VOKERA Linea Release note

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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

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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
Section 3 Technical Data 3
Dimensions & Contents 3
Connection Sizes 3
Installation Requirements 3
Electrical Details 3
Performance & Limitations 3
Working Pressure (H/W & C/H) 4
Flow Rates 4
Central Heating Pump Duty 4
Section 4 General Requirements 5
Related Documents 5
Location of Appliance 5
Gas Supply 5
Flue System 5
Air Supply 6
Water Circulation (C/H) 6
Pipework 6
By-Pass 6
System Design 6
Draining Taps 6
Air Release Points 7
Filling Point 7
Electrical Supply 7
Showers 7
Section 5 Installation 8
Delivery 8
Unpacking 8
Siting the Appliance 9
Connecting the Gas & Water 9-10
Fitting The Flue (Horizontal) 13
Fitting The Flue (Vertical) 14
Electrical connections 22
Section 6 Commissioning 17
Gas Installation 17
Initial Flushing of Pipework 17
Initial Filling of System 17
System Design Pressure 17
Filling the Hot Water System 17
Checking Electrical supply 17
Lighting The Boiler 17
Checking Burner Pressures 18
Range Rating C/H 19
Checking The Flue System 19
Checking The Heating Thermistor 19
Regulating The C/H System 19
Final Flushing The C/H System 19
Filling & Testing H/W System 19
Final Checks For Operation 20
Concluding Operations 20
Section Subject Page no
Section 7 Instructing The User 20
Section 8 Servicing Instructions 20
General 20
Recommended Routine Servicing 20
Annual Servicing 20
Replacement Of Parts 21
To Gain General Access 21
To Remove:
Room Sealed Chamber Front Cover 21
Main Burner & Electrode 22
Main Burner Injectors 22
Main Heat Exchanger 22
Flue Fan 23
Pressure Differential Switch 23
Combustion Chamber Insulation Panel 23
Ignition Control Box 24
Gas Control Valve 24
Pump 25
Domestic Flow Switch 25
Diverter Valve & Flow Switch Manifold 25
Domestic H/W Heat Exchanger 26
Diverter Valve 26
Main Expansion Vessel 26
Safety Valve 26
Flow Microswitch 26
Motorised Valve 26
Printed Circuit Board 26
Display Printed Circuit Board 26
Safety Thermostat 26
Thermistor Sensors 26
Pressure Gauge 26
Setting Gas Pressures 27
Combustion Analysis 27
Section 9 Operational Checks & Wiring 28
Sequence of Functions 28
Diagnostic Error Codes 29
Fault Finding Guides 30-40
Section 10 Appendix 41
Internal Time Clock Installation 41-42
External Time Clock Installation 42
S & Y Plan Installations 43
Exploded Diagrams 45-51
Short Spare Parts List 52
Abling & Disabling Controls 52
Functional Flow Diagram 53
Illustrated Wiring Diagram 54
Preliminary Electrical System Checks 55
LPG Instructions 56-57

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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 with the electronic
burner modulation. The domestic hot water
dhw) service utilises a motorised valve
combined with a 3 port diverter valve to give
hot water priority which also benefits from a
heatbank having a nominal capacity of 58
litres of circulating primary hot water posi-
tioned at the rear of the appliance.
SECTION 1 INTRODUCTION
3
2
4
5
6
7
10
9
1216171820 19 15
8
21
22
23
24
25
26
27
29 28303233
34
1
11
14 13
Fig.1 General Layout
1 Flue Elbow
2 Pressure Differential Switch
3 Silicone Pressure Tubes
4 Main Heat Exchanger
5 Combustion Chamber
6 Spark Electrode
7 Main Burner
8 Primary Store Isolation Valve 1 of 3)
9 Primary Store
10 Electronic Ignition Unit
11 Gas Valve
12 Gas Inlet
13 Domestic Flow Switch
14 Filling/Inlet Valve
15 Domestic NTC
16 Domestic Heat Exchanger
17 Hot Water Outlet
18 Safety Valve Outlet
19 Central Heating Flow
20 Central Heating Return
21 Motorised Valve
22 Pump
23 Sensing Electrode
24 Expansion Vessel
25 Fan
26 Automatic Air Vent
27 Timeclock Aperture Optional)
28 Front Door Panel
29 Pressure Gauge
30 Status LED
31 Central Heating Temperature Control
32 Mode Selector Switch
33 Hot Water Temperature Control
34 Temperature Indicator
35 Combustion Switch
31
Fig. 1
35
The Vokèra Linea Max is a com-
bined central heating and domestic hot
water appliance. By design it incorporates
full sequence electronic ignition, circulating
pump, expansion vessel, safety valve,
temperature gauge, pressure gauge, 3 port
diverter valve and filling loop.
It is produced as a room sealed appliance
suitable for floor mounting only. It is pro-
vided with a fan powered flue outlet with an
annular co-axial combustion air intake, twin
flue option is also available.

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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 controls
impose a demand for heat, the pump is
started. The flow of water from the pump
operates a flow switch. This in turn ener-
gises the electronic circuitry. The fan is
started, the gas valve is energised at an
intermediate rate and the electronic ignition
goes through an ignition attempt.
2.2.2 The burner ignition is checked by the elec-
tronic circuitry to ensure correct ignition of
the burner.
2.2.3 As water temperature increases this is
sensed by the temperature sensor on the
flow pipe which modulates the burner to
match the heat output to the heat require-
ment of the system.
2.2.4 Depending on the load, either a) the water
temperature will continue to rise and the
burner will continue to modulate down until
the maximum setting is reached at which
point the burner is switched off, or b) the
water temperature will fall and the burner
will return to a higher output to match the
demand.
2.3 Domestic Hot Water Mode
2.3.1 The appliances incorporate a hot water
preheat facility. The appliance will therefore
ignite periodically to maintain heat within the
appliance.
2.3.2 The appliance will operate in domestic hot
water mode whenever the mode selector
switch is on regardless of mode selector
switch position and any demand for central
heating.
2.3.3 The diverter valve will automatically ener-
gise into the hot water position after central
heating demand, or will stay in the hot water
position after hot water demand. Opening a
draw off tap will energise the pump and fan
sending primary water to the domestic hot
water heat exchanger.
2.3.4 Temperature control is transferred to the
domestic hot water thermostat
potentiometer) which modulates the burner
output between high and low flame to
maintain an average heat input to suit the
dhw output required.
2.3.5 An overrun is incorporated in the boiler in
both c/h & dhw modes. The fan overruns
until the boiler water cools to approximately
80°C 176°F).
2.4 Sa ety Devices
2.4.1 In both central heating and hot water modes
safe operating is ensured by:
A. Differential pressure unit in the primary
circuit which prevents burner operation if
water flow rates are too low.
B. An electronic device that checks the
primary pressure unit for activation. Failure
results in deactivation of the pump, after
approximately 10 minutes of operation.
C. A safety thermostat, which interrupts the
control circuit shutting off the gas valve. At
the same time the fan will still operate.
D. A Pressure differential switch in the flue
system to check the fan's operation before
allowing ignition.
2.4.2 A safety valve is provided to relieve excess
pressure from the primary circuit.
2.4.3 Frost Thermostat
The appliance has a built in frost protection
circuit. Should the boiler temperature sensed
at the primary thermistor fall below 5°C, the
boiler will operate in central heating mode and
continue to operate until the primary thermis-
tor reaches approximately 40°C.
KEY:
A Gas
B Hot Water Outlet
C Cold Water Inlet
D Central Heating Flow
E Central Heating Return
Fig. 2
This drawing is indicative only and does
not accurately represent pipe positioning.
A
B
C
DE
flue outlet air intake
26
2
4
7
11
9
24
22
21
16

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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.)
Weight Dry 88Kg 194lb)
Weight Full 151Kg 333lb)
Water content: 65 litres 14.3 gals)
For further dimensions see fig.13
3.3 Connection sizes
Heating flow and return: Nut and olive for
22mm o.d.Cold water inlet: Nut and olive for
15mm o.d.Hot water outlet: Nut and olive for
15mm o.d. Gas Service: Nut and olive for
15mm o.d. Safety valve outlet: Nut and olive
for 15mm o.d.
Flue outlet/Air inlet: nom dia 60/100mm
specially supplied with boiler concentric).
Flue outlet/Air inlet: nom dia 80/80mm
specially supplied with boiler twin).
3.4 Installation Requirements
3.4.1 Clearances (Horizontal or Vertical Flue)
Minimum - above casing 20mm 3/4in)
Minimum - In front 600mm 24in)
Minimum - At sides 12mm ½in) from casing
3.4.2 Maximum heating system contents approx.
100 litres 21.9 gals). Acceptance capacity
of expansion vessel 10 litres 2.2 gals).
3.4.3 Means of filling sealed system: To accord
with BS and/or local Water Authority require-
ments.
3.4.4 Maximum lue lengths
Using extension tubes the flue may be
extended to the following lengths.
Concentric
Horizontal: 1.8 metres max.
Vertical: 4.4 metres max.
Twin: 6m/6m + concentric terminal.
Horizontal termination only)
The reduction in flue length for each bend
used is:
Concentric Flue
Twin Flue
3.5 Electrical Details
Mains supply 230v ~ 50Hz Fused 3A
Internal fuse rating F2A and T100mA
Power consumption: 150W
3.6 Per ormance and Limitations
Max. input 31.0 kW 105,802 Btu/h) net)
Min. input 11.9 kW 40,614 Btu/h) net) c/h)
Min. input 10.5 kW 35,836 Btu/h) net) h/w)
Max. input 34.4 kW 117,406 Btu/h) gross)
Min. input 13.2 kW 45,051 Btu/h) gross) c/h)
Min. input 11.6 kW 39,590 Btu/h) gross) h/w)
Max. output 28.0 kW 95,563 Btu/h)
Min. output 9.9 kW 33,788 Btu/h) c/h)
Min. output 8.7 kW 29,692 Btu/h) h/w)
Central Heating output range
Max. 28.0 kW 95,563 Btu/h)
Min. 9.9 kW 33,788 Btu/h)
Designed temp rise 20°C
Max. flow temperature 85°C
Nominal hot water production
Max.water flow at temp rise of 25°C
16.1l/min Max.water flow at temp rise of
35°C 11.5l/min
Nominal hot water production For first 10
minutes) Inlet temp 12°C)
Water flow at 18 l/min - average water
temperature 43°C.
Gas Pressures
Max. gas pressure 10.1mbar
Min. gas pressure C/H 1.6mbar
Min. gas pressure H/W 1.3mbar
Gas Rate
Max. 3.27 m3/h 115.8 ft3/h
Min. 1.10 m3/h 39.0 ft3/h
Note: Use gross input values when gas
rating the appliance
Burner Details Main burner:
Polidoro type NP14
Main burner injectors 14 x 1.35
3.7 Working Pressure Heating System
Maximum 1.5bar/15m w.g./50ft w.g.
Minimum 0.15bar/1.5m w.g./5ft w.g.
Safety valve setting 3bar/30m/102ft w.g.
3.8 Flow Rates
Min. water flow dhw) 2.0l/min. 0.45 gal/
min) Min central heating flow rate through
appliance 350litres/hr 1.28 gal/min)
3.9 Working Pressure Hot Water System
Maximum 6.0 bar/90psig
Minimum 0.6 bar/7psig
For LPG instructions see page 62
Bend Reduction influe lenght for each bend
90° 850 mm
45° 425 mm
Offset 850 mm
Bend Reduction in flue lenght for each bend
90°850 mm
45°850 mm

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Linea Max
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3.10 Central Heating Pump Duty
0
100
200
300
400
500
600
700
123456789101112131415X 100
Water flow
l/h
Fig. 3
Water
pressure
mbar

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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 boiler must be in
accordance with the relevant requirements
of the Gas Safety Installation & Use)
Regulations 1998 the Local Building Regula-
tions, the current l.E.E. Wiring Regulations,
the by-laws of the local water undertaking,
and in Scotland, in accordance with the
Building Standards Scotland) Regulation. In
Ireland the local building regulations IE).
It should be in accordance also with any
relevant requirements of the local authority
and the relevant recommendations of the
following British Standard Codes of Practice:
4.2 Location o Appliance
The combination boiler may be installed in
any room or internal space, although par-
ticular attention is drawn to the requirements
of the current l.E.E. Wiring Regulations, and
in Scotland, the electrical provisions of the
Building Regulations applicable in Scotland,
with respect to the installation of the combi-
nation boiler in a room or internal space
containing a bath or shower.
Where a room-sealed appliance is installed
in a room containing a bath or shower, any
electrical switch or appliance control, utilis-
ing mains electricity, should be located in
such a position that it cannot be touched by
a person using the bath or shower.
The location chosen for the boiler must
permit the provision of a satisfactory flue
and termination. The location must also
permit an adequate air supply for combus-
tion purposes and an adequate space for
servicing and air circulation around the
boiler.
Where the installation of the boiler will be in
an unusual location special procedures may
be necessary and BS 6798:1987 gives
detailed guidance on this aspect.
Pipework from the meter to the boiler must
be of adequate size. Pipes of a smaller size
than the boiler inlet connection must not be
used.
The complete installation must be tested for
soundness as described in the above code.
N.B. If the gas supply for the boiler serves
other appliances ensure that an adequate
supply is available both to the boiler and the
other appliance when they are in use at the
same time.
4.4 Flue System
The terminal should be located where
dispersal of combustion products is not
impeded and with due regard for the dam-
age or discoloration that might occur to
building products in the vicinity see fig 4).
The terminal must not be located in a place
where it is likely to cause a nuisance.
In cold and/or humid weather water vapour
may condense on leaving the flue terminal.
The effect of such steaming must be
considered.
A compartment used to enclose the boiler
must be designed and constructed specifi-
cally for this purpose. An existing cupboard
or compartment may be used provided that
it is modified for this purpose.
Details of essential features of cupboard/
compartment design including airing cup-
board installations are given in BS
6798:1987. This appliance is not suitable for
external installation.
4.3 Gas Supply
A gas meter is connected to the service pipe
by the gas supplier.
An existing meter should be checked,
preferably by the gas supplier, to ensure that
the meter is adequate to deal with the rate of
gas supply required for all appliances it
serves.
Installation pipes should be fitted in accord-
ance with BS 6891:1988.
BS 6891 1988 Low pressure installation pipes
BS 6798 1987 Boilers of rated input not exceeding 60kW.
BS 5449 Part 1 1990 Forced circulation hot water systems
BS 5546 1990 Installation of gas hot water supplies
for domestic purposes 2nd family gases).
BS 5440 Part 1 1990 Flues.
BS 5440 Part 2 1989 Flues & Ventilation.
BS 7074 Part 1 1989 Application, selection & installation of expansion
vessels & ancillary equipment for sealed water
systems.

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Linea Max
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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 durable material).
A suitable guard is available from Vokéra
Ltd. Part No 018, G.C. No. 301 106
This guard must be fitted centrally over the
terminal. Mark the positions of the fixings,
drill the wall and secure using wall plugs and
3 of 1½" No.8 plated screws.
Fig. 4
Positions
of
Air Vents
Air Vent areas
Air From
Room or
Internal
Spaces
Air Direct
From
Outside
High
Level 310 cm2
48 in2155 cm2 24 in2
Low
Level 310 cm2
48 in2155 cm2 24 in2
Terminal position for fan assisted boiler
(minimum distance) mm
A - Directly elow an open window or other 300
opening (e.g. air rick)
B - Below gutters, soil pipes or drain pipes 25
C - Below eaves 25
D - Below alconies or car port roof 25
E - From vertical drain pipes and soil pipes 75
F - From internal or external corners 25
G - A ove ground or elow alcony level 300
H - From a surface facing a terminal 600
I - From a terminal facing a terminal 1200
J - From an opening in the car port (e.g. door
window) into dwelling. 1200
K - Vertically from a terminal on the same wall 1500
L - Horizontally from a terminal on the same wall 300
M - Horizontally from a vertical terminal to a wall 300
NOTE: The flue must be terminated in a place not likely
to cause a nuisance.
4.5 Air Supply
The following notes are intended for general
guidance.
The room sealed fan flued boiler does not
require a permanent air vent for combustion
air supply.
Where installed in a cupboard or compart-
ment ventilation is required for cooling.
The table following gives the recommended
minimum effective areas of such air vents.
4.6 Water Circulation (Central Heating)
Detailed recommendations are given in
BS 6798:1987 and BS 5449:1:1990 for
smallbore and microbore central heating
systems).
4.6.1 The following notes are given for general
guidance.
4.6.2 Pipework
Copper tubing to BS 2871:1:1971 is recom-
mended for water pipe. Jointing should be
either by capillary soldered or with compres-
sion fittings.
Where possible, pipes should have a gradi-
ent to ensure air is carried naturally to air
release points and water flows naturally to
drain taps.
It should be ensured as far as possible that
the appliance heat exchanger is not a
natural collecting point for air.
Except where providing useful heat, pipes
should be insulated to prevent heat loss and
to avoid freezing. Particular attention should
be paid to pipes passing through ventilated
spaces in roofs and under floors.
4.6.3 By-Pass
An automatic by-pass is incorporated in the
boiler, but systems should be designed to
ensure that with all radiators turned off a
flow rate of at least 350 litres/hour 1.28
gals/min) is achieved through the system.
See 6.9.4
4.6.4 System Design
Vokèra Ltd recommend a 2-pipe system. Sin-
gle pipe systems are more liable to be trouble-
some unless carefullly designed and installed.
4.6.5 Draining Taps
These must be located in accessible posi-
tions to permit the draining of the whole
system. The taps must be at least 15mm
nominal size and manufactured in accord-
ance with BS 2879:1980.