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  4. Synergy 29
  5. Installation & Servising Instruction

VOKERA Synergy 29 Installation & Servising Instruction

Summary of Synergy 29

  • Page 1

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

  • Page 2

    Contents design principles and operating sequence page 1.1 principle components 2 1.2 mode of operation (at reset) 2 1.3 mode of operation 2 1.4 safety devices 2 technical data page 2.1 central heating 3 2.2 gas pressure 3 2.3 expansion vessel 3 2.4 dimensions 3 2.5 clearances 3 2.6 connections 3 2....

  • Page 3

    1 the synergy is a high-efficiency system boiler with an output of 28kw. The appliance - by design - incorporates electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge and automatic by-pass. The synergy is produced as room sealed, category ii2h3+ appliances, suitable ...

  • Page 4

    2 1.1 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. ● electronic ignition with flame supervision ● ...

  • Page 5

    3 section 2 technical data 2.1 central heating synergy 29 heat input 29.0 kw max heat output 60/80 ° c (return & flow temp.) 28.1 kw max heat output 30/50 ° c (return & flow temp.) 29.7 kw min heat output 60/80 ° c (return & flow temp.) 9.5 kw min heat output 30/50 ° c (return & flow temp.) 10.2 kw ...

  • Page 6

    4 2.10 pump duty fig. 3 shows the flow-rate available - af- ter 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 20 ° c temperature differ- ential. Section 2 technical data fig. 3 w ...

  • Page 7

    5 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 related documents the installation of this boiler must be in accordance with the relevant requirements of the gas safety (installation ...

  • Page 8

    6 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. Except where providing us...

  • Page 9

    7 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 buildin...

  • Page 10

    8 3a.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 sufficient, however if the system has an unusually high water content,...

  • Page 11

    9 section 4 installation 4.1 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. 4.2 contents...

  • Page 12

    10 horizontal flue terminals and accessories part no. Description min-max length 0225720 horizontal flue kit for use 1000mm with add. Bends & extensions 0225755 telescopic extension 350mm – 500mm 0225740 0.5m extension 500mm 0225745 1.0m extension 1000mm 0225750 2.0m extension 2000mm 0225730 45 ° be...

  • Page 13

    11 4.5.2 concentric vertical flue 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 vokera condensing 60/100mm concentric flue system. For specific details on the ins...

  • Page 14

    12 bend reduction in maximum flue length for each bend 45 ° bend 1.0 metre 90 ° bend 1.0 metre reduction for bends part no. Description length 0225805 horizontal flue terminal 1.0 metre 0225810 vertical flue terminal 1.0 metre 359 twin adapter kit n/a 0225770 pitched roof flashing plate n/a 0225765 ...

  • Page 15

    13 4.5.3.2 horizontal termination (see fig. 12) 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 130mm hole is required for the passage of the concentric term...

  • Page 16

    14 4.6 connecting the gas and water the appliance is supplied with service valves (fig. 14). The service valves are of the compression type. The accessories pack contains sealing washers etc, for use with the service valves. When connecting pipe work to the valves, tighten the compression end first ...

  • Page 17

    15 4.6.4 condense pipe during normal operation the boiler produces condense which is collected in a trap located in the lower part of the boiler. A flexible pipe (condense outlet pipe) is connected to the outlet of the trap. The flexible pipe must be connected to a plastic waste pipe only. The plast...

  • Page 18

    16 connect the supply cable wires (live and neutral) to their corresponding terminals on the appliance terminal block. Connect the earth wire to the earth block (see fig. 16) ensuring that it’s left slightly longer that the others, this will prevent strain on the earth wire should the cable become t...

  • Page 19

    17 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 resi...

  • Page 20

    18 5.8.1 inhibitors see section 3 “general requirements”. 5.9 setting the boiler operating tem- perature the flow outlet temperature can be adjusted between 40 ° c - 80 ° c via the thermostat knob (see fig.1). 5.10 setting the system design pressure the design pressure should be a minimum of 1 bar a...

  • Page 21

    19 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. To ensure correct and safe operation of the appliance, it is essential that any worn or failed component be replaced only with a genuine voker...

  • Page 22

    20 fig. 22 fig. 20 fig. 23 6.7 automatic air release valve (see fig. 18) (aav) carry out component removal procedure as described in 6.4. Using a suitable pair of pump pliers, unscrew the aav from the rear of the pump assembly. Replace in the reverse order. 6.8 water pressure switch (see fig. 20) ca...

  • Page 23

    21 fig. 25 fig. 24 6.13 gas valve (see fig. 25) carry out component removal procedure as described in 6.4. The gas valve must be changed as complete unit. Disconnect the electrical plug and leads from the gas valve. Slacken and unscrew gas valve inlet and outlet connections (3). Please note, the sea...

  • Page 24

    22 fig. 28 6.16 flue fan (see fig. 27 & 28) carry out component removal procedure as described in 6.4. Fig. 27: unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging (2). Locate and remove the six screws that secure the front combustion cover, then...

  • Page 25

    23 6.17 main heat exchanger (see fig. 27 & 29) carry out component removal procedure as described in 6.4. Fig. 27: unclip and remove the air chamber cover, gently pull the cover towards you before lifting and disengaging (2). Locate and remove the six screws that secure the front combustion cover, t...

  • Page 26

    24 fig. 31 carefully unclip the wires from the air chamber and withdraw the wiring & grommet from the air chamber. Disconnect the electrode lead and burner thermostat wires. Disconnect the outlet gas pipe, the flow & return pipes and the condense pipe from the air chamber. Locate and remove the 2-sc...

  • Page 27

    25 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 ens...

  • Page 28

    26 note always check and/or adjust the minimum and maximum gas pressures whilst the appliance is heating the radiators and hw cylinder. 7.3.2 setting the mimimum burner pressure (see fig. 37) once the maximum burner pressure has been checked and/or adjusted, remove one of the grey wires from the mod...

  • Page 29

    27 7.7 electrical checks any electrical checks must be carried out by a suitably qualified person. 7.7.1 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 and the e...

  • Page 30

    28 fault code d1 fault code d1 appears if the condense trap/pipe has become blocked. ● ensure the condense trap is clear ● ensure the condense pipe is clear fault code 09 pcb fault fault code 08 fault code 08 appears if the burner thermostat has been activated. ● check gas pressures ● check burner t...

  • Page 31

    29 start status led is green go to test "c" status led is red does the selector knob rotate the switch on the display pcb status led is blank have the fuses been checked no no yes yes have the electrical checks as detailed in 7.7 been carried out does the selector knob rotate the switch on the displ...

  • Page 32

    30 f a ul t finding test ‘b’: turn the selector s witch to the “on” position st ar t displa y sho ws 01 displa y sho ws 02 displa y sho ws 03 displa y sho ws 04 reset chec k gas supply displa y sho ws 06 displa y sho ws 07 reset ensure jp5 tag is on chec k ther mistor v alues and/or replace go to te...

  • Page 33

    31 f a ul t finding test ‘c’: turn the selector to the “on” position st ar t does pump r u n is there 230v betw een ter minals m15.1 & m15.2 no no replace main pcb yes no replace pump chec k wir ing & connections does fan r u n yes is there 230v at l & n of pump is there a spar k at the electrode no...

  • Page 34

    32 f a ul t finding test ‘d’: turn the selector to the “on” position st ar t does b u rner light does b u rner sta y light no yes end yes is spar k electrode ok yes yes no is there 230v betw een 1 & 2 of ignition pcb is there 230v betw een gas v alv e yes yes replace ignition pcb no chec k wir ing &...

  • Page 35

    33 fault finding test ‘e’: turn the selector to the “on” position start is there 230v between terminals m14.1 & m14.2 no no replace main pcb check wiring & connections yes is there 230v between 4 & 5 on ignition pcb is there 230v between 4 & earth no no replace ignition pcb yes yes is spark electrod...

  • Page 36

    34 section 8 wiring diagrams 8.1 external wiring the appliance comes with a factory fitted link to allow basic operation of the boiler via the mode selector switch. If external controls are to be added to the system, they must be connected to the appliance as shown in the following diagrams. For adv...

  • Page 37

    35 fig. 42 “s” plan system: external programmer or integral vokera programmer appliance terminal strip room thermostat cylinder thermostat load live load common motorised valve (hot water) wiring centre or junction box wiring centre motorised valve (heating) twin channel programmer 3 amp fuse n l e ...

  • Page 38

    36 fig. 43 “y” plan system: external programmer or integral vokera programmer appliance terminal strip 3-port mid-position valve cylinder thermostat wiring centre twin channel programmer 3 amp fuse heating hot water off on off on live load calling common satisafied add if programmer has heating only...

  • Page 39

    37 note: l-n-e connection is advisable control switching of time clock and room thermostat is 230 v.A.C. B.C.B. (acf02x) burner control board r.T. Room thermostat p.S. Water pressure switch d.A.P.S. Differential analogue pressure switch h.L.T. Hight limit thermostat h.T. Heat thermistor mod modulato...

  • Page 40

    38 fig. 45.

  • Page 41

    39 section 9 exploded diagrams 16 17 18 20 48 38 26 12 49 50 43 51 326 39 40 226 270 19 90 31 1 400 401 402 52 53 pos. Description 29 1 frame r01005294 12 quick primer pressure gauge r1857 16 2a fuse r8960 17 100 ma fuse r1947 18 cover r10021849 19 ignition module r10021848 20 printed circuit board ...

  • Page 42

    40 2 1 2 201 26 370 370 371 372 289 50 388 45 393 47 394 395 396 200 200 277 394 398 3 4 290 28 200 288 8 202 288 285 200 9 287 48 200 6 10 200 11 25 40 7 49 27 400 5 500

  • Page 43

    41 pos. Description 29 1 expansion vessel r2573 2 flexible pipe r2164 3 circulation pump r10020438 4 wiring harness r1845 5 automatic air vent bottle r0439 6 pipe r10023202 7 pipe r10024130 8 heat exchanger r2378 9 pipe r10021041 10 pipe r10022859 11 bracket r1642 25 siphon r10023495 26 siphon pipe ...

  • Page 44

    42 27 27 63 22 277 9 3 31 7 353 353 400 pos. Description 29 3 pressure switch r2044 7 by-pass valve r1552 9 heating manifold r10021821 22 safety valve r1806 27 heating cock r1789 31 venting plugs kit r01005137 63 pipe r10023065 277 screw r6903 353 nut r1824 400 wiring harness r10024740

  • Page 45

    43 15 1 5 12 200 13 200 14 17 18 19 4 9 332 351 21 2 2 21 16 3 10 400 401 pos. Description 29 1 air box bottom r10024385 2 ambidx air box side r10024166 3 air box clip r0442 4 ng burner r10022980 4 lpg burner r10023081 5 spark electrode r10022027 9 ng plate r5172 10 gas valve solenoid r10020838 12 g...

  • Page 46

    44 23 20 19 16 10 7 13 1 2 3 4 3 25 295 300 pos. Description 29 1 combustion chamber assembly r6028 2 combustion chamber back panel r5316 3 combustion chamber lateral panel r5271 4 combustion chamber front panel r5315 7 hood assembly r10024125 10 fan r10024035 13 venturi and pressure tube kit r01005...

  • Page 47

    45 section 10 lpg instructions 10.3 converting the appliance gas type to convert the appliance to another gas type it is necessary to change the burner injectors and adjust the gas pressures. It is also necessary to ensure the jumper tag at jp8 is enabled or disabled according to the gas type used. ...

  • Page 48: Energizing Home Heating

    Cod. 10024531 - 26/03 - ed. 1 vokèra ltd. 4 th 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 281460 after sales service - tel: 0870 333 0220 vokèra i...