Max HE Installation & Servicing Instructions Manual

Summary of Linea Max HE

  • Page 1

    Supplied by www.Heating spares.Co tel. 0161 620 6677 installation & servicing instructions these instructions to be retained by user vokèra is a licensed member of the benchmark scheme which aims to improve the standards of installation and commissioning of domestic hot water systems in the uk. Line...

  • Page 2

    Supplied by www.Heating spares.Co tel. 0161 620 6677.

  • Page 3

    Supplied by www.Heating spares.Co tel. 0161 620 6677 contents section subject page no section 1 introduction 1 general layout 1 section 2 design principles & operating principles 2 schematic diagram 2 central heating mode 2 domestic hot water mode 2 safety devices 2 frost thermostat 2 section 3 tech...

  • Page 4

    Supplied by www.Heating spares.Co tel. 0161 620 6677.

  • Page 5

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 1 section 1 introduction the vokèra linea max is a combined central hea- ting and domestic hot water appliance. By design it incorporates full sequence electronic ignition, circulating pump, expansion vessel, safety valve, temperature...

  • Page 6

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 2 section 2 design principles and operating sequence 2.1 fig.1 illustrates the general layout of compo- nents. Fig.2 illustrates the operating principles described below. 2.2 central heating mode 2.2.1 when the various switches and co...

  • Page 7

    Supplied by www.Heating spares.Co tel. 0161 620 6677 3.1 central heating heat input (kw) 29.0 maximum heat output@ 80/60 °c (kw) 28.1 maximum heat output@ 50/30 °c (kw) 30.2 minimum heat output@ 50/30 °c (kw) 14.8 minimum working pressure 0.5 bar maximum working pressure 3.0 bar 3.2 domestic hot wat...

  • Page 8

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 4 3.11 central heating pump duty fig. 3 water pressure mbar x 100 water flow l/h.

  • Page 9

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 5 section 4 general requirements 4.0 general requirements this appliance must be installed by a competent person in accordance with the gas safety (installation & use) regulations 1998. 4.1 related documents the installation of this b...

  • Page 10

    Supplied by www.Heating spares.Co tel. 0161 620 6677 4.5 air supply the following notes are intended for general gui- dance. The room sealed fan flued boiler does not requi- re a permanent air vent for combustion air supply. Where installed in a cupboard or compartment ventilation is required for co...

  • Page 11

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 7 4.6.5 air release points these must be fitted at all high points where air will naturally collect, and must be sited to facilita- te complete filling of the system. 4.6.6 expansion vessel the appliance has an integral sealed expansi...

  • Page 12

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 8 section 4a 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). 4a.1 related documents ...

  • Page 13

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 9 4a.6.5 expansion vessel the appliance has an integral expansion vessel to accommodate the increased volume of water when the system is heated. It can accept up to 10 litres of expansion from within the system, generally this is suff...

  • Page 14

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 10 section 5 installation 5.1 delivery (see fig. 7) the appliance is delivered in a crated heavy duty cardboard carton. 5.2 unpacking (see fig. 7 & 8) stand the boiler the correct way up and remove the surrounding timber frame.Slide t...

  • Page 15

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 11 5.3 siting the appliance 5.3.1 the appliance is floor standing. Place the base plate on a smooth firm and level surface. The back of the base tray can be pushed flush again- st the back wall if necessary (this will still allow pipi...

  • Page 16

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 12 5.3.11 cold water connect a 15mm cold water service pipe to the inlet stopcock of the appliance. Tighten the nut. If the cold water supply is liable to high pressure or large pressure fluctuations, a flow/pressure regulator should ...

  • Page 17

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 13 intakes for flue gas analysis fig. 14 fig. 15 fig. 13.

  • Page 18

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 14 5.4 installing the flue system care should be exercised when determining the position of the appliance and route of the flue system with respect to hidden obstructions such as pipes, cables, etc. 5.5 fitting the flue the top flue o...

  • Page 19

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 15 5.5.2 concentric vertical flue (see fig. 16b) the appliance can be used with either the vokera condensing 60/100mm concentric flue system or the optional 80/125mm concentric flue system. Note: these instructions relate only to the ...

  • Page 20

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 16 using the dimensions given in fig. 15 & 16b as a reference, mark and cut a 107mm hole in the cei- ling and/or roof. Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the fla- shing plate f...

  • Page 21

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 17 5.5.3 twin flue system the vokera twin flue system enables greater flue distances to be achieved than that of the stan- dard concentric flue system. The twin flue system can be used for horizontal applications, however it must be c...

  • Page 22

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 18 5.5.3.2 horizontal termination (see fig. 18) 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 ...

  • Page 23

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 19 5.6 electrical connections 5.6.1 the electricity supply must be as specified in clause 4.7. If controls external to the appliance are required, design of the external electrical cir- cuits should be undertaken by a competent per- s...

  • Page 24

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 20 5.6.4 pass the cable through one of the cord anchora- ge points and connect the wires brown to l1, blue to n, and green/yellow to x x of the terminal strip. Arrange the cable so that should the cable slip the anchorage the current ...

  • Page 25

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 21 section 6 commissioning 6.1 where the text bears identifying numbers in brackets, refer to figs. 1 and 2 unless otherwise instructed. 6.2 gas supply installation inspect the entire installation including the meter. Test for soundne...

  • Page 26

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 22 6.6.2 switch on the mains electricity and turn the on / off / mode switch to y z . 6.6.3 set the c/h control knob to the highest setting. 6.6.4 the pump only will run for approximately 1 minu- te, the appliance will then go through...

  • Page 27

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 23 6.7.8 setting the maximum rate for central heating the maximum heat input for the central heating mode is not adjustable. 6.8 checking the flue system 6.8.1 the flue system should be visually checked for soundness. Check all clamps...

  • Page 28

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 24 6.14 concluding operations 6.14.1 if external/internal controls have been disconnec- ted and terminals 2 & 3 temporarily linked, remo- ve the link and reconnect the controls circuit. Check the operation of the controls. 6.15 discon...

  • Page 29

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 25 4. Ensure central heating valves are open. See 6.3.2.2. Observe pressure gauge reading (fig. 1, 28) which should be approximately 1 bar when the system is cold see 6.3.4 5. Turn off mains electricity and turn off gas ser- vice tap ...

  • Page 30

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 26 8.5 room sealed chamber front cover refer to figs. 25 & 26. 8.5.1 gain general access as 8.4 8.5.2 loosen the two screws (a) on the bracket (b) of the expansion vessel (c) (see fig. 25a). A b c d e f b c 8.5.5 remove top casing (e)...

  • Page 31

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 27 8.6 remove front combustion cover refer to fig. 27. 8.6.1 gain general access as 8.4. 8.6.2 remove room sealed front cover as 8.5 8.6.3 locate and remove the 6 screws securing the front combustion cover (1), pull the cover towards ...

  • Page 32

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 28 8.8.6 fig. 30: locate and remove the four screws which secure the burner in position (1), gently ease the burner out of its location. 8.8.7 once the burner has been removed, the electro- deretaining screw can be removed. 8.8.8 loca...

  • Page 33

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 29 8.11 flue pressure differential switch refer to fig. 32 8.11.1 gain general access as 8.4. 8.11.2 remove room sealed front cover as 8.5. 8.11.3 remove the air chamber right side panel as 8.7. 8.11.4 locate and remove the two screws...

  • Page 34

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 30 8.17 domestic flow switch refer to fig. 36 8.17.1 gain general access as 8.4. 8.17.2 place receptacle or an absorbent pad below swit- ch to catch trapped water. 8.17.3 close cold water inlet stopcock. 8.17.4 open lowest draw-off or...

  • Page 35

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 31 8.18 combined diverter valve & flow switch manifold refer to fig. 37 8.18.1 gain general access as 8.4 8.18.2 remove pump as 8.15 8.18.3 remove motorised valve as 8.23.8. 8.18.4 release flow microswitch from the hydraulic group by ...

  • Page 36

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 32 a fig. 39 8.20.6 disconnect pipe union at the base of the expan- sion vessel. 8.20.7 move the expansion vessel as described in point 8.5. 8.20.8 identify and loosen the screws (a) at the top of the expansion vessel. 8.20.9 support ...

  • Page 37

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 33 8.22 safety valve refer to fig. 40 8.22.1 gain general access as 8.4. 8.22.2 turn the 3 butterfly primary store isolation valves to the closed position (handle across valve body) this isolates the primary store thus preventing unne...

  • Page 38

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 34 1 2 3 fig. 44 8.23.32 thermistor sensors refer to fig. 42 8.23.33 gain general access as 8.4. 8.23.34 remove room sealed chamber front cover as 8.5 8.23.35 remove the air chamber right side panel as 8.7 8.23.36 primary turn the 3 b...

  • Page 39

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 35 8.25 setting gas pressures all settings done with a suitable manometer connected to gas valve as instructed in 6.7. 8.25.1 setting maximum rate turn off electrical supply to boiler. Gain general access as 8.4 and gain access to the...

  • Page 40

    Supplied by www.Heating spares.Co tel. 0161 620 6677 8.26 latent heat collector refer to figs. 48, 49, 50 8.26.1 gain general access as 8.4. 8.26.2 remove the flue hood and fan assembly as detai- led in 8.10. 8.26.3 disconnect and remove the inlet, outlet and con- dense pipes from the collector. 8.2...

  • Page 41

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 37 8.26.7 retarder refer to fig. 50 8.26.8 gain general access as 8.4. 8.26.9 unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging. 8.26.10 remove the 3-screws that secure the seali...

  • Page 42

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 38 9.1 on completion of any service/fault finding task which has required the breaking and remaking of electrical connections, the checks earth continuity, polarity and resistance to earth must be repeated. The following flow diagrams...

  • Page 43

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 39 if a flame is detected during the ignition attempt time (8-12 seconds) the sparking will cease, the gas valve will remain energised and the appliance will produce hot water as described below. If a flame is not detected the applian...

  • Page 44

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 40 important: the timer delay can be de-activated by the inser- tion of a ‘jumper’ on the pcb at jp1 or by isola- ting the appliance from the electrical supply for 30 seconds. Any dhw requests will always have priority over a heating ...

  • Page 45

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 41 on the following pages are the fault finding guides. Be sure to read the notes below before begining any fault finding. Notes: 1. To ensure correct fault diagnosis it is important that these guides are carried out in the set order....

  • Page 46

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 42 vokera linea max test a: checking operation of electronic control board at start up no a2 yes yes turn on hot tap yes no is the 3 way valve in the dhw position is there 0 vac between terminals m5.5 & m5.6 on pcb is the pump running...

  • Page 47

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 43 a1 is there 24 vdc between terminals m5.4 on pcb & black wire on air pressure switch is there 24 vdc between terminals m5.4 on pcb & red wire on air pressure switch is there 24 vdc between terminals m5.4 on pcb & red wire on hight ...

  • Page 48

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 44 a2 red led flashes digital display showing bicoloured assembly ok digital display showing 01 digital display showing 02 green led alight green led alight ignition box ok fuse ok 230v present between blue & brown wires at boiler ter...

  • Page 49

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 45 start switch on boiler and select mode to summer. Dhw thermostat to max turn on tap does the burner light check boiler startup: test a is voltage across terminals of modulator coil > 10 vdc turn the dhw thermostat to min do the bur...

  • Page 50

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 46 start switch on boiler and select mode to winter. C/h thermostat to max make a link between 2 & 3 at boiler terminal strip is the 3 way valve on c/h position? 0 vac present between pin m16.Ta and m16.Ta on control board 230 v prese...

  • Page 51

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 47 a spark at electrode ignition lockout after ignition check electrode and lead ok end electrode and lead ok replace ingition box replace electrode and lead ingition box ok replace ingition box gas valve ok replace gas valve check ga...

  • Page 52

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 48 a4 digital display showing 03 digital display showing 04 digital display showing 05 digital display showing 06 digital display showing 07 replace control board replace control board check dhw ntc sensor or connection check flow ntc...

  • Page 53

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 49 do burner, fan and pump switch off turn off tap b end is water flow temerature >78 ° c is dhw pressure switch ok is dhw ntc ok does the fan switch off is water flow temperature ° c does the fan run is dhw ntc ok is dhw pressure swi...

  • Page 54

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 50 c1 do the burner and fan switch on remove link between pin m16.Ta and m16.Ta on control board wait 30 sec. Do the burner, fan and pump switch off is water flow temperature >78 ° c does the pump run is flow ntc ok does the pump swit...

  • Page 55

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 51 c wait 1 min. Is voltage across terminals of modulator coil >10 vdc do the burner and fan switch off is water flow temperature >40 ° c is timer jumper on do the burner and fan switch on switch c/h thermostat to min switch c/h therm...

  • Page 56

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 52 section 10 appendix gain general access to electrical panel as 5.6.2. Remove the clock aperture blanking plate (1) (see fig.1) by squeezing the 4 lugs on the rear of the plate together and push the plate out. Remove the central cir...

  • Page 57

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 53 fig. 4 showing 230v input electrical connection without room thermostat or internal time clock. (internal wiring loom for timeclock and link between 2 & 3 remains) fig. 5 showing 230v input electrical connection and internal timer ...

  • Page 58

    Supplied by www.Heating spares.Co tel. 0161 620 6677 certain electronic functions on the linea range of appliances can be abled or disabled accor- ding to customer preference. The selections can be made by the addition or removal of jumper tags situated on the printed circuit board. Refer to fig. 53...

  • Page 59

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 55 general layout & illustrated wiring diagram key f2 fuse (2a f) f1 fuse (t100ma) san h/w flow switch pf air pressure switch r1 ,2 & 3 relay v fan p pump tl high limit thermostat 3v motorised valve ts primary store safety thermostat ...

  • Page 60

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 56 preliminary electrical system checks a. Earth continuity check - appliance must be elec- trically disconnected - meter set on Ω (ohms) x 1 scale and adjust zero if necessary. A) test leads from any appliance earth point to earth pi...

  • Page 61

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 57 section 11 l.P.G. Instructions 11.1 gas rates (lpg) 11.2 burner details (lpg) 11.3 related documents 11.4 gas supply a gas supply should be connected to the b o i - ler by a competent l.P.G. Installer and should be of sufficient si...

  • Page 62

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 58 switch on the electricity supply, the boiler will now light at the minimum setting. 11.6.7 when low flame is established the pressure rea- ding should be : 4.3mbar. (plus or minus 0.43mbar.) if it is different adjustment should be ...

  • Page 63

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 59 section 12 spare parts 1 2 4 3 6 5 7 8 pos description 612102280 50-37685-12890-8 1 cover r102796 2 left side r102915 3 door r102785 4 right side r102914 5 complete electrical panel r106326 6 closing pin r100940 8 spring r100939 9 ...

  • Page 64

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 60 9 8 5 13 7 4 11 6 12 2 14 3 1 10 pos description 612102280 50-37685-12890-8 1 instrument holder panel cover r106334 2 temperature setting knob r102402 3 function selection knob r102403 4 closing pin r103277 5 management board r1063...

  • Page 65

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 61 6 4 1 3 14 5 7 8 9 10 11 13 12 2 11 15 16 17 18 20 19 21 pos description 612102280 50-37685-12890-8 1 air box botton r10027894 2 air box side with washer r10024166 3 air box clip r0442 4 ng burner r10027564 5 spark-sensing electrod...

  • Page 66

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 62 5 1 2 3 3 4 6 7 8 9 10 11 12 pos description 612102280 50-37685-12890-8 1 combustion chamber assembly r10026406 2 rear panel r5316 3 lateral panel r5271 4 front panel r5315 5 hood assembly r10024125 6 fan r10024035 7 venturi and pr...

  • Page 67

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 63 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 11 9 11 13 13 pos description 612102280 50-37685-12890-8 1 pipe r10024130 2 heat exchanger r2378 3 pipe r10021041 4 condensing unit assembly r01005411 5 retarder r10024136 6 pipe r10024129...

  • Page 68

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 64 11 1 3 4 9 5 6 7 4 10 14 15 16 17 18 19 20 21 8 12 2 13 4 pos description 612102280 50-37685-12890-8 1 pump r103321 2 gasket or r102960 3 system return pipe r102964 4 water cock r102961 5 storage return pipe r102927 6 water distrib...

  • Page 69

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 65 3 2 4 1 pos description 612102280 50-37685-12890-8 1 insulation r104198 2 storage heater body 60 l r102799 3 automatic vent valve r100618 4 safety thermostat r104199.

  • Page 70

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 66 1 8 2 5 4 3 6 7 pos description 612102280 50-37685-12890-8 1 complete template r106340 2 water cock r106329 3 water cock r103317 4 water outlet fitting r103325 5 water cock r106330 6 water cock r103327 7 3-position water cock r1033...

  • Page 71

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 67 1 2 3 6 5 4 7 pos description 612102280 50-37685-12890-8 1 fuse 100ma-t r102936 2 fuse 2a-t r102937 3 timer wiring r106335 4 condensate drain pipe r106336 5 key r103539 6 hose r103318 7 safety valve connection pipe r102946.

  • Page 72

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 68.

  • Page 73

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max he 69.

  • Page 74

    Supplied by www.Heating spares.Co tel. 0161 620 6677.

  • Page 75

    Supplied by www.Heating spares.Co tel. 0161 620 6677.

  • Page 76

    Supplied by www.Heating spares.Co tel. 0161 620 6677 cod. 068463(en) - rev . 1 (10/05) registered address: vokèra ltd borderlake house unit 7 riverside industrial estate london colney herts al2 1hg enquiries@vokera.Co.Uk www.Vokera.Co.Uk www.Vokera.Ie sales, general enquires t 0844 391 099 f 0844 39...