VOKERA Eclipse ESC Installation & Servicing Instructions Manual

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ESC

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 Domestic hot water mode 2

1.4 Central heating mode 2

1.5 Safety devices 2

Technical data Page

2.1 Central heating 3

2.2 Domestic hot water 3

2.3 Gas pressure 3

2.4 Expansion vessel 3

2.5 Dimensions 3

2.6 Clearances 3

2.7 Connections 3

2.8 Electrical 3

2.9 Flue details 3

2.10 Efficiency 3

2.11 Parameter defaults 4

2.12 Emissions 4

2.13 Pump duty 4

General requirements Page

3.1 Related documents 5

3.2 Location of appliance 5

3.3 Gas supply 5

3.4 Flue system 5

3.5 Air supply 6

3.6 Water circulation 6

3.7 Electrical supply 7

3.8 Showers 7

3.9 Mounting on a combustible surface 7

3.10 Timber framed buildings 7

3.11 Condensate disposal 7

3.12 Inhibitors 7

Installation Page

4.1 Delivery 7

4.2 Contents 7

4.3 Unpacking 7

4.4 Preparation for mounting the appliance 7

4.5 Fitting the flue 8

4.6 Connecting the gas & water 11

4.7 Condensate outlet 12

4.8 Electrical connections 12

Commissioning Page

5.1 Gas supply installation 14

5.2 The heating system 14

5.3 Initial filling of the system 14

5.4 Initial flushing of the system 14

5.5 Filling the hot water system 14

5.6 Pre-operation checks 14

5.7 Initial lighting 14

5.8 Final flushing of the heating system 14

5.9 Operating parameters 14

5.10 Functional parameters 15

5.11 Range rating 15

5.12 Setting the system design pressure 15

5.13 Regulating the central heating system 16

5.14 Final checks 16

5.15 Instructing the user 16

Servicing Page

6.1 General 17

6.2 Routine annual servicing 17

6.3 Replacement of components 17

6.4 Component removal procedure 17

6.5 Pump head removal 17

6.6 Safety valve removal 17

6.7 Automatic air valve removal 17

6.8 Pressure gauge removal 18

6.9 Temperature sensor removal 18

6.10 Main PCB removal 18

6.11 Gas valve removal 18

6.12 Fan removal 19

6.13 Burner removal 19

6.14 Electrode removal 19

6.15 Injector removal 19

6.16 DHW heat exchanger removal 20

6.17 Motorised valve actuator removal 20

6.18 Divertor valve assembly removal 20

6.19 Condense trap removal 20

6.20 Condense pressure switch removal 20

6.21 Combustion cover removal 20

6.22 Expansion vessel removal 21

6.23 Input & status PCB removal 21

Checks, adjustments, and fault finding Page

7.1 Checking appliance operation 22

7.2 Mode of operation 22

7.3 Checking/adjusting fan speeds 22

7.4 Adjusting the gas valve 23

7.5 Status code 24

7.6 Lockout faults codes 25

7.7 Diagnostic recall 25

7.8 Temperature sensor viewing mode 26

7.9 Checking the expansion vessel 26

7.10 External faults (installation) 26

7.11 Electrical checks 26

7.12 Fault finding 27

Wiring diagrams Page

8.1 Important note 31

8.2 Installation of Vokera time clock 31

8.3 External controls 31

Exploded diagrams Page

9.1 Table 1 35

9.2 Table 2 36

9.3 Table 3 37

9.4 Table 4 38

9.5 Table 5 39

9.6 Table 6 40

L.P.G. instructions Page

10.1 Technical data 41

10.2 Related documents 41

10.3 Gas supply 41

10.4 Gas supply installation 41

10.5 Adjusting the gas valve 41

10.6 Range rating 41

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INTRODUCTION

The Vokera Eclipse ESC is a combined central heating and domestic hot water condensing boiler, which – by design – incorporates full sequence electronic ignition, circulating pump, expansion vessel, safety valve, pressure gauge, and automatic by-pass.

The Eclipse is produced as a room sealed, category C1, C3, C6 appliance, 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 10 Cold water inlet 11 Hot water outlet 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 Three port valve actuator 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, the boiler will periodically light to pre-heat the domestic hot water heat exchanger to approximately 55°C. This ensures that the appliance is at operating temperature when there is a request for domestic hot water. The parameter for the allowable temperature drop – between preheat operation – can be adjusted. If the appliance remains inactive for a period of 24 hours, the pump and motorised valve will be energised for a few moments to prevent these components 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.

1.3 DOMESTIC HOT WATER MODE

When the appliance is at rest, the motorised valve is energised to the hot water position, when a demand for hot water is made the cold water temperature sensor activates the pump and fan. 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 return temperature sensor, consequently a high temperature at the return sensor results in a lower fan speed. As the water temperature increases, the temperature sensors – located on the flow and 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.

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 and 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.

1.5 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.

NTC2 (return sensor)

Domestic Heat Exchanger

NTC1 (flow sensor)

Main Heat Exchanger

Expansion vessel

NTC 3 (inlet sensor)

1.4 CENTRAL HEATING MODE

Fig. 2

gas

return flow hw

outlet

cold inlet

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SECTION 2 TECHNICAL DATA

2.1 Central heating

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

2.2 Domestic hot water

Maximum input 29,00 kW Maximum output 25,3 kW Minimum output 8,1 kW Flow rate (35°C rise) 10,4 l/min Maximum inlet pressure 6,0 bar Minimum inlet pressure to operate 0,15 bar Minimum flow rate to operate 2,5 l/min.

2.3 Gas pressure Maximum

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

2.4 Expansion vessel

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

2.5 Dimensions

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

2.6 Clearances

Sides 25 mm Top Bottom 150 mm Front 600 mm

2.7 Connections

Flow & return 22 mm compression Hot & cold water 15 mm compression Gas 1/2 inch BSP Safety valve 1/2 inch BSP

2.8 Electrical

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

2.9 Flue details

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

2.10 Efficiency

SEBDUK rating Band “A”

150 mm from casing or 25mm above 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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2.11 Adjustable operating parameters PARAMETER MINIMUM MAXIMUM FACTORY SETTING

Maximum fan speed (HW mode) Fixed Fixed 5.500 RPM Maximum fan speed (CH mode) See fig. 32 See fig. 32 5.500 RPM Minimum fan speed Fixed Fixed 1.700 RPM Soft-light fan speed Fixed Fixed 4.400 RPM Pre-heat Fixed Fixed 55°C Pre-heat temperature drop 5°C30°C20°C Anti-cycle delay 0 seconds 306 seconds 92 seconds Central heating flow temperature 20°C90°C75°C Hot water outlet temperature 40°C65°C65°C Pump over-run 3 m 99 m 10 m

2.12 Emissions MIN. OUTPUT MAX. OUTPUT

15 ppm 30 ppm CO 50 ppm 50 ppm CO

9,8% 9,8% CO/CO2 ratio 0.0005 to 1 0.0005 to 1

2.13 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

J - From an opening in the car port (e.g. door

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

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, airbric k,

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

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

Fig. 4

window) into dwelling. 1200

openable window, etc. 300

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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.

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.

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.

BS 5440 PART 1 FLUES BS 5440 PART 2 FLUES AND VENTILATION BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

(2ND FAMILY GASES) BS 6798 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

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 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

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.

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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’.

3.6.6 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.

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

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

Fig. 5 A

3.6.8 FREQUENT FILLING

the system is heated. It can accept up to 8 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).

Non-return

valve

Stopcock

5.0 metres minimum

Heating return

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.

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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 thermostat, etc. Alternatively an un-switched shuttered socket with a fused 3-pin plug both complying with BS 1363 is acceptable.

3.8 SHOWERS

If the appliance is intended for use with a shower, the shower must be thermostatically controlled and be suitable for use with a combination boiler.

3.9 MOUNTING ON A COMBUSTIBLE SURFACE

If the appliance is to be fitted on a wall of combustible material, a sheet of fireproof material must protect the wall.

3.10 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”.

3.11 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.

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

Fig. 6

3.12 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.

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).

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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 2.9). A reduction must also be made to the maximum length (see table below) when additional bends are used.

Reduction for additional bends

Bend

Reduction in maximum flue length for each bend

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.

45° bend 90° bend

Part No. 0225720

0225755 0225740 0225745 0225750 0225730 0225735 0225760

0,5 metre 1,0 metre

Horizontal flue terminals and accessories

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)

Min-Max length 1000mm

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

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.

Fig. 7A

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.

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 brack et.

FITTING THE HORIZONTAL FLUE KIT

Boiler top

Black

adaptor

gasket

Flue outlet

Boiler

Fig. 7

Fig. 7B

Boiler

Push-fit connection

Boiler top adaptor

Extension

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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).

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.

Push-fit connection

Plain end

Extension pipe

Boiler top adaptor

Vertical flue terminal and accessories

Part No. 0225725

0225770 0225765 0225755 0225740 0225745 0225750 0225730 0225735 0225760

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

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.

300mm minimum

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 2.9), 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

Fig. 8

520mm

139mm

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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 2.9) 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.

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

Part No. Description 0225805

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

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)

MOUNTING THE BOILER

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

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.

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 pref erable 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 have been made f or 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

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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.

convertor box

Fig. 10

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.

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 prefer able 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.

convertor box

4.6 CONNECTING THE GAS AND WATER

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 or connection to the appliance.

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 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)

Fig. 11

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.

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4.6.4 COLD WATER INLET (see fig. 12)

The appliance is supplied with a 15mm service valve, connect a 15mm pipe to the inlet of the valve and tighten both nuts.

4.6.5 HOT WATER OUTLET (see fig. 12)

The appliance is supplied with a 15mm male connector. Using a suitable coupling, connect a 15mm pipe to the supplied connector and tighten the nut.

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.

4.8.1 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.

Fig.13

Safety valve

outlet

Condensate

outlet pipe

Fig. 12

Return Gas

Flow

Cold water

inlet

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.

4.8.2 ELECTRICAL INPUT BOARD

The appliance electrical input board is located behind the control fascia (see fig.14). Locate and remove the 4 screws securing the input board 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.

Cable

entries

Hot water

outlet

Fig.14

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4.8.3 CONNECTING THE MAINS (230V) INPUT (see fig. 15)

Remove the electrical input board 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 electrical input board. 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 2 & 3 on plug M4) unless additional external controls are to be fitted (see section 8). Re-fit the electrical input board 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.

Fig. 15

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SECTION 5 COMMISSIONING

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 and 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 1 bar 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 5.8. 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 FILLING THE HOT WATER SYSTEM

Close all hot water outlets, turn appliance stopcock on (anti-clockwise), slowly open each outlet until all air has been expelled and clear water is discharged. Check pipe-work etc. for water soundness.

● 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.

5.7 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 in the pre-heat mode as described in 1.2. Once the pre-heat function has been completed, the appliance will operate in the central heating mode as described in 1.4. Should the appliance fail to ignite, refer to

5.6 and/or section 7 (fault finding).

5.8 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.

5.8.1 INHIBITORS

See 3.12

5.9 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.

5.6 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;

Fig. 16

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STEP

1 2

OPERATING PARAMETER

Hot water outlet temperature Pre-heat temperature drop

Central heating mode

Central heating flow temperature

5.10 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 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 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 above - be changed or adjusted. Please refer to section 7 before making any adjustments to the fan speed parameters of the boiler.

5.11 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

VALUE

Variable between 40°-65°C

DEFAULT SETTING

60°C

02 = 5°C 03 = 10°C 04 = 20°C

04 = 20°C

05 = 30°C 00 = off

01 = on

01 = on Variable between 20° 90°C

75°C

Fig. 17

& 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 section 7 for more details.

5.12 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).

STEP

OPERATING PARAMETER

Anty-cycle

VALUE DEFAULT SETTING

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

Pump over-run

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

CH delay after HW request

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

CH fan speed (maximum)

Variable between 17-55

(where 1=100 RPM) L n

DHW fan speed (maximum) Minimum fan speed (CH & DHW)

Fixed

Variable between 16-55

(where 1=100 RPM) o

Soft-light fan speed

Variable between 1-100

(where 1=1%)

9 (91,8 seconds) 10 (10 minutes) 3 (30,6 seconds) 55 (5500 RPM) 55 (5500 RPM)

17 (1700 RPM) 80 (%)

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5.13 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.

5.14 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.

5.15 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.

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SECTION 6 SERVICING INSTRUCTIONS

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 5.12).

● 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.

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.

Pump head

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. Replace in the reverse order.

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.

6.4 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 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

Fig. 19

Safety valve

Locking screw

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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

6.9 NTC THERMISTORS (temperature sensors)

Carry out component removal procedure as described in 6.4.

Cold water inlet sensor (see fig. 21)

Disconnet thermistor electrical plug. Using a 13mm spanner slacken and remove the thermistor and sealing washer. Replace in the reverse order.

Screw

Fig. 22

6.10 PRINTED CIRCUIT BOARD (PCB) (see fig. 23)

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.

Housing

P.C.B.

Cover

Actuator

locking pin

Actuator

Fig. 21

Cold water

inlet sensor

Flow & return sensors (see fig. 1 & 22)

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

Fig. 23

6.11 GAS VALVE (see fig. 24)

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.

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6.12 FAN (see fig. 24)

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.

Silicone tube

Outlet

All dimensions in mm.

Pre-mix manifold

Gas valve

Inlet

Fig. 24

Fan securing bolts

6.13 BURNER (see fig. 25)

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

Fan

Fig. 26

6.14 ELECTRODE (see fig. 25 & 26)

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.

6.15 INJECTOR (see fig. 27)

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.

Securing nuts

Spark

electrode

Fig. 27

Fig. 25

Gas valve outlet

connection

Burner plate

Injector

Fan

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6.16 DOMESTIC HOT WATER HEAT EXCHANGER (see fig. 31)

Carry out component removal procedure as described in 6.4. Remove motorised valve actuator as described in 6.17. Disconnect condense outlet pipe from the condense trap. Remove the insulation cover from the DHW heat exchanger. Locate and remove both inlet and outlet securing screws. Gently ease the heat exchanger from its location. Replace in the reverse order, ensuring the rubber O’ ring seals are in good condition and are correctly located.

6.20 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.

6.17 MOTORISED VALVE ACTUATOR (see fig. 31)

Carry out component removal procedure as described in 6.4. Disconnect the electrical plug from the actuator. Remove the locking pin from the divertor valve cover. Withdraw the actuator. Replace in the reverse order.

6.18 DIVERTOR VALVE ASSEMBLY (see fig. 31)

Carry out component removal procedure as described in 6.4. Remove motorised valve actuator as described in 6.17. Remove the divertor valve cover by unscrewing the 4 retaining screws. The divertor valve assembly is held in place by an O’ ring seal, the components are spring loaded. Care should be taken when removing the valve cover or when levering the sealing plate from its position. Replace in the reverse order, ensuring that the divertor valve spring and bobbin are seated properly.

NOTE

It may be prudent to replace the O’ ring seals and valve cover gasket whenever the divertor valve assembly is disturbed.

6.19 CONDENSE TRAP (see fig. 28)

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 v oid spillage. Replace in the reverse order.

Condense pressure switch

Fig. 29

6.21 COMBUSTION COVER (see fig. 31)

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

Fig. 28

Fig. 30

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6.22 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.

6.22.1 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.

DHW heat exchanger

6.23 INPUT PCB & 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 PCB cover. Carefully note the positions of all connections relative to the PCB that is to be removed. 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.

Flow-rate restrictor

Manifold

Divertor valve assembly

Outlet securing screw

Non-return valve

Cold water inlet sensor

Auto-bypass assembly

Inlet securing screw

Locking pin

Fig. 31

Motorised valve actuator

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SECTION 7 CHECKS, ADJUSTMENTS, AND FAULT FINDING

7.1 CHECKING APPLIANCE OPERATION

When carrying out any repairs or servicing to the appliance, the relevant commissioning 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.

7.2 APPLIANCE MODE OF OPERATION

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, and motorised valve will be momentarily energised. The boiler will then operate in either one of the following modes:

● DHW pre-heat

● Central Heating

● DHW operation

NOTE

A DHW request has priority over the other modes of operation.

7.2.2 PRE-HEAT

When there is no demand for heating or hot water, the boiler will periodically light to pre-heat the domestic hot water heat exchanger to approximately 55°C (measured via the cold water inlet sensor). This ensures that the appliance is at operating temperature when there is a request for domestic hot water. The parameter for the allowable temperature drop – between pre-heat operation – can be adjusted. If the appliance remains inactive for a period of 24 hours, the pump and motorised valve will be energised for a few moments to prevent these components 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.

7.2.3 DOMESTIC HOT WATER MODE

7.2.4 DHW TEMPERATURE ADJUSTEMENT

The temperature of the hot water outlet can be adjusted via the operating parameters (see 5.9). The boiler is also fitted with a flow-rate restrictor (see fig. 28) that limits the actual flow of hot water

to the taps or outlets. This is to ensure that the boiler maintains a reasonable outlet temperature even if the tap or outlet is fully open.

However if the incoming mains pressure is unusually high, it may possible for the flow-rate to exceed the desired limit, if this situation occurs the following procedure should be followed:

● set the hot water outlet temperature to maximum

(see 5.9);

● open the hot water outlet (preferably the bath

tap) fully;

● use the adjustable stopcock (fitted on the cold

water inlet) to reduce the flow of water through the boiler until a reasonable temperature is achieved.

7.2.5 CENTRAL HEATING MODE

When there is a request for heat via the time clock and/or external controls the motorised valve and pump will go through a self-test function this is to ensure correct operation and valve configuration. Once the self-test function is complete, the pump and 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 and 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.

7.3 CHECKING/ADJUSTING FAN SPEEDS

To check the fan speeds, you must first access the engineer mode. Before entering the appliance engineer mode, allow the boiler to purge and preheat the DHW heat exchanger. The fan speed should only be changed or adjusted by the commissioning engineer or service technician (see 5.10). 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’;

Page 25

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● 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).

7.3.1 MAXIMUM FAN SPEED (central heating)

● Press the STEP button until it shows the

letter ‘J’ (LED 1).

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

(see fig. 33)

● Press STORE to save the new setting.

7.3.2 MAXIMUM FAN SPEED (DHW)

● Press the STEP button until it shows the letter

‘L’ (LED 1).

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

until it shows ‘55’

● Press STORE to save the new setting.

7.3.3 MINIMUM FAN SPEED (DHW & CH)

● 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.

7.3.4 SOFT-LIGHT FAN SPEED

● 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.

7.3.5 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);

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

MODE button until LED 1 shows an alternating cursor (see fig. 33);

● 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. 33);

● 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.

7.3.6 EXIT ENGINEER MODE

Press the RESET button to exit the appliance engineer mode.

Output BTU/H

102,360

85,300

68,240

51,180

34,120 17,060

0 1500 2000 2500 3000 3500 4000 4500 5000 5500

Fig. 32

50°C flow & 30°C return temperature

Fan speed in RPM

Digit to the left

LED 2 showing first two digits of actual fan speed

80°C flow & 60°C return temperature

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 & 7.3.5 respectively, enter the appliance engineer mode and set the fan speed to minimum.

Digit to the right

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

Fig. 33

Fan speed shown is 4198 RPM

Page 26

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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:

● Remove the cover, then using a suitable

screwdriver, very slowly turn the minimum adjustment screw (see fig. 34) – clockwise to increase, counter clockwise to decrease – until the correct value is displayed on the CO analyser (allow time for the analyser to stabilise).

● Using the procedure detailed in 7.3.5, 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.

NOTE

You should ensure that all radiators or heat

2 2

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.

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

LED 1

0 1

LED 2

CH inlet temp.

Flow/return temp.

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

7.3.5, 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. 34) – 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 7.3.5, 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.

Ignition

CH mode

DHW mode

Fan-speed low

Built-in delay

CH over-run

DHW over-run

High temperature

LED 1

E E E E E

2 3 4 5 6 7 8 9

Flow/return temp. Flow/return temp.

Return temperature

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

DHW over-run

Return temperature

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

LED 2

18 19 24

Temperature differential exceeded

Reason for lockout

Flow sensor above 95°C

Return sensor above 95°C

26 30

Return sensor 35°C higher than flow

sensor

Insufficient fan speed

Maximum screw

Minimum screw

Fig. 34

Page 27

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

31 32 33 36 37 38 41 42 44 60 28 29 61 65 12 18 19 25

Short circuit on flow sensor

Short circuit on return sensor

Short circuit on inlet sensor Open circuit on flow sensor

Open circuit on return sensor

Open circuit on inlet sensor

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

No signal from fan Internal fault (PCB) Internal fault (PCB)

Insufficient fan speed

Condense trap blocked

Flow temperature too high

Return temperature too high

Rapid temperature increase

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 5.10.

● Press the MODE button until a flashing ‘1’

appears in LED 1.

● Press the STEP button to recall the information

as detailed below.

Press the RESET button to exit the appliance engineer mode.

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

LED 2 shows

0 1 2 3 4 5 6 7 8 9

LED 2 shows °C

LED 1 shows 1

Reason

False flame

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

Short circuit on inlet sensor Open circuit on flow sensor

Open circuit on return sensor

Open circuit on inlet sensor

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 increase

LED 1 shows 2

Reason

Standby

Purge

Ignition

CH mode

DHW mode

Fan-speed low

Built-in delay

CH over-run

DHW over-run

High temperature

LED 1 shows 3

Temperature of flow sensor at time

of lockout

Page 28

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LED 1 shows 4

LED 2 shows °C

Temperature of return sensor at

time of lockout

LED 1 shows 5

LED 2 shows °C Temperature of cold water inlet

sensor at time of lockout

7.8 TEMPERATURE SENSOR VIEWING MODE

The current temperature of the three 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)

Temperature rise per second

LED 2 SHOWS

Flow sensor temperature

Return sensor temperature

Cold water inlet temperature

N/A N/A

Return rise per 8 seconds

7.9 CHECKING THE EXPANSION VESSEL

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.

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

438

Cold water inlet 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.

7.11.3 POLARITY CHECK

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.

● 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.

closed

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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.

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.

FAULT

No display, boiler

inactive

No display, valve

actuator working

(press reset to test)

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 36 & 37 indicate the positions of all plugs, fuses and internal wiring configuration.

GO TO

Test 1

Test 1A

Test 2 Test 3 Test 4

7.11.6 FUSES

The appliance is equipped with spare fuses. These fuses are located on the covers of the input board 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 plug M4

(terminals 2 & 3) 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 plug M4.

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.

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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’

CHECK CONTINUITY

BETWEEN

INPUT PCB &

MAIN PCB

YES

IS THERE 10-14 Vdc

A T TERMINALS

1 & 7 OF

PLUG X7

TEST 1A

IS THERE

230V AT

PLUG X1

(L & N)

YES

GO TO

TEST 1

IS FUSE

F1 OK?

REPLACE

FUSE

REPLACE

PCB

YES

REPLACE

PCB

YES

ARE FUSES F2 & F3

OK?

YES

24Vac

A T TERMINALS

6 & 7 OF

PLUG X10

REPLACE

FUSE/S

YES

230V AT

TERMINALS

1 & 3 OF

PLUG X10

REPLACE

TRANSFORMER

YES

REPLACE

DISPLAY PCB

IS THERE 10-14 Vdc

A T TERMINALS

1 & 7 OF PLUG X7a

OF 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

4-9 Vdc

A T TERMINALS

1 & 2 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

OK?

IS IONISATION

VOLTAGE

ABOVE 2,0 Vdc

YES

DOES BURNER STAY LIT

YES

REPLACE

PCB

YES

FINISH

SILICONE PIPE &

YES

REPLACE

GAS VALVE

DOES

BURNER

LIGHT

YES

CHECK: GAS

SUPPLY,

NOZZLE, VALVE

REGULATOR

OK?

REST ART TEST

24 VA C

AT GAS VALVE

RECTIFY &

YES

REPLACE

PCB

YES

CHECK

CONTINUITY

ARE

ELECTRODE

& LEAD OK

24 VA C

A T TERMINALS

11 & 12 OF PLUG X2

REPLACE &

REST ART TEST

REPLACE

PCB

REPLACE

PCB

RECTIFY &

REST ART TEST

IONISATION CHECK: Terminal 5 on plug X2 to Earth

Page 33

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SECTION 8 WIRING DIAGRAMS

8.1 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 plug M4.

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

● Isolate the appliance from the electrical supply

and remove the casing as described in 4.8.1.

● Gain access to the electrical input board 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.35.

● Mount the clock to the clock bezel using the

screws provided.

● Remove the factory fitted link between terminals

2 & 3 on plug M4.

● Connect the clock wires to the electrical input

board as shown in fig. 35.

● Replace the input board cover and appliance

casing once the clock installation has been completed.

Fig. 35

red/white

blue

Electrical input board

white

red/black

12 345

clock

24V room thermostat

8.3 EXTERNAL CONTROLS IMPORTANT (see 8.1)

If additional or alternative controls are required, they must be connected to the boiler as shown in figure 35A or 35C.

NOTE

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

Fig. 35A

Fig. 35C

Page 34

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FUNCTIONAL DIAGRAM

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

Fig. 36

Key

R.T. Room thermostat F Fan P Pump S1 Flow thermistor (NTC) S2 Return thermistor (NTC) S3 D.H.W. 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 3W 3 way valve RL3V 3 way relay P.S. Pressure switch (NC)

Page 35

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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. 37

Page 36

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PCB

Input PCB Input PCB Input PCB Input PCB Input PCB Input PCB Input PCB Input PCB

PLUG or CONNECTION

M1 M4 M5 M6 M7 M8 M9

DESIGNATION

3-port valve actuator

Low voltage connector

Incoming 230V supply

230V supply to main PCB

Low voltage connector

230V connector (unused)

230V clock supply

2AF fuse

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

PCB

Gas valve

Fan

Condense pressure switch

Flow sensor

Return sensor

Pump

External transformer

Cold water inlet sensor

External sensor (if fitted)

Actuator

24V connection for time clock or

room thermostat

Relay for actuator

Status LED

PLUG or CONNECTION

OPE

P.S.

S1 S2

S3 S4

3W (M)

R.T.

RL3V 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

Plug M4 on input PCB Plug M4 on input PCB

Plug M1on input PCB

Plug M4 on input PCB (terminals 2 & 3)

Input PCB

Plug X20 on display PCB

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SECTION 9 EXPLODED DIAGRAMS

141516

17 18

Pos Description Code

1 FRAME ASSEMBLY 8344 6 GUARD 9814 9 GREEN-RED LED 8921 10 2A INLINE FUSE (5 pcs.) 8968 11 DISPLAY BOARD 8918 12 INSTRUMENTAL PANEL 8346 13 QUICK PRIMER PRESSURE GAUGE 8968 14 HOLE COVER 9709 15 ADHESIVE FILM FOR INSTRUMENTAL PANEL 8349 16 PLASTIC TRADE MARK LABEL 1748

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

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8 18

Pos Description Code

1 CASE 01005170 4 3A FUSE 3478 6 CASE CLIP (10 pcs.) 5588 8 WIRED TRANSFORMER 1048 9 PRESSURE GAUGE 1037 11 PRINTED CIRCUIT BOARD MTN SETTING 10022685 11 PRINTED CIRCUIT BOARD LPG SETTING 10022688 12 3,15A INLET FUSE 8969 13 2A INLET FUSE (5 pcs.) 8968 14 PRINTED CIRCUIT FRONT SEMI-BOX 8862 15 BLACK VELCRO 1041 18 SCREW (20 pcs.) 5080 23 EDGE CLIP (20 pcs.) 5128

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42 41

Pos Description Code

1 EXPANSION VESSEL 7204 2 DOMESTIC WATER HEAT EXCHANGER 1957 3 O-RING (10 pcs.) 7999 4 CONNECTION 8952 5 NTC SENSOR 8855 6 EXPANSION VESSEL PIPE 7207 7 HEATING MANIFOLD 2916 8 HEATING BY-PASS BACK PLUG 2911 9 CONNECTION 8432 10 NON RETURN VALVE 2908 11 BLANKING PLUG 4611 12 FLOW MANIFOLD FRONT PLATE 6853 13 SAFETY VALVE 1806 14 HEATING BY-PASS VALVE 1734 15 RUBBER DIAPHRAGM 6872 16 FLOW MANIFOLD FRONT PLATE 6853 17 BRASS CAP 8866 18 3 PORT VALVE SPRING 6862 19 O-RING (5 pcs.) 6895 20 SHUTTER FOR 3 WAY 2910 21 WASHER (5 pcs.) 2913 22 PUSH ROD 6887

23 O-RING (10 pcs.) 8444 24 SEATING PLATE 7134 25 MOTORIZED VALVE FIXING FORK WRENCH 2906 26 3 WA Y VALVE COVER 2904 27 OR UNION ASSEMBLY BRAKET 6919 28 MOTORIZED V ALVE 2905 29 CONNECTIONS COVER 7216 30 FIXING KNOB 7172 31 HEATING WA TER COCK 7100 33 WATER SUPPLY STOP COCK 7099 34 CONNECTION 8958 35 PIPE 8956 36 PIPE 8957 38 WASHER (10 pcs.) 5041 40 WASHER (10 pcs.) 5071 41 BLUE FLOW GOVERNOR 8009 42 O-RING 8959 43 WASHER (10 pcs.) 5026 44 SCREW 6903 46 WASHER (10 pcs.) 5042 49 WASHER (10 pcs.) 5023 50 WIRING HARNESS 10022483

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15 14

7 8

4 16 3

20 21

Pos Description Code

2 PIPE 1011 3 NTC SENSOR 1194 4 WASHER (10 pcs.) 5023 5 CONNECTIONS 8873 6 PIPE 1013 7 CONNECTION 9730 8 WASHER (10 pcs.) 9732 9 PIPE 9731 10 CONNECTION 10022570 11 PIPE 1192

12 SIPHON 1191 13 SILICONE TUBE 1457 14 PRESSURE SWITCH 10022556 15 BLACK VELCRO 1041 16 PUMP PIPE 8868 17 RUBBER RING 6897 18 PUMP 8876 19 WIRING HARNESS 1045 20 BRASS NUT 10022444 21 O-RING 6898

Page 41

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33 3517

Pos Description Code

1 AIR VENT BOTTLE 9849 2 NON RETURN VALVE 8910 3 CONNECTION FOR NON RETURN VALVE 8911 4 UPPER PANEL FOR AIR BOX 8881 5 CLAMP 8675 6 WASHER CLAMP (10 pcs.) 5920 7 AIR BOX HOLE CAP 8084 9 WASHER (10 pcs.) 5905 10 CONNECTION 8908 11 WASHER 8912 12 HEAT EXCHANGER 8884 13 WASHER 9287 14 EXCHANGER LOWER INSULATING PANEL 1193 15 COVER FOR HEAT EXCHANGER 1033

18 19

20 21

16 EXCHANGER UPPER INSULATING PANEL 1016 17 ROOMSEALED CHAMBER 10022672 18 WASHER 8903 19 GLASS 8900 20 WASHER 8902 21 GLASS SUPPORT COVER 8901 22 WASHER 8896 23 SPARK-SENSING ELECTRODE 9288 24 GASKET 8904 25 SP ARK ELECTRODE CABLE 1044 26 FRONT PANEL FOR AIR BOX 1035 27 PLUG 8909 33 WASHER 1033 35 SCREW R5216 38 CLIP (10 pcs.) 10021115

Page 42

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24 21

24 19

6 7 8

Pos Description Code

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

15 MAIN BURNER JET (MTN) 8970 15 MAIN BURNER JET (LPG) 9295 16 MAIN BURNER JET SUPPORT 1195 17 GAS PIPE 10022442 18 GAS VALVE 10022441 19 GAS PIPE 10022443 21 PIPE 9772 22 GAS COCK 7098 23 SCREW (20 pcs.) 5176 24 WASHER (10 pcs.) 5023 25 SCREW 1006 31 WIRING HARNESS 10022355

Page 43

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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

Gas rate

Injector size

CO2 level (cover off)

Fan speed (RPM)

Soft-light

NOx

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

Maximum

37 mbar

4,08 l/per hr.

Single injector with six 2.3mm holes

9,80%

5.500

3.025 30 ppm 50 ppm

10% (cover on)

0.0005 to 1

Single injector with six 2.3mm holes

Minimum

37 mbar

1,19 l/per hr.

9,80%

1.700

3.025 20 ppm 20 ppm

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. 34) – 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 7.3.5, 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 7.3.5, 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. 34) – 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 7.3.5, 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

2 2

10.6 RANGE RATING

is not compromised due to a high flow temperature.

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 max. 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

0 1500 2000 2500 3000 3500 4000 4500 5000 5500

50°C flow & 30°C return temperature

80°C flow & 60°C return temperature

Fan speed in RPM

Page 44

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energizing home heating

Vokèra Ltd.

4th Floor, Catherine House, Boundary Way, Hemel Hempstead, Herts, HP2 7RP

Cod. 10022484 - Ed. 2 - 16/02

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

COLLECTIVE MARK

“Vokèra”

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