VOKERA Eclipse 216 ESS, Eclipse 226 ESS Installation & Servicing Instructions Manual

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ESS

Installation & Servicing Instructions

THESE INSTRUCTIONS TO BE RETAINED BY USER

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Contents

Design principles & operating sequence Page

1.1 Principle components 2

1.2 Mode of operation (at rest) 2

1.3 Heat request mode 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

2.7 Electrical 3

2.8 Flue details 3

2.9 Efficiency 3

2.10 Parameter defaults 3

2.11 Emissions 3

2.12 Pump duty 4

General requirements Page

3.1 Related documents 4

3.2 Location of appliance 4

3.3 Gas supply 5

3.4 Flue system 5

3.5 Air supply 5

3.6 Water circulation 5

3.7 Electrical supply 6

3.8 Combustible surfaces 6

3.9 Timber framed buildings 6

3.10 Condensate disposal 6

3.11 Inhibitors 6

Installation Page

4.1 Delivery 7

4.2 Contents 7

4.3 Unpacking 7

4.4 Preparation for mounting 7

4.5 Fitting the flue 7

4.6 Connecting the gas & water 10

4.7 Condensate outlet 11

4.8 Electrical connections 11

Commissioning Page

5.1 Gas supply installation 12

5.2 The heating system 12

5.3 Initial filling of the system 12

5.4 Initial flushing of the system 12

5.5 Pre-operation checks 12

5.6 Initial lighting 12

5.7 Final flushing of the system 12

5.8 Operating parameters 13

5.9 Functional parameters 13

5.10 Range rating 13

5.11 Setting the system design pressure 13

5.12 Regulating the central heating system 13

5.13 Final checks 14

5.14 Instructing the user 14

Servicing Page

6.1 General 14

6.2 Routine annual servicing 14

6.3 Replacement of components 14

6.4 Component removal procedure 14

6.5 Pump head removal 15

6.6 Safety valve removal 15

6.7 Automatic air valve removal 15

6.8 Pressure gauge removal 15

6.9 Temperature sensor removal 15

6.10 Main PCB removal 15

6.11 Gas valve removal 16

6.12 Fan removal 16

6.13 Burner removal 16

6.14 Electrode removal 16

6.15 Injector removal 16

6.16 Hydraulic manifold assembly 17

6.17 Condense trap removal 17

6.18 Condense pressure switch removal 17

6.19 Combustion cover removal 17

6.20 Expansion vessel removal 18

6.21 Input & status PCB removal 18

Checks, adjustments, and fault finding Page

7.1 Checking appliance operation 19

7.2 Mode of operation 19

7.3 Checking/adjusting fan speeds 19

7.4 Adjusting the gas valve 20

7.5 Status code 21

7.6 Lockout faults codes 21

7.7 Diagnostic recall 21

7.8 Temperature sensor viewing mode 22

7.9 Checking the expansion vessel 22

7.10 External faults (installation) 22

7.11 Electrical checks 22

7.12 Fault finding 23

Wiring diagrams Page

8.1 Important note 26

8.2 Installation of Vokera time clock 26

8.3 External controls 26

Exploded diagrams Page

9.1 Table 1 31

9.2 Table 2 32

9.3 Table 3 33

9.4 Table 4 34

9.5 Table 5 35

L.P.G. instructions Page

10.1 Technical data 36

10.2 Related documents 36

10.3 Gas supply 36

10.4 Gas supply installation 36

10.5 Adjusting the gas valve 36

10.6 Range rating 37

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INTRODUCTION

The Vokera Eclipse 216 ESS & 226 ESS are central heating condensing boilers, which - by design incorporates full sequence electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge and automatic by-pass.

The Eclipse 216 & 226 ESS boilers are produced as room sealed, category C1, C3, C6 appliances, suitable for wall mounting applications only. The Eclipse is provided with a fan powered flue outlet with an annular co-axial

combustion air intake that can be rotated – horizontally – through 360 degrees for various horizontal or vertical applications. The Eclipse can also be used with the Vokera twin flue system.

These appliances are designed for use with sealed systems only; consequently they are not intended for use on open vented systems.

A range rating facility is incorporated in the appliance.

General layout

1 Auto air vent 2 Flue outlet & air intake 3 Flue gas analysis test point 4 Burner plate 5 Spark/Sensing Electrode 6 Fan assembly 7 Pressure switch 8 Electronic Control Board (PCB) 9 Condense trap 12 Gas connection 13 Pressure gauge 14 Time clock aperture 15 Function key pad 16 LED display 17 Reset button 18 Heating flow connection 19 Safety valve 20 Heating return connection 21 Auto by-pass 22 Hydraulic manifold 23 Pump 24 Return sensor (NTC2) 25 Gas valve 26 Flow sensor (NTC1)

Fig. 1

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SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

1.1 PRINCIPLE COMPONENTS

● A fully integrated electronic control board

featuring electronic temperature control, continuous air/gas modulation, anti-cycle control, pump over-run, self-diagnostic fault indicator, electronic ignition with flame supervision, & appliance frost protection.

● Cast aluminium mono-block heat exchanger.

● Low Nox burner with pre-mix.

● Two-stage gas valve.

● Pump.

● Expansion vessel.

● Pressure gauge.

● Safety valve.

1.2 MODE OF OPERATION (at rest)

When there is no demand for heating or hot water. And the appliance remains inactive for a period of 24 hours, the pump will be energised for a few moments to prevent it from seizing. Should the flow temperature sensor fall below 7°C the pump will be energised. If the flow sensor temperature falls to below 3°C the burner will be lit and the appliance will operate at the minimum output until the temperature of the flow sensor reaches 10°C, whereupon the pump will continue to run in pump over-run mode.

1.4 SAFETY DEVICES

When the appliance is in use, safe operation is ensured by:

● a high limit thermostat that interrupts the

operation of the burner;

● a differential temperature protection circuit which

interrupts the burner if the temperature differential is inverted;

● a fan speed sensor which checks the correct

operation of the fan, thereby allowing safe operation of the burner;

● a safety valve which releases excess pressure

from the primary circuit.

● a condense pressure switch that will stop the

burner from operating should the condense trap become blocked.

1.3 MODE OF OPERATION (heating/hot water request)

When there is a request for heat via the time clock and/or external controls, the pump will start and the fan will be activated via the flow temperature sensor. When the fan is sensed to be operating correctly, the ignition sequence commences. The speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow & return temperature sensors, consequently a high temperature at the flow sensor results in a lower fan speed. As the water temperature increases, the temperature sensors – located on the flow & return pipes of the boiler – reduce the fan speed via the electronic circuitry. Depending on the load, either the water temperature will continue to rise until the set point is achieved or the water temperature will fall whereby fan speed will increase relative to the output required. When the boiler has reached the set point, the burner will switch off. The built-in anti-cycle device prevents the burner from relighting for an adjustable period of time (factory default is 3 minutes). When the temperature of the flow sensor falls below the set-point, the burner will re-light.

Fig. 2

return flowgas

Main Heat Exchanger

Expansion vessel

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SECTION 2 TECHNICAL DATA

216 226

2.1 Central heating

Heat input 17,80 kW 29,00 kW Maximum heat output 60/80°C (return & flow temperature) 15,40 kW 25,30 kW Maximum heat output 30/50°C (return & flow temperature) 16,80 kW 26,8 kW Minimum heat output 60/80°C (return & flow temperature) 4,40 kW 7,3 kW Minimum heat output 30/50°C (return & flow temperature) 4,90 kW 8,10 kW Minimum working pressure 0,45 bar 0,45 bar Maximum working pressure 3 bar 3 bar Minimum flow rate 350 l/h 350 l/h

2.2 Gas pressure

Inlet pressure (G20) 20,0 mbar 20,0 mbar Maximum gas rate 1,69 m3/h 2,76 m3/h Minimum gas rate 0,49 m3/h 0,80 m3/h Injector size single injectors with six 3,1mm holes single injectors with six 3,8mm holes

2.3 Expansion vessel

Capacity 8 litres 8 litres Maximum system volume 76 litres 76 litres Pre-charge pressure 1,0 bar 1,0 bar

2.4 Dimensions

Height 790 mm 790 mm Width 450 mm 450 mm Depth 322 mm 322 mm Dry weight 57 kg 57 kg

2.5 Clearances

Sides 25 mm 25 mm Top

Bottom 150 mm 150 mm Front 600 mm 600 mm

2.6 Connections

Flow & return 22 mm compression 22 mm compression Gas 1/2 inch BSP 1/2 inch BSP Safety valve 1/2 inch BSP 1/2 inch BSP

2.7 Electrical

Voltage 230V/~ 50hz 230V/~ 50hz Power consumption 130 W 130 W Internal fuse 2 A 2 A External fuse 3 A 3 A

2.8 Flue details

Maximum horizontal flue length (concentric) 10 metres 6,45 metres Maximum vertical flue length (concentric) 11 metres 7,45 metres Maximum twin flue length (horizontal or vertical) 39 m + 39 m 29 m + 29 m

2.9 Efficiency

SEBDUK rating Band “A” Band “A”

2.10 Operating parameters (factory default shown)

Maximum fan speed 4.000 RPM 5.500 RPM Minimum fan speed 1.300 RPM 1.700 RPM Soft light setting 100 (%) 80 (%) Anti-cycle delay (variable between 0 sec.-360 sec.) 180 sec. 180 sec. Flow temperature (variable between 20°-90°)75°C75°C Pump over-run (variable between 3-99 minutes) 10 minutes 10 minutes

2.11 Emissions

NOx at maximum output 40 ppm 30 ppm NOx at minimum output 20 ppm 15 ppm CO at maximum output 50 ppm 50 ppm CO at minimum output 50 ppm 50 ppm CO2 at maximum output (air chamber cover off) 9,8 % 9,8 % CO2 at minimum output (air chamber cover off) 9,8 % 9,8 % CO/CO

ratio 0.0005 to 1 0.0005 to 1

150mm from casing or 25mm above 150mm from casing or 25mm above flue elbow (whichever is applicable) flue elbow (whichever is applicable)

Ref. Condition 15 °C , 1013,25 mbar, dry gas NOTE: L.P.G. data refer to section 10

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2.12 PUMP DUTY

Fig. 3 shows the flow rate available – after 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 20°C temperature differential.

600

500

400

300

200

100

Water pressure (mbar)

0 100 200 300 400 500 600 700 800

Fig. 3

Litres Per Hour (x100)

900 1000

1100 1200 1300 1400

Terminal position for fan assisted boiler

(minimum distance) mm A - Directly above or below an open window 300

or other opening (e.g. air brick) B - Below gutters, soil pipes or drain pipes 25 C - Below eaves 25 D - Below balconies or car port roof 25 E - From vertical drain pipes and soil pipes 75 F - From internal or external corners 25 G - Above ground or below balcony level 300 H - From a surface facing a terminal 600 I - From a terminal facing a terminal 1200

Fig. 4

SECTION 3 GENERAL REQUIREMENTS

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 local building regulations, the current I.E.E. wiring regulations, the bylaws of the local water undertaking, the Building Standards (Scotland) Regulation and Building Standards (Northern Ireland) Regulations.

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.

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

N – Horizontally from an opening, airbrick, openable

window, etc. 300

NOTE:The flue must be terminated in a place not likely to cause a nuisance.

3.2 LOCATION OF APPLIANCE

The appliance may be installed in any room or

internal space, although particular attention is

drawn to the requirements of the current I.E.E.

wiring regulations, and in Scotland, the electrical

provisions of the Building Regulations, with

respect to the installation of the appliance in a

room or internal space containing a bath or shower.

When an appliance is installed in a room or

internal space containing a bath or shower, the

appliance or any control pertaining to it must not

be within reach of a person using the bath or

shower.

The location chosen for the appliance must permit

the provision of a safe and satisfactory flue and

termination. The location must also permit an

adequate air supply for combustion purposes

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BS 5440 PART 1 FLUES BS 5440 PART 2 FLUES AND VENTILATION BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW BS 6891 LOW PRESSURE INSTALLATION PIPES BS 7074 PART 1 APPLICATION, SELECTION, AND INSTALLATION OF EXPANSION VESSELS AND

ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS

and an adequate space for servicing and air circulation around the appliance. Where the installation of the appliance will be in an unusual location special procedures may be necessary, BS 6798 gives detailed guidance on this aspect.

A compartment used to enclose the appliance must be designed and constructed specifically for this purpose. An existing compartment/cupboard may be utilised provided that it is modified to suit.

Details of essential features of compartment/ cupboard design, including airing cupboard installations, are given in BS 6798. This appliance is not suitable for external installation.

3.3 GAS SUPPLY

The gas meter – as supplied by the gas supplier – must be checked to ensure that it is of adequate size to deal with the maximum rated input of all the appliances that it serves. Installation pipes must be fitted in accordance with BS 6891. Pipe-work from the meter to the appliance must be of adequate size. Pipes of a smaller size than the appliance gas inlet connection must not be used. The installation must be tested for soundness in accordance with BS 6891.

If the gas supply serves more than one appliance, it must be ensured that an adequate supply is maintained to each appliance when they are in use at the same time.

3.4 FLUE SYSTEM

The terminal should be located where the dispersal of combustion products is not impeded and with due regard for the damage and discoloration that may occur to building products located nearby. The terminal must not be located in a place where it is likely to cause a nuisance (see fig. 4).

Water vapour will condense on leaving the flue terminal, the effect of such pluming must be considered.

If installed less than 2m above a pavement or platform to which people have access (including balconies or flat roofs) the terminal must be protected by a guard of durable material. The guard must be fitted centrally over the terminal. Refer to BS 5440 Part 1, when the terminal is 0,5 metres (or less) below plastic guttering or 1 metre (or less) below painted eaves.

3.5 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 also not required.

3.6 WATER CIRCULATION

Detailed recommendations are given in BS 5449 Part 1 and BS 6798. The following notes are for general guidance only.

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 useful heat, pipes should be insulated to avoid heat loss and in particular to avoid the possibility of freezing. Particular attention should be paid to pipes passing through ventilated areas such as under floors, loft-space, and void areas.

3.6.2 AUTOMATIC BY-PASS

The appliance has a built-in automatic by-pass, consequently there is no requirement for an external by-pass, however the design of the system should be such that it prevents boiler ‘cycling’.

3.6.3 DRAIN COCKS

These must be located in accessible positions to facilitate draining of the appliance and all water pipes connected to the appliance. The drain cocks must be manufactured in accordance with BS 2879.

3.6.4 AIR RELEASE POINTS

These must be positioned at the highest points in the system where air is likely to be trapped. They should be used to expel trapped air and allow complete filling of the system.

3.6.5 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 8

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litres of expansion from within the system, generally this is sufficient, however if the system has an unusually high water content, it may be necessary to provide additional expansion capacity (see 6.19).

3.6.6 FILLING POINT

A method for initial filling of the system and replacing water lost during servicing etc. must be provided. This method of filling must comply with the local water authority regulations. Fig. 5 shows a widely accepted method.

3.7 ELECTRICAL SUPPLY

The appliance is supplied for operation on 230V

@ 50Hz electrical supply, it must be protected

with a 3-amp fuse. The method of connection to

the mains electricity supply must allow for

complete isolation from the supply. The preferred

method is by using a double-pole switch with a

contact separation of at least 3mm. The switch

must only supply the appliance and its

corresponding controls, i.e. time clock, room ther-

mostat, etc. Alternatively an un-switched shuttered

socket with a fused 3-pin plug both complying

with BS 1363 is acceptable.

3.8 MOUNTING ON A COMBUSTIBLE SURFACE

If the appliance is to be fitted on a wall of combus-

tible material, a sheet of fireproof material must

protect the wall.

3.9 TIMBER FRAMED BUILDINGS

If the appliance is to be fitted in a timber framed

building, it should be fitted in accordance with the

Institute of Gas Engineers publication (IGE/UP/7)

“Guide for Gas Installations in Timber Frame Buildings”.

Fig. 5

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 (see fig. 5 A). The cold feed from the make-up vessel or tank must be fitted with an approved non-return valve and stopcock for isolation purposes. The feed pipe should be connected to the return pipe as close to the boiler as possible.

Make-up vessel or tank

Automatic air-vent

Non-return

valve

Stopcock

3.10 CONDENSATE DISPOSAL

When choosing a location for the boiler,

consideration should be given to the disposal of

the condensate discharge into a suitable drain or

soil pipe. The condensate outlet pipe must be

connected to the drain in accordance with building

regulations or other rules in force.

3.11 INHIBITORS

The system shall be flushed in accordance with

BS 7593. If an inhibitor is to be used, it shall be

from a reputable manufacturer and shall be

administered in strict accordance with the

manufacturers instructions.

5.0 metres minimum

Heating

Fig. 5 A

return

3.6.8 FREQUENT FILLING

Frequent filling or venting of the system may be indicative of a leak. Care should be taken during the installation of the appliance to ensure all aspects of the system are capable of withstanding pressures up to at least 3 bar.

Fig. 6

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SECTION 4 INSTALLATION

4.1 DELIVERY

The appliance is delivered in a heavy-duty cardboard 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;

● template;

● an accessories pack containing the appliance

service valves and washers;

● the instruction pack containing the installation

& servicing instructions, user instructions, Benchmark logbook, guarantee registration card, and a 3amp fuse.

4.3 UNPACKING

At the top of the carton pull both sides open – do not use a knife – unfold the rest of the carton from around the appliance, carefully remove all protective packaging from the appliance, and lay the accessories etc. to one side.

4.4 PREPARATION FOR MOUNTING THE APPLIANCE

The appliance should be mounted on a smooth, vertical, non-combustible surface, which must be capable of supporting the full weight of the appliance. Care should be exercised when determining the position of the appliance with respect to hidden obstructions such as pipes, cables, etc.

When the position of the appliance has been decided – using the template supplied – carefully mark the position of the wall-mounting bracket (see fig. 6) and flue-hole (if applicable).

Horizontal flue terminals and accessories

Part No.

0225720

0225755 0225740 0225745 0225750 0225730 0225735 0225760

Description

Horizontal flue kit for use with add. bends & extensions

350-500 T elescopic extension 0,5m extension 1,0m extension 2,0m extension 45° bend (pair) 90° bend Wall bracket (5)

Using the template provided (see fig. 6), mark and drill a 125mm hole for the passage of the flue pipe. The hole should ha ve a 1° rise from the boiler to outside.

The fixing holes for the wall-mounting bracket should now be drilled and plugged, an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely. Once the br acket has been secured to the wall, mount the appliance onto the brack et.

FITTING THE HORIZONTAL FLUE KIT

Black

gasket

Min-Max length 1000mm

350mm-500mm 500mm 1000mm 2000mm N/A N/A N/A

Boiler top

adaptor

Flue outlet

4.5 FITTING THE FLUE

The top flue outlet permits both horizontal and vertical flue applications to be considered, alternatively, the Vokera twin flue system can be utilised if longer flue runs are required.

4.5.1 CONCENTRIC HORIZONTAL FLUE

(For concentric vertical flue, see 4.5.2). (For twin flue applications, see 4.5.3). The appliance flue outlet elbow can be rotated through 360° on its vertical axis. In addition the flue may be extended from the outlet elbow in the horizontal plane (see 2.8). A reduction must also be made to the maximum length (see table below) when additional bends are used.

Reduction for additional bends Bend 45° bend 90° bend

Reduction in maximum flue length for each bend 0,5 metre

1,0 metre

Boiler

Fig. 7

Take the large black gasket - supplied with the flue terminal kit - and stretch it over the appliance flue outlet (fig. 7). Using a twisting motion, connect the boiler top adaptor - supplied with the flue terminal kit - to the appliance flue outlet ensuring the male spigot of the adaptor is pushed fully into the flue outlet spigot of the boiler (fig. 7). Carefully measure the distance from the centre of the appliance flue outlet to the edge of the finished outside wall (dimension X). Add 45mm to dimension X to give you Dimension Y (see fig 7A). Measure dimension Y from the terminal end of the concentric flue pipe and cut off the excess. Pass the concentric flue pipe through the previously drilled hole. Fit the flue bend to the boiler top adaptor and insert the concentric flue pipe into the flue bend ensuring the correct seal is made.

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NOTE

You must ensure that the entire flue system is properly supported and connected.

Seal the flue assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The interior and exterior trim can now be fitted.

Push-fit connection

Extension pipe

Plain end

Fig. 7A

4.5.1.1 EXTENDING THE FLUE

Connect the bend – supplied with the terminal kit – to the top of the boiler using the boiler top adapter (supplied, see fig. 7). The additional bends & extensions have push-fit connections, care should be taken to ensure that the correct seal is made when assembling the flue system. Connect the required number of flue extensions or bends (up to the maximum equivalent flue length) to the flue terminal (see fig. 7B & 7C).

Push-fit connection

Boiler top adaptor

Extension

Boiler top adaptor

Boiler

Fig. 7C

4.5.2 CONCENTRIC VERTICAL FLUE

The vertical flue terminal can be connected directly to the appliance flue outlet. Alternatively, an extension or bend can be connected to the appliance flue outlet if desired (see 2.8), however if additional bends are fitted, a reduction must be made to the maximum flue length (see table below).

Reduction for bends

Bend 45° bend 90° bend

Reduction in maximum flue length for each bend 0,5 metre

1,0 metre

Boiler

Part No.

Fig. 7B

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension (see fig. 7B & 7C). Remove any burrs, and check that any seals are located properly. You must ensure that the entire flue system is properly supported and connected.

0225725 0225770 0225765 0225755 0225740 0225745 0225750 0225730 0225735 0225760

Vertical flue terminal and accessories

Description Vertical flue terminal

Pitched roof flashing plate Flat roof flashing plate 350-500 telescopic extension 0,5m extension 1,0m extension 2,0m extension 45° bend (pair) 90° bend Wall bracket (4)

Min-Max length 1000 mm

N/A N/A 350mm-500mm 500mm 1000mm 2000mm N/A N/A N/A

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Using the dimensions given in fig. 8 as a reference, mark and cut a 105mm hole in the ceiling and/or roof.

IMPORTANT

You must ensure that the terminal is at least 300mm from any structure or surface (see fig. 8). The vertical flue terminal is 1,0 metre in length and cannot be cut; therefore it may be necessary to adjust the height of the appliance to suit or use a suitable extension. Encure that any horizontal sections of the flue system have a 1° fall back to the boiler (17mm per 1000mm).

Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing.

The fixing holes for the wall-mounting bracket should now be drilled and plugged, an appropriate type and quantity of fixing should be used to ensure that the bracket is mounted securely. Once the bracket has been secured to the wall, mount the appliance onto the bracket.

GUIDANCE NOTES ON TWIN FLUE INSTALLATION

● The flue must hav e a f all back of 1° back to the

appliance to allow any condensate that forms in the flue system to drain. Consideration must also be given to the fact that there is the possibility of a small amount of condensate dripping from the terminal.

● Ensure that the entire flue system is adequately

supported, use at least one bracket for each extension.

● As the exhaust outlet pipe can reach v ery high

temperatures it must be protected to prevent persons touching the hot surface.

Reduction for bends

Bend 45° bend

90° bend

Reduction in maximum flue length for each bend 1,0 metre

1,0 metre

Twin flue accessories

300mm minimum

Fig. 8

NOTE

When cutting an extension to the required length, you must ensure that the excess is cut from the plain end of the extension. Remove any b urrs, and check that an y seals are located properly .

4.5.3 TWIN FLUE SYSTEM

The Vokera twin flue system enables greater flue distances to be achieved (see 2.8) than that of the standard concentric flue system. It can be used f or horizontal or vertical applications, howev er the twin flue system must be converted to the dedicated concentric flue kit for termination. It is essential that the installation of the twin flue system be carried out in strict accordance with these instructions.

520mm

Part No.

0225805 0225810 359 0225770 0225765 0225815 0225820 0225825 0225830 0225835 0225840 0225845 0225850 0225855

Description Horizontal flue terminal

Vertical flue terminal Twin adapter kit Pitched roof flashing plate Flat roof flashing plate Condensate drain kit 0,25m extension (pair) 0,5m extension (pair) 1,0m extension (pair) 2,0m extension (pair) 45° bend (pair) 90° bend (pair) Twin bracket (5) Single bracket (5)

Length 1000 mm

1000 mm N/A N/A N/A N/A 250mm 500mm 1000mm 2000mm N/A N/A N/A N/A

MOUNTING THE BOILER

4.5.3.1 INSTALLATION OF TWIN ADAPTOR KIT (see fig. 9)

● Discard the restrictor ring (supplied with the twin

adapter kit).

● Insert the exhaust connection manifold onto the

appliance flue outlet.

● Place the silicone seal (supplied with twin

adapter kit) over the rim of the exhaust connection manifold.

● Remove one of the blanking plate (located to

the left & right of the appliance flue outlet) and – using the same screws – install the air baffle.

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Fig. 9

4.5.3.2 HORIZONTAL TERMINATION (see fig. 10)

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 terminal through the wall.

Depending on site conditions it may be prefer able to install the terminal assembly prior to fitting the twin flue pipes.

Mark and drill a 130mm hole for the passage of the horizontal flue terminal, ensuring that there is a 1° fall back to the boiler (17mm per 1000mm). Insert the terminal assembly into the flue hole.

Push-fit the twin flue pipes onto the concentric to twin converter box ensuring that the exhaust pipe connects to the exhaust connection on the concentric to twin converter. If necessary cut the plain ends (male) of the twin flue pipes to allow connection to the concentric to twin converter.

NOTE

Before cutting twin flue pipes ensure allowances ha ve been made for connection onto the previous piece and onto the concentric to twin converter. The last twin flue pipes must be pushed 50mm onto the male spigots of the concentric to twin converter.

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. Remove an y burrs, and check that both seals are located properly.

Seal the flue terminal assembly to the wall using cement or a suitable alternative that will provide satisfactory weatherproofing. The interior and exterior trim can now be fitted.

4.5.3.3 VERTICAL TERMINATION (see fig. 11)

The twin flue system must be converted to the dedicated concentric flue kit for termination.

● The vertical terminal is supplied with a built-in

converter box and cannot be shortened.

● A 130mm hole is required for the passage of

the concentric terminal through the ceiling and/or roof. Depending on site conditions it may be pref erable

to install the terminal assembly prior to fitting the twin flue pipes. Fit the appropriate flashing plate to the roof and insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar on the flue terminal fits over the flashing. Push-fit the twin flue pipes onto the concentric to twin converter ensuring that the exhaust pipe connects to the exhaust connection on the concentric to twin converter. If necessary cut the plain ends (male) of the twin flue pipes to allow connection to the concentric to twin converter.

NOTE

● Before cutting twin flue pipes ensure

allowances have been made for connection onto the previous piece and onto the concentric to twin converter. The last twin flue pipes must be pushed 50mm onto the male spigots of the concentric to twin converter.

● You must ensure that the entire flue system is

properly supported and connected.

● Ensure that any horizontal sections of pipe hav e

a 1° fall towards the appliance (17mm per 1000mm).

● The convertor box on the vertical terminal will

have to be temporarily remo ved when inserting the terminal through the flashing.

convertor box

Fig. 11

convertor box

4.6 CONNECTING THE GAS AND WATER

Fig. 10

The appliance is supplied with an accessories pack that contains sealing washers and service valves. When connecting pipe work to the valves, tighten the compression end first, then insert the sealing washers before tightening the valve to the appliance.

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NOTE

It will be necessary to hold the valve with one spanner whilst tightening with another.

4.6.1 GAS (see fig. 12)

The appliance is supplied with a 1/2 inch BSP service valve, connect the supply pipe to the inlet of the valve and tighten the connecting nut.

NOTE

It will be necessary to calculate the diameter of the gas supply pipe to ensure the appliance has an adequate supply of gas.

4.6.2 FLOW & RETURN (see fig. 12)

The appliance is supplied with 22mm service valves for the flow and return connections, connect a 22mm pipe to the inlet of each valve and tighten both nuts.

4.6.3 SAFETY VALVE (see fig. 12)

Connect a suitable coupling and 15mm pipe to the safety valve outlet and tighten.The discharge pipe must have a continuous fall away from the appliance to outside and allow any water to drain away thereby eliminating the possibility of freezing. The discharge pipe must terminate in a position where any water - possibly boiling - discharges safely without causing damage or injury, but is still visible.

4.7 CONDENSATE OUTLET (see fig. 12)

During normal operation the boiler produces condensate which is collected in a trap located in the lower part of the boiler. A flexible pipe (condensate outlet pipe) is connected to the outlet of the trap. The flexible pipe must be connected to a plastic waste pipe only. The plastic waste pipe must have a minimum of a 3° fall towards the drain. Any external run of pipe should be insulated to prevent the risk of freezing.

CONNECTING THE CONDENSATE OUTLET

Gently pull the condensate outlet pipe down from its location inside the boiler until approximately 250mm protrudes from the underside of the boiler. Connect a suitable pipe (no less than 20mm diameter) to the outlet pipe and ensure it discharges in accordance with building regulations or other rules in force.

4.8 ELECTRICAL CONNECTIONS

The electrical supply must be as specified in 3.7. A qualified electrician should connect the electrical supply to the appliance. If controls - external to the appliance - are required, a competent person must undertake the design of any external electrical circuits, please refer to section 8 for detailed instructions. ANY EXTERNAL CONTROL OR WIRING MUST BE SERVED FROM THE SAME ISOLATOR AS THAT OF THE APPLIANCE. The supply cable from the isolator to the appliance must be 3-core flexible sized 0,75mm to BS 6500. Wiring to the appliance must be rated for operation in contact with surfaces up to 90°C.

4.8.1 CASING REMOVAL

To gain access to the appliance electrical connections you must first remove the casing, proceed as follows:

● locate and remove the 2 screws that secure the

controls fascia to the appliance casing (see fig. 13).

● locate and remove the 2 screws that secure the

casing to the back frame of the boiler (see fig. 13).

● gently pull one side of the casing then the other

to disengage it from the retaining clips.

● lift the casing upward to disengage it from the

top locating hooks and then remove.

● store the casing and screws safely until required.

Re-fit in the reverse order.

Screws

Fig.13

Screw

4.8.2 APPLIANCE TERMINAL STRIP

The appliance terminal strip is located behind the control fascia (see fig.14). Locate and remove the 4 screws securing the terminal strip cover.

NOTE

The appliance comes with a factory fitted link to allow basic operation of the boiler via the keypad. If it is anticipated that external controls will be required please refer to the wiring diagrams in section 8 for more detailed information.

Screw

Safety valve

outlet

Condensate

outlet pipe

Fig. 12

Return Flow Gas Cable entries

Fig.14

Electrical input

board cover

Appliance

terminal strip

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4.8.3 CONNECTING THE MAINS (230V) INPUT

230

V.a.c.

(see fig. 15)

Remove the terminal strip cover as described in

4.8.2. Pass the cable through the cable anchorage (see fig. 6). Connect the supply cable wires (earth, live & neutral) to their corresponding terminals on the appliance terminal strip. Ensure that the EARTH wire is left slightly longer than the others, this will prevent strain on the Earth wire should the cable become taut. Do not remove the 24V link wire (between terminals 4 & 6) unless additional external controls are to be fitted (see section 8). Re-fit the appliance terminal strip cover. The securing screw on the cable anchorage should now be tightened. This must be done before the control fascia is re-fitted in the upright position. The appliance casing and screws can now be re-fitted.

SECTION 5 COMMISSIONING

Fig. 15

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 residual from the installation of the system, consequently it is essential that the system be flushed in accordance with the following instructions.

5.3 INITIAL FILLING OF THE SYSTEM

Ensure both flow & return service valves are open, remove appliance casing as described in

4.8.1, identify the automatic air release valve and loosen the dust cap by turning cap anti-clockwise one full turn. IMPORTANT, THERE ARE NO MANUAL AIR RELEASE VALVES LOCATED ON THE APPLIANCE. Ensure all manual air release valves located on the heating system are closed. Using the method of filling as described in fig. 5, slowly proceed to fill the system. As water enters the system the pressure gauge will begin to rise. Once the gauge has reached 1bar close the filling valve and begin venting all manual air release valves, starting at the lowest first. It may be necessary to go back and top-up the pressure until the entire system has been filled. Inspect the system for water soundness, rectifying any leaks.

5.4 INITIAL FLUSHING OF THE SYSTEM

The whole of the heating system must be flushed both cold and hot as detailed in 5.7. Open all radiator or heating valves and the appliance flow & return service valves. Drain the boiler and system from the lowest points. Open the drain valve full bore to remove any installation debris from the boiler prior to lighting. Refill the boiler and heating system as described in 5.3.

5.5 PRE-OPERATION CHECKS

Before attempting to initial lighting of the appliance, the following checks must be carried out:

● ensure all gas service valves from the meter to

the appliance are open and the supply pipe has been properly purged;

● ensure the proper electrical checks have been

carried out (see 7.7), particularly continuity, polarity and resistance to earth;

● ensure the 3 amp fuse – supplied with the

appliance – has been fitted;

● ensure the system has been filled, vented, and

the pressure set to 1 bar;

● ensure the flue system has been fitted properly

and in accordance with the instructions;

● ensure all appliance service valves are open.

5.6 INITIAL LIGHTING

Ensure the electrical supply to the appliance is switched on. Switch the time clock or programmer to an ‘on’ position and ensure all external controls are also calling for heat.

The appliance will now operate as described in 1.3. Should the appliance fail to ignite, refer to 5.5 and/ or section 7 (fault finding).

5.7 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 manufacture products that have proved suitable for use with Vokera appliances. Vokera Ltd. cannot comment on the suitability of any other such product with our appliances.

5.7.1 INHIBITORS

See 3.11.

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5.8 OPERATING PARAMETERS

The Eclipse boiler is supplied with built-in parameter defaults (see 2.11), the following procedure can be used if any parameters require to be adjusted or changed.

● Press the MODE button until a FIXED decimal

point appears in LED 1 (see fig. 16).

● Press the STEP button until the desired

parameter is shown in LED 1.

● Using the +/- buttons, change the parameter

value (shown in LED 2).

● Press the STORE button to save the new value.

● Press the MODE button until no decimal point

is shown.

Fig. 16

STEP

OPERATING PARAMETER

Central heating mode

Central heating flow temperature

5.9 FUNCTIONAL PARAMETERS

These parameters should only be changed or adjusted by the commissioning engineer or service technician. To change or adjust the functional parameters, it is necessary to access the appliance engineer mode.

● Press and hold the MODE and STEP buttons

simultaneously, LED 1 should now show “C” (see fig. 17).

● Whilst continuing to hold down the MODE and

STEP buttons, using the +/- buttons, adjust LED 2 until it shows “33”.

● Press STORE.

● LED 2 will now flash once, the MODE and

STEP buttons can now be released.

● Press the MODE button until it shows a FIXED

decimal point (see fig. 16).

● Press the STEP button until it shows the desired

parameter (LED 1).

● Adjust the value (LED 2) using the +/- buttons

● Press STORE to save the new setting.

● Press the RESET button to exit the appliance

engineer mode.

IMPORTANT

Under no circumstances should any parameters

- other than those shown - be changed or adjusted. Please refer to section 7 before making any adjustments to the fan speed parameters of the boiler.

5.10 RANGE RATING

The output of the boiler is automatically adjusted by a continuous air/gas modulation system. The system is controlled by the NTC thermistors (flow & return temperature sensors) which ensures stability of temperature irrespective of load conditions. However the appliance also has a range rating facility which can be used to limit the maximum output if required. Please refer to section 7 for more details.

VALUE

00 = off

DEFAULT SETTING

01 = on

01 = on Variable between 20° 90°C

75°C

Fig. 17

5.11 SETTING THE SYSTEM DESIGN PRESSURE

The design pressure should be a minimum of 1 bar and a maximum of 1,5 bar.

The actual reading should ideally be 1 bar plus equivalent height in metres (0,1 bar = 1 metre) to the highest point in the system above the base of the appliance (up to the maximum of 1,5 bar total). N.B. The safety valve is set to lift at 3 bar/30 metres/45 psig.

To lower the system pressure to the required value, pull lever on head of safety valve to release water until the required figure registers on the pressure gauge (see fig. 1).

5.12 REGULATING THE CENTRAL HEATING SYSTEM

Fully open all radiator and circuit valves and run the appliance for both heating and hot water until heated water is circulating. If conditions are warm remove any thermostatic heads. Adjust radiator return valves and any branch circuit return valves until the individual return temperatures are correct and are approximately equal.

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STEP

A b J n o

FUNCTION

PARAMETER

Anti-cycle Pump over-run Max. fan speed Min. fan speed Soft-light fan

speed

VALUE DEFAULT SETTING

216 226

Variable between 0-30 (where 1=10,2 seconds)

Variable between 3-99 (where 1=1 minute)

Variable between

13-55

(where 1=100 RPM) Variable between 13-55

(where 1=100 RPM) Variable between 0-100 (where 0.0=100%)

Variable between 0-30 (where 1=10,2 seconds)

Variable between 3-99 (where 1=1 minute)

Variable between 13-55 (where 1=100 RPM)

Variable between 0-100 (where 80=80%)

9 (91,8 seconds) 10 (10 minutes) 40 (4000 RPM) 13 (1300 RPM) 100 (%)

226216

9 (91,8 seconds) 10 (10 minutes) 55 (5500 RPM)

17 (1700 RPM) 80 (%)

5.13 FINAL CHECKS

● ENSURE ALL TEST NIPPLES ON THE AP-

PLIANCE GAS VALVE ARE TIGHT AND HAVE BEEN CHECKED FOR SOUNDNESS.

● ENSURE THE APPLIANCE FLUE SYSTEM IS

FITTED CORRECTLY AND IS PROPERLY SECURED.

● ENSURE ALL PIPE WORK IS RE-CHECKED

FOR SOUNDNESS.

● RE-FIT APPLIANCE CASING.

● COMPLETE APPLIANCE LOGBOOK.

Complete details of the boiler, controls, installation and commissioning in the logbook supplied with the boiler. This is an important document, which must be correctly completed and handed to the user. Failure to install and commission the appliance to the manufacturers instructions may invalidate the warranty.

SECTION 6 SERVICING

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, once per year should be adequate.

It is the law that any servicing work is carried out by a competent person such as a Vokera engineer, an approved service agent, British Gas, or other CORGI registered personnel.

The following instructions apply to the appliance and its controls, but it should be remembered that the central heating system will also require attention from time to time.

6.2 ROUTINE ANNUAL SERVICING

● Check the operation of the appliance and ensure

it functions as described in section 7.

● Compare the performance of the appliance

with its design specification. The cause of any noticeable deterioration should be identified and rectified without delay.

● Thoroughly inspect the appliance for signs of

damage or deterioration especially the flue system and the electrical apparatus.

● Check and adjust – if necessary – the system

design pressure (see 5.11).

5.14 INSTRUCTING THE USER

Hand over all documentation supplied with this appliance – including these instructions – and explain the importance of keeping them in a safe place.

Explain to the user how to isolate the appliance from the gas, water and electricity supplies, and the locations of all drain points.

Show the user how to operate the appliance and its associated controls correctly.

Show the user the location of the filling valve and how to top-up the system pressure correctly, and show the location of all manual air release points.

Explain to the user how to turn off the appliance for both long and short periods, and advise on the necessary precautions to prevent frost damage.

● Ensure both the burner and heat exchanger are

clean and free from any debris or obstruction.

● Carry out an analysis of the flue gases (see

7.4), and visually check the condition of the entire flue assembly.

● Compare the results with the appliance design

specification. Any deterioration in performance must be identified and rectified without delay.

● Inspect all joints for signs of leakage and repair

if necessary.

● Refer to the commissioning section and/or re-

placement of parts section for detailed instruction if required.

6.3 REPLACEMENT OF COMPONENTS

Although it is anticipated that this appliance will give years of reliable, trouble free service, the life span of components will be determined by factors such as operating conditions and usage. Should the appliance develop a fault, the fault finding section will assist in determining which component is malfunctioning.

6.4 COMPONENT REMOVAL PROCEDURE

To remove a component, access to the interior of the appliance is essential. Isolate the appliance from the electrical supply and remove the fuse. And when necessary, close all service valves on

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the appliance, remove the appliance casing as described in section 4.8.1. Drain the water content from the appliance via the safety valve. Ensure some water absorbent cloths are available to catch any residual water that may drip from the appliance or removed component. Undertake a complete commissioning check as detailed in section 5, after replacing any component.

ALWAYS TEST FOR GAS SOUNDNESS IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED OR DISTURBED.

6.5 PUMP HEAD (see fig. 18)

Carry out component removal procedure as described in 6.4. Using a 4mm Allen key or ‘T’ bar, unscrew and remove the four Allen screws that hold the pump in position, pull firmly on the pump head to release it from the base. Disconnect the electrical leads. Replace in the reverse order.

6.8 PRESSURE GAUGE (see fig. 20)

Carry out component removal procedure as described in 6.4. Remove pressure gauge locking screw, located on manifold, and withdraw the pressure gauge pipe, locate the spring tabs on the pressure gauge body, push and hold tabs in, to enable extraction of the gauge from its location. Replace in the reverse order.

Manifold

Pressure gauge connection

Locking screw

Fig. 20

Fig. 18

6.6 SAFETY VALVE (see fig. 19)

Carry out component removal procedure as described in 6.4. Disconnect the outlet pipe from the safety valve. Remove safety valve locking screw from the underside of the appliance manifold. Pull safety valve free from manifold. Replace in the reverse order.

Safety valve

Locking screw

Fig. 19

6.7 AUTOMATIC AIR RELEASE VALVE (AAV)

Carry out component removal procedure as described in 6.4. Using a suitable pair of pump pliers, unscrew the AAV from its position. Replace in the reverse order.

6.9 NTC THERMISTORS (temperature sensors)

Carry out component removal procedure as described in 6.4.

Flow & return sensors (see fig. 1 & 21)

Pull back protective boot and remove the 2 spade connectors. Slacken and remove the 2 securing screws. Replace in the reverse order.

Screw

Fig. 21

6.10 PRINTED CIRCUIT BOARD (PCB) (see fig. 22)

Carry out component removal procedure as described in 6.4.

● Locate and remove the 4 screws that secure

the PCB housing cover, then remove cover.

● After carefully taking note of all wiring connections,

disconnect all wiring from the PCB.

● Locate and remove the PCB housing securing

screws, remove PCB housing.

● Remove the 4 screws that secure the

transformer to the PCB housing.

● Locate and remove the 3 screws that secure

the PCB to the housing.

Replace in the reverse order.

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Housing

P.C.B.

Replace in the reverse order. Please note, ensure all seals are in good condition, taking care to ensure they are replaced correctly.

Fig. 22

6.11 GAS VALVE (see fig. 23)

Carry out component removal procedure as described in 6.4. The gas valve must be changed as complete unit. Unclip and remove the air chamber cover. Disconnect the electrical plug from the gas valve. Disconnect silicone tube from gas valve regulator. Slacken and unscrew gas valve inlet and outlet connections. Please note, the sealing washers must be discarded and replaced with new sealing washers. The gas valve can now be removed. Replace in the reverse order. Refer to section seven for detailed instructions on how to set-up the gas valve. WARNING, A GAS SOUNDNESS

CHECK MUST BE CARRIED OUT.

6.12 FAN (see fig. 23)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber cover. Disconnect the electrical plug from the fan. Locate and remove the 4 bolts that secure the fan to the pre-mix manifold. Replace in reverse order.

Cover

Securing nuts

Gas valve outlet

connection

Fig. 24

6.14 ELECTRODE (see fig. 24 & 25)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber cover. Remove the electrode lead. Remove the 2 screws that secure the electrode to the combustion cover, and gently withdraw the electrode. Replace in the reverse order, ensuring that the electrode seal is in good condition and that the combustion cover insulation board is undisturbed.

All dimensions in mm.

Spark

electrode

Silicone tube

Outlet

Gas valve

Inlet

Fig. 23

Fan securing bolts

6.13 BURNER (see fig. 24)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber cover. Locate and remove the 8 nuts (10mm) securing the pre-mix manifold/burner assembly. Disconnect the gas valve outlet pipe at its connection to the pre-mix manifold. Disconnect the silicone pipe from the pre-mix manifold. Gently pull away the fan/pre-mix manifold assembly from the heat exchanger. Remove the earth wire from the burner earth tab and gently lift the burner from its location.

Pre-mix manifold

Fan

Fig. 25

6.15 INJECTOR (see fig. 26)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber cover. Remove the fan as detailed in 6.12 using a 17mm socket, locate and unscrew the injector. Replace in the reverse order.

Burner plate

Injector

Fan

Fig. 26

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6.16 HYDRAULIC MANIFOLD ASSEMBLY (see fig. 28)

Carry out component removal procedure as described in 6.4. Refer to figure 27 for an exploded view of the manifold and its internal components. Care should be taken when removing the manifold cover or when levering the automatic bypass from its position. Replace in the reverse order, ensuring that the components are seated and located properly.

NOTE

It may be prudent to replace the seals and/or diaphragm whenever tha manifold assembly is disturbed.

6.17 CONDENSE TRAP (see fig. 27)

Carry out component removal procedure as described in 6.4. Remove the PCB housing as described in 6.10. Disconnect the pressure switch tube from the condense trap. Disconnect both the inlet and outlet connections from the trap. Carefully withdraw the trap, keeping it upright to a void spillage . Replace in the reverse order.

Fig. 27

6.18 CONDENSE PRESSURE SWITCH (see fig. 29)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber cover. Disconnect the electrical wiring and pressure tube from the pressure switch. Remove the retaining screws and/or clip. Replace in the reverse order.

Condense pressure switch

Fig. 29

6.19 COMBUSTION COVER (see fig. 30)

Carry out component removal procedure as described in 6.4. Unclip and remove the air chamber cover. Remove the gas valve as described in 6.11. Remove the condense pressure switch as described in 6.20. Disconnect the electrical connection from the fan, disconnect the spark electrode lead and earth wire from the spark electrode. Locate and remove the twelve 10mm securing nuts. Carefully remove the combustion cover from the locating studs. Remove the combustion cover from the air chamber, withdrawing it at a slight angle from the right hand

Manifold

Fig. 28

Auto-bypass assembly

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side. Replace in the reverse order, ensuring that all seals and insulation panels are undamaged and in good condition.

Fig. 30

6.20 EXPANSION VESSEL (see fig. 1)

Due to the compact design of this appliance, removal and/or replacement of the expansion vessel may require the appliance to be removed from the wall, if this is deemed impractical, an external expansion vessel may be fitted to the return pipe as close to the appliance as possible.

6.20.1 EXPANSION VESSEL (removal)

Carry out component removal procedure as described in 6.4. Disconnect the flue from the appliance. Disconnect the expansion pipe from the hydraulic manifold. Locate and remove the 2 screws that secure the vessel to the rear frame. The expansion vessel can now be removed. Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly.

6.21 STATUS PCB (see fig. 14)

Carry out component removal procedure as described in 6.4. Refer to 4.8.2 for details on how to remove the appliance terminal strip cover. Carefully note the positions of all connections. Remove the wiring and plugs from the PCB. Locate and remove the securing screws. Remove PCB. Replace in the reverse order, ensuring correct configuration of wiring.

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SECTION 7 CHECKS, ADJUSTMENTS, AND FAULT FINDING

1500 2000 2500 3000 3500 4000 4500 5000 5500

7.1 CHECKING APPLIANCE OPERATION

When carrying out any repairs or servicing to the appliance, the relevant commissioning and/or set-up 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 the electrical integrity of the appliance.

7.3 CHECKING/ADJUSTING FAN SPEED

To check the fan speeds, you must first access the engineer mode. The fan speed should only be changed or adjusted by the commissioning engineer or service technician (see 5.9). To access the appliance engineer mode:

● press and hold the MODE and STEP buttons

simultaneously, LED 1 should now show ‘C’ (see fig. 17).

7.2 APPLIANCE MODE OF OPERATION

● whilst continuing to hold down the MODE and

STEP buttons, using the +/- buttons, adjust

7.2.1 START-UP

When power is first supplied to the appliance it will go through a self-purge procedure whereby the pump & fan will be momentarily energised. The boiler will then operate in either one of the following modes:

● At rest

● Heating and/or Hot Water request

7.2.2 AT REST

When there is no demand for heating or hot water and the appliance remains inactive for a period of 24 hours, the pump will be energised for a few

7.3.1 MAXIMUM FAN SPEED

LED 2 until it shows ‘33’.

● press STORE

● LED 2 will now flash twice, the MODE and

STEP buttons can now be released

● press the MODE button until it shows a FIXED

decimal point (see fig. 16).

● Press the STEP button until it shows the

letter ‘J’ (LED 1).

● Adjust the value (LED 2) using the +/- buttons

(see fig. 31).

● Press STORE to save the new setting.

moments to prevent it from seizing. Should the flow temperature sensor fall below 7°C the pump will be energised. If the flow sensor temperature falls to below 3°C the burner will be lit and the appliance will operate at the minimum output until the temperature of the flow sensor reaches 10°C, whereupon the pump will continue to run in pump

7.3.2 MINIMUM FAN SPEED

● Press the STEP button until it shows the letter

‘N’ (LED 1).

● Adjust the value (LED 2) using the +/- buttons

until it shows ‘17’.

● Press STORE to save the new setting.

over-run mode.

7.3.3 SOFT-LIGHT FAN SPEED

7.2.3 MODE OF OPERATION (heating/hot water request)

When there is a request for heat via the progremmer and/or external controls, the pump and fan will be activated via the flow temperature

● Press the STEP button until it shows the letter

‘O’ (LED 1).

● Adjust the value (LED 2) using the +/- buttons

until it shows ‘80’

● Press STORE to save the new setting.

sensor. When the fan is sensed to be operating correctly, the ignition sequence commences. The

Output BTU/H

speed of the fan and therefore the output of the boiler is determined by the temperature of the water sensed by the flow & return temperature sensors, consequently a high temperature at the flow sensor results in a lower fan speed. As the water temperature increases, the temperature sensors – located on the flow & return pipes of the boiler – reduce the fan speed via the electronic circuitry. Depending on the load, either the water temperature will continue to rise until the set point is achieved or the water temperature will fall whereby fan speed will increase relative to the output required. When the boiler has reached the set point, the burner will switch off. The built-in anti-cycle device prevents the burner from relighting for an adjustable period of time (factory default is 3 minutes). When the temperature of the flow sensor falls below the set-point, the burner will re-light.

102,360

85,300

68,240

51,180

34,120 17,060

Fig. 31

50°C flow & 30°C return temperature

80°C flow & 60°C return temperature

Fan speed in RPM

7.3.4 FAN SPEED CONFIRMATION

To verify that the new fan speed has been accepted into the memory:

● press and hold the MODE and ‘+’ buttons for 3

Seconds;

● allow the boiler to purge (approx. 10 seconds);

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● when ‘H’ is displayed in LED 1, press the

MODE button until LED 1 shows an alternating cursor (see fig. 32);

● when the digit is to the left, LED 2 shows the first

two digits of the maximum fan speed;

● when the digit is to the right, LED 2 shows the

last two digits of the maximum fan speed;

● press the MODE button until a fixed decimal is

shown in LED 1;

● press and hold the MODE and ‘-–‘ buttons until

‘L’ appears in LED 1;

● press the MODE button until LED 1 shows an

alternating cursor (see fig. 32);

● when the digit is to the left, LED 2 shows the first

two digits of the minimum fan speed;

● when the digit is to the right, LED 2 shows the

last two digits of the minimum fan speed.

NOTE

The actual fan speed displayed may not exactly match what has been programmed. However, providing the displayed speed is within 200 RPM (+/-) of the programmed speed, this is acceptable.

7.3.5 EXIT ENGINEER MODE

Press the RESET button to exit the appliance engineer mode.

Digit to the left

Digit to the right

Fan speed shown is 4198 RPM

LED 2 showing first two digits of actual fan speed

LED 2 showing the last two digits of the actual fan speed

Fig. 32

7.4.1 MINIMUM SETTING

With the boiler operating at minimum output the CO2 reading should be 8.6% (+/- 0.2%). If the CO reading is correct, proceed to 7.4.2. If the CO reading is incorrect, the minimum gas pressure must be adjusted as follows:

● using a suitable screwdriver, very slowly turn the

minimum adjustment screw (see fig. 33) – clockwise to increase, counter clockwise to decrease – until the correct value is displayed on the CO2 analyser (allow time for the analyser to stabilise).

● using the procedure detailed in 7.3.4, change

the fan speed momentarily from minimum to maximum, then back to minimum.

● check that the correct value is still being

obtained. If not, repeat the above procedure.

7.4.2 MAXIMUM SETTING

The maximum setting must only be checked and/or adjusted after the correct minimum setting has been verified. Using the procedure detailed in 7.3.4, change the fan speed from minimum to maximum.

With the boiler operating at maximum output the CO2 reading should be 8.6% (+/- 0.2%). If the CO reading is correct, press the RESET button to exit the appliance engineer mode. If the CO2 reading is incorrect, the maximum gas pressure must be adjusted as follows:

● using a suitable screwdriver, very slowly turn the

maximum adjustment screw (see fig. 33) – clockwise to increase, counter clockwise to decrease – until the correct value is displayed on the CO2 analyser (allow time for the analyser to stabilise).

● using the procedure detailed in 7.3.4, change

the fan speed momentarily from maximum to minimum, then back to maximum.

● check that the correct value is still being

obtained. If not, repeat the above procedure.

● press the RESET button to exit the appliance

engineer mode.

Remove the analyser test probe from the analysis test point and refit cap. Refit the air chamber cover. Refit appliance casing.

NOTE

You should ensure that all radiators or heat emitters are fully open during the above procedures. This will ensure that the fan speed (output) of the boiler is not compromised due to a high flow temperature.

2 2

7.4 ADJUSTING THE GAS VALVE THE GAS VALVE MUST BE SET-UP OR

ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYSER.

Remove the appliance casing as detailed in 4.8.1. Unclip and remove the air chamber cover. Set the flue gas analyser to read CO2 and insert the probe into the flue analysis test point (see fig. 1). Using the procedure as detailed in 7.3 & 7.3.4 respectively, enter the appliance engineer mode and set the fan speed to minimum.

Fig. 33

Maximum screw

Minimum screw

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7.5 LED 1 STATUS CODES

When the boiler is operating normally (without fault), LED 1 displays the current status of the boiler whilst LED 2 will normally display the relevant outlet temperature.

Status

Standby

Purge

Ignition

Heat request mode

N/A

Fan-speed low

Built-in delay

CH over-run

DHW over-run

High temperature

LED 1

0 1 2 3 4 5 6 7 8 9

Flow/return temp. Flow/return temp. Flow temperature

Return temperature

Flow/return temp.

In addition to the above operating status codes, the boiler may also display intermittent anomaly codes as featured below.

LED 1

LED 2

E E E E E

18 19 24 25 30

Flow sensor 35°C higher than return

Insufficient fan speed after 1 minute

Reason for lockout

Flow sensor above 95°C

Return sensor above 95°C

Temperature differential inverted

Rapid temperature rise

7.6 LOCKOUT FAULT CODES

The built-in fault diagnostic system automatically displays a unique fault code that can be used to determine why the boiler has locked out.

LED 1

LED 2

0 1 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 24 26 30

Reason for lockout

False flame

24V short circuit

No flame detected

Internal fault (PCB)

Lockout then power off

Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB)

Flow/return sensors reversed

Internal fault (PCB)

Difference between flow & return

temperature too high 4 4 4 4 4

31 32 33 36 37

Short circuit on flow sensor

Short circuit on return sensor

Internal fault (PCB)

Open circuit on flow sensor

Open circuit on return sensor

LED 2

N/A

sensor

LED 1

LED 2

4 4 4 4 4 5 5 5 5 9 9 9 9

38 41 42 44 60 28 29 61 65 12 18 19 25

Reason for lockout

Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB)

No signal from fan No signal from fan

Internal fault (PCB)

Insufficient fan speed

Condense trap blocked

Flow temperature too high

Return temperature too high

Rapid temperature rise

7.7 DIAGNOSTIC RECALL

In addition to displaying a fault code, the appliance memorises the operating conditions at the time of lockout, this information can be recalled and displayed using the following procedure:

● access the appliance engineer mode as detailed

in 5.9.

● press the MODE button until a flashing ‘1’

appears in LED 1.

● press the STEP button to recall the information

as detailed below.

LED 1 shows 1

LED 2 shows

00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 24 26 30 31 32 33 36 37 38 41 42 44 60 28 29 61 65 12 18 19 25

24V short circuit

No flame detected

Internal fault (PCB)

Lockout then power off

Flow/return sensors reversed

Insufficient gas pressure

Internal fault (PCB)

Short circuit on flow sensor

Short circuit on return sensor

Internal fault (PCB)

Open circuit on flow sensor

Open circuit on return sensor

Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB) Internal fault (PCB)

No signal from fan No signal from fan

Internal fault (PCB)

Insufficient fan speed

Condense trap blocked

Flow temperature too high

Return temperature too high

Rapid temperature rise

Reason

False flame

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LED 1 shows 2

LED 2 shows

0 1 2 3 4 5 6 7 8 9

Reason

Standby

Purge

Ignition

Heat request

N/A

Fan-speed low

Built-in delay

Pump over-run

N/A

High temperature

LED 1 shows 3

LED 2 shows °C

Temperature of flow sensor at time

of lockout

LED 1 shows 4

LED 2 shows °C

Temperature of return sensor at

time of lockout

Press the RESET button to exit the appliance engineer mode.

7.8 TEMPERATURE SENSOR VIEWING MODE

The current temperature of the two temperature sensors can be viewed individually via the LED display, in addition the set-point of the flow or return sensor can also be viewed (depending on mode of operation). To access the viewing mode:

● press the MODE button until a flashing decimal

point is displayed in LED 1.

● press the STEP button to display the relevant

information in LED 2 (see below).

LED 1 SHOWS

1 2 3 4 5 6 7 8

Set-point (dependant on mode)

LED 2 SHOWS

Flow sensor temperature

Return sensor temperature

N/A N/A N/A

Temperature rise per second

Return rise per 8 seconds

7.10 EXTERNAL FAULTS

Before carrying out any fault-finding or component replacement, ensure the fault is not attributable to any aspect of the installation. For example external wiring fault, service valves closed, gas supply turned off, etc. The table below may assist in identifying some common installation faults.

Fault code Displayed

Possible cause

Gas turned off

202

Air in gas pipe

Insufficient gas

Pump seized

918 436

Flow/return service valve

Flow sensor cable

disconnected

437

Return sensor cable

disconnected

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 and the earth wire of the appliance supply cable. The resistance should be less than 1 ohm. If the resistance is greater than 1 ohm check all earth wires and connectors for continuity and integrity.

7.11.2 SHORT CIRCUIT CHECK

Isolate the appliance from the electrical supply, and using a suitable multi-meter, carry out a short circuit test between the Live & Neutral connections at the appliance input board (see fig.15). Repeat above test on the Live & Earth connections at the appliance input board (see fig.15).

NOTE

Should it be found that a fuse has failed but no fault is indicated, a detailed continuity. Check will be required to trace the fault. A visual inspection of components may also assist in locating the fault.

closed

7.9 CHECKING THE EXPANSION VESSEL

7.11.3 POLARITY CHECK

Carry out the component removal procedure as described in 6.4. You must ensure that the boiler is completely drained of water. Using a suitable pressure gauge, remove dust cap on expansion vessel and check the charge pressure. The correct charge pressure should be

1.0 bar ± 0.1 bar. If the charge pressure is less, use a suitable pump to increase the charge.

Please note, you must ensure the safety valve is in the open position whilst re-charging takes place. Replace the dust cap and carry out the relevant commissioning procedure.

With the appliance connected to the electrical supply and using a suitable Multi-meter, carry out the following voltage tests:

● connect test leads between the Live & Neutral

connections at the appliance input board (see fig.15). The meter should read approximately 230V ac. If so proceed to next stage. If not, see

7.11.4.

● connect test leads between the Live & Earth

connections at the appliance input board (see fig.15). The meter should read approximately 230V ac. If so proceed to next stage. If not, see

7.11.4.

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● Connect test leads between the Neutral & Earth

connections at the appliance input board (see fig.15). The meter should read approximately 0 – 15Vac. If so polarity is correct. If not, see

7.11.4.

7.11.4 REVERSED POLARITY OR SUPPLY FAULT

Repeat the above tests at the appliance isolator, if testing reveals correct polarity and/or supply at the isolator, re-check wiring and connections between the isolator and the appliance. If tests on the isolator also reveal reversed polarity or a supply fault, consult the local electricity supplier for advice.

7.11.5 RESISTANCE TO EARTH CHECK

Isolate the appliance from the electrical supply, and using a suitable multi-meter carry out a resistance test. Connect test leads between the Live & Earth connections at the appliance input board (see fig.15). If the meter reads other than infinity there is a fault that must be isolated, carry out a detailed continuity check to identify the location of the fault.

7.12.1 FAULT FINDING TESTS

If a lockout code is displayed on LED’s 1 & 2, please refer to 7.6 for the cause of the lockout.

FAULT

No display, boiler

inactive

No display, pump

running

No display, pump

running, fan speed

alternating

No display, boiler

working okay

Pump failure

Fan fault

Ignition fault

7.12.2 WIRING DIAGRAMS

Figures 35 & 36 indicate the positions of all plugs, fuses and internal wiring configuration.

GO TO

Test 1

Then 1A

Test 1A

Test 2 Test 3 Test 4

IMPORTANT

These series of checks must be carried out before attempting any fault-finding procedures on the appliance. On completion of any task that required the disconnection and re-connection of any electrical wiring or component, these checks must be repeated.

7.11.6 FUSES

The appliance is equipped with spare fuses. These fuses are located on the covers of the terminal strip and main PCB respectively. If a fuse has blown it is usually indicative of an external wiring fault or a faulty component such as the pump, fan, valve actuator, etc. Under no circumstances should a blown fuse be replaced with one of a higher rating.

7.12 FAULT FINDING BEFORE ATTEMPTING ANY FAULT

DIAGNOSIS OR REPAIR THE FOLLOWING PROCEDURE SHOULD BE CARRIED OUT:

● carry out the relevant electrical checks as

detailed in 7.11;

● disconnect any external wiring from the

appliance terminal strip (terminals 4 & 6) and replace with a solid link wire;

● ensure the appliance is protected – externally –

by a 3 amp fuse.

IMPORTANT The Eclipse boiler utilises 24V switching. Any

external controls that are directly connected to the boiler must be suitable for 24V applications and shall be voltage free. Under no circumstances should a 230V supply be connected to terminals 4 & 6 of the appliance terminal strip.

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7.12.3 FAULT FINDING TEST ‘1’

YES

IS THERE

230V AT

YES

PLUG X1 (L & N)

YES

IS THERE

230V AT

PLUG M6 ON INPUT

BOARD?

TEST1

SWITCH ON ELECTRICAL

SUPPL Y T O BOILER

IS THERE

230V AT

PLUG M5 ON INPUT

BOARD?

CHECK

FUSE ON

INPUT BOARD

CHECK

INCOMING

SUPPLY

END OF

TEST

7.12.4 FAULT FINDING TEST ‘1A’

YES

IS FUSE

F1 OK?

CHECK CONTINUITY

BETWEEN

INPUT PCB &

MAIN PCB

YES

A T TERMINALS

IS THERE 10-14 Vdc

1 & 7 OF

PLUG X7

YES

TEST 1A

IS THERE

230V AT

PLUG X1

(L & N)

IS THERE 10-14 Vdc

A T TERMINALS

1 & 7 OF PLUG X7a

OF DISPLAY PCB

YES

GO TO

TEST 1

YES

REPLACE

PCB

YES

ARE FUSES F2 & F3

OK?

YES

24Vac

A T TERMINALS

6 & 7 OF

PLUG X10

REPLACE

FUSE/S

230V AT

TERMINALS

1 & 3 OF

PLUG X10

REPLACE

TRANSFORMER

REPLACE

PCB

REPLACE

FUSE

REPLACE

DISPLAY PCB

CHECK

CONTINUITY OF

RIBBON CABLE

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7.12.5 FAULT FINDING TEST ‘2’

YES

TEST 2

PUMP FAULT

230V ON

TERMINALS P & N

OF PLUG X1

230V AT

L & N OF PUMP

YES

REPLACE

PUMP

7.12.6 FAULT FINDING TEST ‘3’

CHECK

CONTINUITY

YES

REPLACE

YES

PCB

F1 FUSE ON

MAIN PCB OK

TEST 3

FAN

FAULT

IS "5"

DISPLAYED

AT LED 1

REPLACE

FUSE

REPLACE

PCB

IS THERE 4-9 Vdc

A T TERMINALS

1 & 2 ON

PLUG X2

YES

CHECK

CONTINUITY

YES

IS THERE 4-9 Vdc

AT GREY & PINK

WIRE OF FAN

REPLACE

FAN

YES

REPLACE

PCB

YES

FAN IS

OK?

YES

IS THERE 1,8-2 Vdc

A T TERMINALS

2 & 4 ON

PLUG X2

DOES

FAN RUN

YES

REPLACE

YES

IS THERE

1,8-2 Vdc

AT GREY & BLUE

WIRE OF FAN

CHECK

CONTINUITY

FAN

REPLACE

FAN

IS THERE 30-35 Vdc

AT RED & GREY

WIRE OF FAN

YES

CHECK

CONTINUITY

PRESS RESET

ENSURE HEAT

REQUEST

IS THERE 30-35 Vdc

A T TERMINALS

2 & 3 OF

PLUG X2

REPLACE

PCB

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7.12.7 FAULT FINDING TEST ‘4’

YES

TEST 4

IGNITION

FAULT

SPARK

AT ELECTRODE

CHECK:

SPARK GAP,

ELECTRODE & LEAD,

EARTH

CONNECTION

YES

REPLACE

PCB

OK?

IS IONISATION

VOLTAGE

ABOVE 2,0 Vdc

RECTIFY &

REST ART TEST

YES

DOES BURNER STAY LIT

YES

REPLACE

PCB

YES

FINISH

CHECK: GAS

SILICONE PIPE &

NOZZLE, VALVE

REGULATOR

YES

REPLACE

GAS VALVE

IONISATION CHECK: Terminal 5 on plug X2 to Earth

DOES

BURNER

LIGHT

YES

SUPPLY,

OK?

24 VAC

AT GAS VALVE

RECTIFY &

REST ART TEST

YES

REPLACE

PCB

YES

CHECK

CONTINUITY

ARE

ELECTRODE

& LEAD OK

24 VAC

A T TERMINALS

11 & 12 OF PLUG X2

REPLACE &

REST ART TEST

REPLACE

PCB

SECTION 8 WIRING DIAGRAMS

8.1 IMPORTANT The Eclipse boiler utilises 24V switching. Any

8.2 INSTALLATION OF VOKERA TIMECLOCK (part no. 201 or 202)

● Isolate the appliance from the electrical supply

8.3 EXTERNAL CONTROLS IMPORTANT (see 8.1)

and remove the casing as described in 4.8.1.

● Gain access to the appliance terminal strip as

detailed in 4.8.2.

● Remove the square blanking plate from the

clock aperture of the control panel.

● Insert the clock bezel (supplied with boiler) into

the aperture and secure in place with the 2 locking tabs.

● Connect the wires to the clock as shown in fig. 34.

● Mount the clock to the clock bezel using the

screws provided.

● Remove the factory fitted link between terminals

4 & 6 of the appliance terminal strip.

● Connect the clock wires to the appliance terminal

strip as shown in fig. 34.

● Replace the input board cover and appliance casing

once the clock installation has been completed.

Vokera recommend the use of the “S” plan system of controls (see fig. 34B). However the “Y” plan system of controls can be adapted for use with the Eclipse by means of a relay (see fig.34A).

NOTE

Guidance on the recommended practice for the installation of external controls, can be found in CHeSS – HC1/HC2 (www.energy-efficiency.gov.uk).

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Fig. 34A

Fig. 34

“Y” plan installations are only possible with the addition of an external relay as above. The switching contacts of the relay must be suitable for 24vac at 100ma, the relay coll must be suitable for 24vac

“S” plan with external programmer

Fig. 34B

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FUNCTIONAL DIAGRAM

NOTE. L-N-E CONNECTION MUST NOT BE INTERCHANGED

Fig. 35

Key

R.T. Room thermostat F Fan P Pump S1 Flow thermistor (NTC) S2 Return thermistor (NTC) L1 Led OK (green)

L2 Led alarm (blink red) F1 Fusibile 2 AF F.se/I.E. Spark/sense electrode OPE Gas valve solenoids RL3V 3 way relay P.S. Pressure switch (NC)

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FUNCTIONAL DIAGRAM

NOTE. L-N-E CONNECTION MUST NOT BE INTERCHANGED

CONTROL SWITCHING OF TIME CLOCK AND ROOM THERMOSTAT IS 24 vdc

Fig. 36

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LOCATION

Appliance terminal strip Appliance terminal strip Appliance terminal strip Appliance terminal strip Appliance terminal strip Appliance terminal strip Appliance terminal strip Appliance terminal strip Appliance terminal strip

TERMINAL

1 2 3 4 5 6 7 8 9

DESIGNATION

Earth connection

Live connection

Neutral connection

24V connection

Spare

24V connection

Spare Spare Spare

PCB

Main PCB Main PCB

Main PCB Main PCB Main PCB Main PCB Main PCB Main PCB Main PCB

PCB

display PCB display PCB display PCB

PLUG or CONNECTION

X1 X2

X3 X7 X8

X10

F1 F2 F3

PLUG or CONNECTION

X7A

X20

DESIGNATION

Incoming 230V supply & pump connection

Fan connection, condense pressure switch

connection, gas valve connection

Sensor connections

Display board connection

Unused

External transformer connection

2AF fuse 2AF fuse 4AT fuse

DESIGNATION

Connection from main PCB

Unused

Status LED connection

INTERNAL COMPONENT

Gas valve

Fan

Condense pressure switch

Flow sensor

Return sensor

Pump

External transformer

24V connection for time clock or

room thermostat

Status LED

SYMBOL

OPE

P.S.

S1 S2

R.T.

L1 L2

DESIGNATION

Plug X2 on main PCB Plug X2 on main PCB Plug X2 on main PCB Plug X3 on main PCB Plug X3 on main PCB Plug X1 on main PCB

Plug X10 on main PCB

Appliance terminal strip (terminals& )

Plug X20 on display PCB

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SECTION 9 EXPLODED DIAGRAMS

141516

17 18

Pos Description Part N.

1 FRAME ASSEMBLY 8344 8344 6 GUARD 9814 9814 9 GREEN-RED LED 8921 8921 10 2A INLINE FUSE (5 pcs.) 8968 8968 11 DISPLAY BOARD 8918 8918 12 INSTRUMENTAL PANEL 8346 8346 13 QUICK PRIMER PRESSURE GAUGE 8968 8968 14 HOLE COVER 9709 9709 15

ADHESIVE FILM FOR INSTRUMENTAL PANEL

216 ESS 226ESS

8349 8349

16 PLASTIC TRADE MARK LABEL 1748 1748 17 PLASTIC TRADE MARK LABEL BRACKET 2138 2138 18 DOOR PANEL 6168 6168 19 DOOR PANEL 5254 5254 20 FLANGE 5304 5304 21 MOUNTING SPINDLE 5301 5301 22 PIN 5303 5303 23 SPRING FOR PANEL 5275 5275 27 O-RING 9289 9289 29 SCREW (20 pcs.) 5080 5080

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8 18

Pos Description Part N.

216 ESS 226ESS

1 CASE 01005170 01005170 4 3A FUSE 3478 3478 6 CASE CLIP (10 pcs.) 5588 5588 8 WIRED TRANSFORMER 1048 1048 9 PRINTED CIRCUIT BACK

SEMI-BOX 1037 1037

11 PRINTED CIRCUIT BOARD

MTN SETTING 10022687 10022686

11 PRINTED CIRCUIT BOARD

LPG SETTING 10022690 10022689 12 3,15A INLET FUSE 8969 8969 13 2A INLET FUSE (5 pcs.) 8968 8968 14 PRINTED CIRCUIT FRONT

SEMI-BOX 8862 8862 15 BLACK VELCRO 1041 1041 18 SCREW (20 pcs.) 5080 5080 23 EDGE CLIP (20 pcs.) 5128 5128

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5 4

24 3

19 20

28 29

Pos Description Part N.

1 EXPANSION VESSEL 7204 7204 2 PIPE 1011 1011 3 NTC SENSOR 1194 1194 4 WASHER (10 pcs.) 5023 5023 5 CONNECTION 3/4” 8873 8873 6 PIPE 10022445 10022445 7 HEATING MANIFOLD 10020799 10020799 8 HEATING BY-PASS BACK PLUG 2911 2911 9 EXPANSION VESSEL PIPE 7207 7207 10 HEATING BY-PASS VALVE 1734 1734 11 RUBBER DIAPHRAGM 6872 6872 12

FLOW MANIFOLD FRONT PLATE 13 BRASS CAP 8866 8866 14 SAFETY V ALVE 1806 1806 15 WASHER (10 pcs.) 5203 5203 16 HEA TING W ATER COCK 7100 7100 17 CONNECTIONS COVER 7216 7216

216 ESS 226ESS

6853 6853

18 FIXING KNOB 7172 7172 19 CONNECTION 9730 9730 20 WASHER (10 pcs.) 9732 9732 21 PIPE 9731 9731 22 SIPHON 1191 1191 23 SIPHON PIPE 1192 1192 24 PUMP PIPE 8868 8868 25 RUBBER RING (10 pcs.) 6897 6897 26 PUMP 8876 8876 27 WIRING HARNESS 1045 1045 28 BRASS NUT 10022444 10022444 29 O-RING (10 pcs.) 6898 6898 33 SCREW 6898 6898 35 WASHER (10 pcs.) 5041 5041 37 BLACK VELCRO 1041 1041 38 PRESSURE SWITCH 10022556 10022556 39 SILICONE TUBE 1457 1457 40 CONNECTION 10022570 10022570

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33 3517

Pos Description Part N.

216 ESS 226ESS

1 AIR VENT BOTTLE 9849 9849 2 NON RETURN VALVE 8910 8910 3 CONNECTION FOR

NON RETURN VALVE 8911 8911 4 UPPER PANEL FOR AIR BOX 8881 8881 5 CLAMP 8675 8675 6 WASHER CLAMP (10 pcs.) 5920 5920 7 AIR BOX HOLE CAP 8084 8084 9 WASHER (10 pcs.) 5905 5905 10 CONNECTION 8908 8908 11 WASHER 8912 8912 12 HEAT EXCHANGER 8884 8884 13 WASHER 9287 9287 14 EXCHANGER LOWER

INSULATING PANEL 1193 1193

18 19

20 21

24 25

15 COVER FOR HEAT EXCHANGER 16 EXCHANGER UPPER

INSULATING PANEL 1016 1016 17 ROOMSEALED CHAMBER 10022672 10022672 18 WASHER 8903 8903 19 GLASS 8900 8900 20 WASHER 8902 8902 21 GLASS SUPPORT COVER 8901 8901 22 WASHER 8896 8896 23 SPARK-SENSING ELECTRODE 9288 9288 24 GASKET 8904 8904 25 SPARK ELECTRODE CABLE 1044 1044 26 FRONT PANEL FOR AIR BOX 1035 1035 27 PLUG 8909 8909 33 WASHER 1033 1033 35 SCREW 5216 5216 38 CLIPS (10 pcs.) 10021115 10021115

1033 1033

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24 19

6 7 8

14 15

29 30

Pos Description Part N.

2 MAIN BURNER 1196 1196 3 WASHER 9285 9285 5 AIR CONVEYOR 10022450 8886 6 PRESSURE CONNECTION 8916 8916 7 SILICONE TUBE 1457 1457 8 SPRING 9296 9296 9 FAN GASKET (5 pcs.) 8893 8893 10 FAN 1018 1018 11 SCREW 1006 1006 12 SCREW 9292 9292 13 PRESSURE CONNECTION 8915 8915 14 WASHER 9299 9299 15 MAIN BURNER JET (MTN) 8897 8897 16 MAIN BURNER JET (LPG) 10022453 9295

216 ESS 226ESS

17 GAS PIPE 10022442 10022442 18 GAS VALVE 10022441 10022441 19 GAS PIPE 10022443 10022443 21 PIPE 9772 9772 22 GAS COCK 7098 7098 23 SCREWS (20 pcs.) 5176 5176 24 WASHER (10 pcs.) 5023 5023 25 SCREW 1006 1006 29 GAS DIAPHRAGM 10022451 30 SCREWS (10 pcs.) 10021080 31 WIRING HARNESS 10022333 10022333

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SECTION 10 L.P.G. INSTRUCTIONS

For details of converting boilers to LPG please refer to the instructions supplied with the relevant conversion kit.

10.1 TECHNICAL DATA

Inlet pressure

Maximum gas rate

Minimum gas rate

Injector size

CO2 level (cover off)

Maximum fan speed (RPM)

Minimum fan speed (RPM)

Soft-light

Maximum NOx emission

Minimum NOx emission

Maximum CO emission

Minimum CO emission

Maximum CO2 emission

Minimum CO2 emission

CO/CO2 ratio

10.2 RELATED DOCUMENTS BS 6798

BS 5449 BS 5546 BS 5440 BS 5482

PART 1

PART 1 PART 1

INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60 kW FORCED CIRCULATION HOT WATER SYSTEMS INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES FLUES DOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS

216

37 mbar 2,49 l/per hr. 0,72 l/per hr.

Single injector with six 1.6mm holes

9,80%

4.100

1.400

3.850 40 ppm 20 ppm 50 ppm 50 ppm

10% (cover on) 10% (cover on)

0,0005 to 1

226

37 mbar 4,08 l/per hr. 1,19 l/per hr.

Single injector with six 2.3mm holes

9,80%

5.500

1.700

3.025 30 ppm 20 ppm 50 ppm 20 ppm

10% (cover on) 10% (cover on)

0,0005 to 1

10.3 GAS SUPPLY

The gas supply must be connected to the appliance by a competent LPG installer and must be of sufficient size to supply the appliance at its maximum output.

An existing supply must be checked to ensure that it is of adequate size to deal with the maximum rated input of this and any other appliances that it serves.

10.4 GAS SUPPLY INSTALLATION

The entire installation, including the meter, must be purged and checked for gas soundness.

10.5 ADJUSTING THE GAS VALVE THE GAS VALVE MUST BE SET-UP OR ADJUSTED WITH THE AID OF A PROPERLY CALIBRATED FLUE GAS ANALYSER.

Remove the appliance casing as detailed in 4.8.1. Unclip and remove the air chamber cover. Set the flue gas analyser to read CO2 and insert the probe into the flue analysis test point (see fig. 1). Using the procedure as detailed in 7.3 & 7.3.5 respectively, enter the appliance engineer mode and set the fan speed to minimum.

10.5.1 MINIMUM SETTING

With the boiler operating at minimum output the CO2 reading should be 9.8% (+/- 0.2%). If the CO reading is correct, proceed to 10.5.2. If the CO reading is incorrect, the minimum gas pressure must be adjusted as follows:

● using a suitable screwdriver, very slowly turn

the minimum adjustment screw (see fig. 33) – clockwise to increase, counter clockwise to decrease – until the correct value is displayed on the CO2 analyser (allow time for the analyser to stabilise);

● using the procedure detailed in 7.3.4, change

the fan speed momentarily from minimum to maximum, then back to minimum;

● check that the correct value is still being

obtained. If not, repeat the above procedure.

10.5.2 MAXIMUM SETTING

The maximum setting must only be checked and/or adjusted after the correct minimum setting has been verified. Using the procedure detailed in 7.3.4, change the fan speed from minimum to maximum.

With the boiler operating at maximum output the CO2 reading should be 9.8% (+/- 0.2%). If the CO reading is correct, press the RESET button to exit the appliance engineer mode. If the CO2 reading is incorrect, the maximum gas pressure must be adjusted as follows:

● using a suitable screwdriver, very slowly turn

the maximum adjustment screw (see fig. 33) – clockwise to increase, counter clockwise to decrease – until the correct value is displayed on the CO2 analyser (allow time for the analyser

2 2

to stabilise);

● using the procedure detailed in 7.3.4, change

the fan speed momentarily from maximum to minimum, then back to maximum;

Supplied By www.heating spares.co Tel. 0161 620 6677

● check that the correct value is still being

obtained. If not, repeat the above procedure;

● press the RESET button to exit the appliance

engineer mode.

Remove the analyser test probe from the analysis test point and refit cap. Refit the air chamber cover. Refit appliance casing.

NOTE

10.6 RANGE RATING

The output of the boiler is automatically adjusted by a continuous air/gas modulation system. The system is controlled by the NTC thermistors (flow & return temperature sensors) which ensures stability of temperature irrespective of load conditions. However the appliance also has a range rating facility which can be used to limit the maximum output - to central heating- if required. Please refer to 7.3.1 & fig. 37 for more details.

Output BTU/H

102,360 85,300

68,240 51,180

34,120 17,060

Fig. 37

50°C flow & 30°C return temperature

1500 2000 2500 3000 3500 4000 4500 5000 5500

Fan speed in RPM

80°C flow & 60°C return temperature

Supplied By www.heating spares.co Tel. 0161 620 6677

energizing home heating

Cod. 10022447 - Ed. 2 - 16/02

Vokèra Ltd.

4th 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 6820

After Sales Service - Tel: 0870 333 0220

Vokèra Ireland

West Court, Callan, Co Kilkenny

Tel: 056 55057 Fax: 056 55060

Vokèra Ltd. reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected.

A Riello Group Company

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