1. DL manuals
  2. VOKERA
  3. Water Heater
  4. Linea
  5. Installation & Servicing Instructions Manual

VOKERA Linea Installation & Servicing Instructions Manual

Summary of Linea

  • Page 1

    Supplied by www.Heating spares.Co tel. 0161 620 6677 installation & servicing instructions these instructions to be retained by user room sealed, fanned flue, combination boiler british gas service listed g.C. No 47 094 30

  • Page 2

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

  • Page 3

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

  • Page 4

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

  • Page 5

    Supplied by www.Heating spares.Co tel. 0161 620 6677 1 linea max this appliance is designed for use with a sealed heating system only and is not intended for use on an open vented system. An automatic range-rating facility is incorpo- rated in the boiler for the central heating system in conjunction...

  • Page 6

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

  • Page 7

    Supplied by www.Heating spares.Co tel. 0161 620 6677 3 linea max section 3 technical data 3.1 units dimensions and values are given in the preferred sl units with imperial units in brackets where applicable. 3.2 dimensions and contents height 850mm (33.5in.) width 600mm (23.6in.) depth 585mm (23in.)...

  • Page 8

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 4 3.10 central heating pump duty 0 100 200 300 400 500 600 700 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 x 100 water flow l/h fig. 3 water pressure mbar.

  • Page 9

    Supplied by www.Heating spares.Co tel. 0161 620 6677 5 linea max 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 boil...

  • Page 10

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 6 for protection of combustibles, refer to bs 5440:1 where the terminal is less than 2m (6.6ft) above a pavement or platform to which people have access (including any balcony or flat roof the terminal must be protected by a guard of dur...

  • Page 11

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 linea max 4.6.6 air release points these must be fitted at all high points where air will naturally collect, and must be sited to facilitate complete filling of the system. 4.6.7 the appliance has an integral sealed expan- sion vessel to accommo...

  • Page 12

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 8 section 5 installation 5.1 delivery (fig. 6) the appliance is delivered in a crated heavy duty cardboard carton. 5.2 unpacking (fig. 6 & 7) stand the boiler the correct way up and re- move the surrounding timber frame.Slide the protect...

  • Page 13

    Supplied by www.Heating spares.Co tel. 0161 620 6677 9 linea max fig. 12 rear pipework reference bar. Fig. 10 fig. 11 fig. 11a base tray securing screws 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 ...

  • Page 14

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 10 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 be ...

  • Page 15

    Supplied by www.Heating spares.Co tel. 0161 620 6677 11 linea max 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 obstruc- tions such as pipes, cables, etc. 5.5 fitting the flue the top flue ou...

  • Page 16

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 12 carefully measure the distance between the appliance flue outlet bend and the 2 nd last extension or bend (dimension ‘x’). Add 40mm to dimension ‘x’ to give dimension ‘y (see fig. 15a). Measuring from the socket end of the last extens...

  • Page 17

    Supplied by www.Heating spares.Co tel. 0161 620 6677 13 linea max note; you must ensure that the entire flue system is properly supported and connected. When cutting an extension to the required length, you should ensure that the excess is cut from the plain end of the extension. Re- move any burrs,...

  • Page 18

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 14 5.5.3.2 installation of condensate drain kit (fig. 17a) 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, howev...

  • Page 19

    Supplied by www.Heating spares.Co tel. 0161 620 6677 15 linea max fig. 19 locating hook locating hook fig. 18 5.5 electrical connections 5.5.1 the electricity supply must be as specified in clause 4.7. If controls external to the appliance are required, design of the exter- nal electrical circuits s...

  • Page 20

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 16 5.5.4 pass the cable through one of the cord anchorage points and connect the wires brown to l1, blue to n, and green/yellow to w of the terminal strip. Arrange the cable so that should the cable slip the anchorage the current carryin...

  • Page 21

    Supplied by www.Heating spares.Co tel. 0161 620 6677 17 linea max 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 soundness ...

  • Page 22

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 18 fig. 22 gas valve manometer u gauge tube main burner test point 6.5.5 if during the ignition attempt period (10 secs approx.) the boiler fails to light, the ignition control circuit will go to lockout. This is indicated by the status ...

  • Page 23

    Supplied by www.Heating spares.Co tel. 0161 620 6677 19 linea max 6.6.8 setting the maximum rate for central heating the maximum heat input for the central heating mode is not adjustable. 6.7 checking the flue system 6.7.1 the flue system should be visually checked for soundness. Check all clamps an...

  • Page 24

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 20 section 7 instructing the user 7.1 hand over the copy of the users instructions and the boiler log book supplied with the appliance, together with these instructions. Explain how to operate the boiler correctly and how to use the time...

  • Page 25

    Supplied by www.Heating spares.Co tel. 0161 620 6677 21 linea max fig. 23 fig. 24 flue gas analysis test point 4. Ensure central heating valves are open. See 6.3.2.1. Observe pressure gauge reading (fig. 1, 19) which should be approximately 1 bar when the system is cold see 6.3.4 5. Turn off mains e...

  • Page 26

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 22 fig. 25 fig. 26 8.5.1 gain general access as 8.4 8.5.2 remove room sealed cover plate by releas- ing two lower retaining clips and easing cover off the top locating hooks. Inspect gasket for damage. If damaged, replace. Note: when ref...

  • Page 27

    Supplied by www.Heating spares.Co tel. 0161 620 6677 23 linea max fig. 27 hood retaining screws air baffle plate maintenance clip pressure differential switch air tubes 8.9 flue fan part no. 5911 8.9.1 remove room sealed front cover plate (8.5) and front of combustion chamber (8.6.3). 8.9.2 loosen m...

  • Page 28

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 24 8.12 ignition control box part no. 099864 8.12.1 gain general access as 8.4. 8.12.2 release 1 screw (upper) securing ignition box to gas valve body. 8.12.3 disconnect electrode lead from ignition box. 8.12.4 disconnect ignition contro...

  • Page 29

    Supplied by www.Heating spares.Co tel. 0161 620 6677 25 linea max 8.14 pump part no. 088031 refer to fig.29 8.14.1 gain general access as 8.4 8.14.2 turn the 3 butterfly primary store isolation valves to the closed position (handle across valve body) this isolates the primary store thus preventing u...

  • Page 30

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 26 8.17 removal of domestic hot water heat exchanger refer to figs. 30 8.17.1 gain general access 8.4 8.17.2 place receptacle or an absorbent pad below heat exchanger to catch trapped water. 8.17.3 close cold water filling/inlet valve. S...

  • Page 31

    Supplied by www.Heating spares.Co tel. 0161 620 6677 27 linea max 8.20 safety valve part no. 1806 refer to fig.30 8.20.1 gain general access as 8.4. 8.20.2 turn the 3 butterfly primary store isolation valves to the closed position (handle across valve body) this isolates the primary store thus preve...

  • Page 32

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 28 8.21.8 motorised valve part no 2905 8.21.9 gain general access as 8.4 8.21.10 release motorised valve by removing retaining clip. 8.21.11 remove electrical plug in connector. 8.21.12 reassemble in reverse order. 8.21.13 printed circui...

  • Page 33

    Supplied by www.Heating spares.Co tel. 0161 620 6677 29 linea max 8.23 setting gas pressures all settings done with a suitable manometer connected to gas valve as instructed in 6.6. 8.23.1 setting maximum rate turn off electrical supply to boiler and follow instructions in section 8.4 & 8.4.1 to gai...

  • Page 34

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 30 8.23.6.1 remove electrical cover plate by removing 6 screws. 8.23.6.2 to use the combustion switch it is important that the gas pressures are set accurately as described in 8.23.1 - 8.23.3. 8.23.6.3 remove combustion switch cap on fro...

  • Page 35

    Supplied by www.Heating spares.Co tel. 0161 620 6677 31 linea max section 9 operational checks and wiring diagrams 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...

  • Page 36

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 32 9.2.3 central heating mode in this mode the mode selector switch must be turned to the position. With all controls calling for heat the motor- ised valve returns, mechanically diverting primary water to the central heating circuit. Th...

  • Page 37

    Supplied by www.Heating spares.Co tel. 0161 620 6677 33 linea max 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 is...

  • Page 38

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 34 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 lim...

  • Page 39

    Supplied by www.Heating spares.Co tel. 0161 620 6677 35 linea max 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 termin...

  • Page 40

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 36 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 burner...

  • Page 41

    Supplied by www.Heating spares.Co tel. 0161 620 6677 37 linea max 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 present ...

  • Page 42

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 38 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 gas a...

  • Page 43

    Supplied by www.Heating spares.Co tel. 0161 620 6677 39 linea max 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 se...

  • Page 44

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 40 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 switch...

  • Page 45

    Supplied by www.Heating spares.Co tel. 0161 620 6677 41 linea max 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 switch ...

  • Page 46

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 42 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 thermost...

  • Page 47

    Supplied by www.Heating spares.Co tel. 0161 620 6677 43 linea max a. Installation of the vokèra time switches (24 hr and 7 day) gain general access to electrical panel as 5.5.2. Remove the clock aperture blanking plate (1) fig.1 by squeezing the 4 lugs on the rear of the plate together and push the ...

  • Page 48

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 44 fig. 4 fig. 5 fig.7 fig. 4 showing 230v input electrical con- nection without room thermostat or inter- nal time clock (internal wiring loom for timeclock and link between 2 & 3 remains) to internal t i m e c l o c k multiplug con- ne...

  • Page 49

    Supplied by www.Heating spares.Co tel. 0161 620 6677 45 linea max b. Wiring to external time switches and thermostats. (i) general schematic diagram. (iii) randall time switch and vokèra room thermostat. (ii) acl time switch and typical room thermostat earths have been omitted for clarity earths hav...

  • Page 50

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 46 c/h 2 port zone valve h/w 2 port zone valve cylinder thermostat mains supply 230v 50hz c. Wiring for 's' plan installations. Wiring for 'y' plan installations. Load mains supply 230v 50hz 3 amp fuse n l e 1 2 4 5 6 7 cylinder thermost...

  • Page 51

    Supplied by www.Heating spares.Co tel. 0161 620 6677 47 linea max r102411 r5317 fig.35a gas assembly fig.35b front panel r102929 r102866 r102930 r102868 r102934 r102935 r102405 r100068 r102397 r102291 r102392 r102936 r102937 r102399 r102938 r102847 r100057 r102254 77085 77086 48897 r1931 r5317 r7721.

  • Page 52

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 48 fig.35c cover fig.35d inlet assembly r2374 r2374 r3139 r5072 r1920 r101954 r103317 r103318 r101319 r102330 r102956 r102955 r102947 r103319.

  • Page 53

    Supplied by www.Heating spares.Co tel. 0161 620 6677 49 linea max r103320 fig.35e expansion vessel fig.35f circulating pump and pipes fig.35g pipes r102957 r100035 r102960 r103321 r102964 r102961 r100035 r100035 r100035 r102962 r100035 r102961 r102963 r102924 r100035 r102927 r100035 r100035 r102931 ...

  • Page 54

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 50 fig.35h thermal store & flue fig.35i thermal store & insulation fig.35j base tray complete kit : part no 48945 r102921 r102923 r103322 r102906 r102991 r102928 r102804 r103323 r103324 r103317 r103325 r103327 r103319 r102946 r103326 r10...

  • Page 55

    Supplied by www.Heating spares.Co tel. 0161 620 6677 51 linea max r101319 fig.35k domestic heat exchanger & pipes fig.35l hydraulic manifold r6895 r2913 r8444 r7134 r1806 r2905 r5041 r6865 r6867 r6872 r2909 r4611 r5042 r4612 r6862 r2910 r6887 r5041 r2904 r6919 r5184 r6860 r5184 r6853 r6888 r2906 489...

  • Page 56

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 52 fig.35n outer casing fig.35o sealed case r5964 r5923 r9805 r1835 r5922 r5927 r2073 r100953 r9232 r8086 r8085 r102796 r100939 r101821 r102768 r102915 r102848 r102919 r102918 r102785 r102914 r100940

  • Page 57

    Supplied by www.Heating spares.Co tel. 0161 620 6677 53 linea max r8083 r5916 r5316 r5271 r6028 r6492 r5917 r1914 r5315 r5909 r7280 r7948 r6985 r5907 r1912 fig.35p combustion chamber.

  • Page 58

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 54 short spare parts list (refer to figs.35) code fig no. Description 099862 35a gas valve complete 08665 35i auto air vent 1914 35p main heat exchanger 1931 35a spark electrode 088031 35f grundfos ups 15-60 pump (complete) 5911 35p fan ...

  • Page 59

    Supplied by www.Heating spares.Co tel. 0161 620 6677 55 linea max fig. 36 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 e.A./r. Electrode acf ignition control box mod modulator coil sr/ss thermi...

  • Page 60

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

  • Page 61

    Supplied by www.Heating spares.Co tel. 0161 620 6677 57 linea max section 11 l.P.G. Instructions 11.1 gas rates (lpg) 11.2 burner details (lpg) burner pressure max. Rate main burner injectors main burner 11.4 gas supply a gas supply should be connected to the boiler by a competent l.P.G. Installer a...

  • Page 62

    Supplied by www.Heating spares.Co tel. 0161 620 6677 linea max 58 disconnect a grey wire from the modulator coil. Switch on the electricity supply, the boiler will now light at the minimum setting. 11.6.7 when low flame is established the pressure reading should be : 4.3mbar. (plus or minus 0.43mbar...

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

  • Page 64

    Supplied by www.Heating spares.Co tel. 0161 620 6677 ver 09/00 p u t t i n g t h e a c c e n t o n q u a l i t y vokèra ltd. Web: www.Vokera.Co.Uk southern region: morson road, enfield, middlesex en3 4nq. Sales: 020 8216 6300. Fax: 020 8805 6320. Parts: 020 8216 6310. Technical heipiine: 01274 86611...