VOKERA Eclipse ESC Release note

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Installation
& Servicing
Instructions
THESE INSTRUCTIONS
TO BE RETAINED
BY USER
ESC

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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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1
INTRODUCTION
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)
The Vokera Eclipse ESC is a combined central heating
and domestic hot water condensing boiler, which – by
design – incorporates full sequence electronic ignition,
circulatingpump,expansionvessel,safetyvalve,pressure
gauge, and automatic by-pass.
The Eclipse is produced as a room sealed, category C1,
C3,C6appliance,suitableforwallmountingapplications
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
systemsonly;consequentlytheyarenotintendedforuse
on open vented systems.
A range rating facility is incorporated in the appliance.
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
isarequestfordomestichotwater.Theparameter
fortheallowabletemperaturedrop–betweenpre-
heat operation – can be adjusted. If the appliance
remainsinactiveforaperiodof24hours,thepump
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
theburnerwillbelitandtheappliancewilloperate
at the minimum output until the temperature of
the flow sensor reaches 10°C, whereupon the
pumpwillcontinuetoruninpumpover-runmode.
1.3 DOMESTIC HOT WATER MODE
When the appliance is at rest, the motorised
valveisenergisedtothehotwaterposition,when
a demand for hot water is made the cold water
temperature sensor activates the pump and fan.
Whenthefanissensedtobeoperatingcorrectly,
theignitionsequencecommences.Thespeedof
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,eitherthewatertemperaturewillcontinueto
rise until the set point is achieved or the water
temperature will fall whereby fan speed will
increase relative to the output required.
1.4 CENTRAL HEATING MODE
Whenthereisarequestforheatviathetimeclock
and/or external controls the motorised valve and
pump will go through a self-test function this is to
ensurecorrectoperationandvalveconfiguration.
Oncetheself-testfunctioniscomplete,thepump
and fan will activated via the flow temperature
sensor. When the fan is sensed to be operating
correctly,theignitionsequencecommences.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,consequentlyahigh 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
theboiler–reducethefanspeedviatheelectronic
circuitry.Depending on theload,either the water
temperaturewillcontinuetoriseuntilthesetpoint
is achieved or the water temperature will fall
whereby fan speed will increase relative to the
outputrequired.Whentheboilerhasreachedthe
set point, the burner will switch off. The built-in
anti-cycle device prevents the burner from re-
lighting 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;
●adifferentialtemperatureprotectioncircuitwhich
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;
●asafetyvalve 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.
Fig. 2
return flow hw
outlet
cold
inlet
gas
1
NTC1 (flow sensor)
NTC 3
(inlet sensor)
Main Heat
Exchanger
Expansion
vessel
4
NTC2
(return sensor)
Domestic Heat
Exchanger

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SECTION 2 TECHNICAL DATA
Ref. Condition 15 °C , 1013,25 mbar, dry gas
NOTE: L.P.G. data refer to section 10
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 150 mm from casing or 25mm above flue elbow (whichever is applicable)
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”

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2.13 PUMP DUTY
Fig.3showstheflowrateavailable–afterallowing
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.
Fig. 4
Terminal position for fan assisted boiler
(minimum distance) mm
A - Directly above or below an open window 300
or other opening (e.g. air brick)
B - Below gutters, soil pipes or drain pipes 25
C - Below eaves 25
D - Below balconies or car port roof 25
E - From vertical drain pipes and soil pipes 75
F - From internal or external corners 25
G - Above ground or below balcony level 300
H - From a surface facing a terminal 600
I - From a terminal facing a terminal 1200
J - From an opening in the car port (e.g. door
window) into dwelling. 1200
K - Vertically from a terminal on the same wall 1500
L - Horizontally from a terminal on the same wall 300
M - Horizontally from a vertical terminal to a wall 300
N – Horizontally from an opening, airbrick,
openable window, etc. 300
NOTE:The flue must be terminated in a place not likely to cause a
nuisance.
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
NOx15 ppm 30 ppm
CO 50 ppm 50 ppm
CO29,8% 9,8%
CO/CO2ratio 0.0005 to 1 0.0005 to 1
Fig. 3
Water pressure (mbar)
Litres Per Hour (x100)
0 100 200 300 400 500 600 700 800
600
500
400
300
200
100
900 1000 1100 1200 1300 1400

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SECTION 3 GENERAL REQUIREMENTS
This appliance must be installed by a competent
personinaccordancewiththeGasSafety(Instal-
lation & Use) Regulations.
3.1 RELATED DOCUMENTS
The installation of this boiler must be in accord-
ance 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.
Itshould be in accordancealsowith any relevant
requirementsofthelocalauthorityandtherelevant
recommendationsofthefollowingBritishStandard
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.
wiringregulations,andin Scotland, the electrical
provisions of the Building Regulations, with
respect to the installation of the appliance in a
roomorinternalspacecontainingabathorshower.
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.
Thelocationchosenfortheappliancemustpermit
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
for this purpose. An existing compartment/cup-
board may be utilised provided that it is modified
to suit.
Details of essential features of compartment/
cupboard design, including airing cupboard in-
stallations, 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
–mustbecheckedtoensurethatitisofadequate
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.
Ifthegassupplyservesmorethanoneappliance,
it must be ensured that an adequate supply is
maintained to each appliance when they are in
use at the same time.
3.4 FLUE SYSTEM
Theterminalshouldbelocatedwherethedisper-
sal of combustion products is not impeded and
withdueregardforthedamageanddiscoloration
that may occur to building products located
nearby.
Theterminalmustnotbelocatedinaplacewhere
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.
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

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Fig. 5
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.
Referto BS 5440Part1, when theterminalis 0,5
metres(orless)belowplasticguttering or1metre
(or less) below painted eaves.
3.5 AIR SUPPLY
Thefollowingnotesareintendedforgeneralguidance
only.
This appliance is a room sealed, fan-flued boiler,
consequentlyitdoesnotrequireapermanentairvent
for combustion air supply.
Wheninstalledinacupboardorcompartment,venti-
lation for cooling purposes is also not required.
3.6 WATER CIRCULATION
Detailedrecommendations aregivenin BS5449
Part 1 and BS 6798. The following notes are for
general guidance only.
3.6.1 PIPEWORK
ItisrecommendedthatcoppertubingtoBS2871Part
1isusedinconjunctionwithsolderedcapillaryjoints.
Where possible pipes should have a gradient to
ensureairiscarriednaturallytoairreleasepoints
and that water flows naturally to drain cocks.
Exceptwhereprovidingusefulheat,pipesshould
beinsulatedtoavoidheatlossandinparticularto
avoid the possibility of freezing. Particular atten-
tion should be paid to pipes passing through
ventilatedareassuchasunderfloors,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 ex-
ternalby-pass,howeverthedesignofthesystem
should be such that it prevents boiler ‘cycling’.
3.6.3 DRAIN COCKS
These must be located in accessible positions to
facilitatedraining of the applianceandall water pipes
connectedtotheappliance.Thedraincocksmustbe
manufactured in accordance with BS 2879.
3.6.4 AIR RELEASE POINTS
Thesemustbepositionedatthehighestpointsin
thesystem whereairis likelytobe trapped.They
should be used to expel trapped air and allow
complete filling of the system.
3.6.5 EXPANSION VESSEL
The appliance has an integral expansion vessel to
accommodate the increased volume of water when
the system is heated. It can accept up to 8 litres of
expansion from within the system, generally this is
sufficient,howeverifthesystemhasanunusuallyhigh
watercontent,itmaybenecessarytoprovideadditional
expansion capacity (see 6.19).
Fig. 5 A
3.6.6 FILLING POINT
A method for initial filling of the system and
replacingwaterlostduringservicingetc.mustbe
provided.This method of fillingmustcomply with
the local water authority regulations.
Fig. 5 shows a widely accepted method.
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
abovetheboiler(seefig.5A).Thecoldfeedfrom
themake-upvesselortankmustbe fittedwith an
approved non-return valve and stopcock for iso-
lation purposes. The feed pipe should be con-
nected to the return pipe as close to the boiler as
possible.
3.6.8 FREQUENT FILLING
Frequent filling or venting of the system may be
indicative of a leak. Care should be taken during
the installation of the appliance to ensure all
aspects of the system are capable of withstand-
ing pressures up to at least 3 bar.
Make-up vessel
or tank
Automatic
air-vent
Non-return
valve Stopcock
5.0 metres minimum
Heating
return

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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
completeisolationfromthesupply.Thepreferred
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
correspondingcontrols,i.e.timeclock,roomther-
mostat,etc.Alternativelyanun-switchedshuttered
socket with a fused 3-pin plug both complying
with BS 1363 is acceptable.
3.8 SHOWERS
Iftheapplianceisintendedforusewithashower,
the shower must be thermostatically controlled
andbesuitable forusewith acombinationboiler.
3.9 MOUNTING ON A COMBUSTIBLE SURFACE
Iftheapplianceistobefittedonawallofcombus-
tible 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,itshouldbefittedinaccordancewiththe
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
thecondensatedischargeintoasuitabledrain or
soil pipe. The condensate outlet pipe must be
connectedtothedraininaccordancewithbuilding
regulations or other rules in force.
Fig. 6
SECTION 4 INSTALLATION
4.1 DELIVERY
The appliance is delivered in a heavy-duty card-
board 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
notuseaknife–unfoldtherestofthecartonfrom
around the appliance, carefully remove all pro-
tectivepackagingfromtheappliance,andlaythe
accessories etc. to one side.
4.4 PREPARATION FOR MOUNTING THE
APPLIANCE
The appliance should be mounted on a smooth,
vertical,non-combustiblesurface,whichmustbe
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–usingthetemplatesupplied–carefully
mark the position of the wall-mounting bracket
(see fig. 6) and flue-hole (if applicable).
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.

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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
fluemaybeextendedfromtheoutletelbowinthe
horizontalplane(see2.9).Areductionmustalso
bemadetothemaximumlength(seetablebelow)
when additional bends are used.
Using the template provided (see fig. 6), mark
and drill a 125mm hole for the passage of the
flue pipe.The hole should have a 1°rise from the
boiler to outside.
The fixing holes for the wall-mounting bracket
should now be drilled and plugged, an
appropriate type and quantity of fixing should be
used to ensure that the bracket is mounted
securely.Once the bracket has been secured to
the wall, mount the appliance onto the bracket.
FITTINGTHE HORIZONTAL FLUE KIT
Reduction for additional bends
Bend Reductioninmaximumfluelengthfor each bend
45°bend
90°bend
0,5 metre
1,0 metre
Horizontal flue terminals and accessories
Part No. Description Min-Max length
0225720
0225755
0225740
0225745
0225750
0225730
0225735
0225760
Horizontal flue kit for use with
add. bends & extensions
350-500 Telescopic extension
0,5m extension
1,0m extension
2,0m extension
45°bend (pair)
90°bend
Wall bracket (5)
1000mm
350mm-500mm
500mm
1000mm
2000mm
N/A
N/A
N/A
Take the large black gasket - supplied with the
flueterminalkit - and stretchitovertheappliance
flueoutlet(fig. 7).Usingatwistingmotion, connect
the boiler top adaptor - supplied with the flue
terminal kit - to the appliance flueoutletensuring
themale spigot of the adaptorispushedfully into
theflue outletspigotof theboiler (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 dimensionY from the terminal end
oftheconcentricflue pipe and cut off theexcess.
Pass the concentric flue pipe through the
previouslydrilledhole.Fitthefluebendtotheboiler
topadaptor and insertthe concentric flue pipeinto
the flue bend ensuring the correct seal is made.
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.
Fig. 7A
Fig. 7 Fig. 7B
Push-fit
connection
Extension
Boiler
Boiler top
adaptor
Boiler
Black
gasket
Boiler top
adaptor
Flue outlet

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4.5.2 CONCENTRIC VERTICAL FLUE
Theverticalflueterminalcanbeconnecteddirectly
to the appliance flue outlet. Alternatively, an
extension or bend can be connected to the
applianceflueoutletifdesired(see2.9),however
ifadditional bends are fitted,areduction must be
made to the maximum flue length (see table
below).
Vertical flue terminal and accessories
Part No. Description Min-Max length
0225725
0225770
0225765
0225755
0225740
0225745
0225750
0225730
0225735
0225760
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)
1000 mm
N/A
N/A
350mm-500mm
500mm
1000mm
2000mm
N/A
N/A
N/A
4.5.1.1 EXTENDING THE FLUE
Connectthe bend – suppliedwiththe 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
Whencuttinganextensiontotherequiredlength,
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.
Fig. 7C
Reductioninmaximumfluelengthfor each bend
Reduction for bends
Bend
45°bend
90°bend
0,5 metre
1,0 metre
Using the dimensions given in fig. 8 as a reference,
markandcuta105mmholeintheceilingand/orroof.
IMPORTANT
You must ensure that the terminal is at least
300mmfromany structureorsurface (seefig.8).
The vertical flue terminal is 1,0 metre in length
andcannotbecut;thereforeitmaybenecessary
toadjust theheight ofthe appliancetosuit oruse
a suitable extension.
Encure that any horizontal sections of the flue
systemhavea1°fallbacktotheboiler(17mmper
1000mm).
Fit the appropriate flashing plate to the roof and
inserttheverticalflueterminalthroughtheflashing
platefromthe outside,ensuringthat thecollaron
the flue terminal fits over the flashing.
The fixing holes for the wall-mounting bracket
shouldnowbedrilledandplugged,anappropriate
type and quantity of fixing should be used to
ensure that the bracket is mounted securely.
Once the bracket has been secured to the wall,
mount the appliance onto the bracket.
Fig. 8
Push-fit connection
Boiler
Extension pipe
Boiler top adaptor
Plain end
520mm
300mm minimum
139mm

Supplied By www.heating spares.co Tel. [phone]
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Fig. 9
NOTE
Whencutting an extensiontotherequired length,
you must ensure that the excess is cut from the
plain end of the extension.
Remove any burrs, and check that any 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
standardconcentricfluesystem.Itcanbeusedfor
horizontalorverticalapplications,howeverthetwin
flue system must be converted to the dedicated
concentricflue kitfortermination.Itisessentialthat
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 have a fall 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.
●Ensurethat theentire fluesystemis adequately
supported, use at least one bracket for each
extension.
●As the exhaust outlet pipe can reach very high
temperatures it must be protected to prevent
persons touching the hot surface.
MOUNTINGTHE BOILER
The fixing holes for the wall-mounting bracket
should now be drilled and plugged, an
appropriate type and quantity of fixing should be
used to ensure that the bracket is mounted
securely.Once the bracket has been secured to
the wall, mount the appliance onto the bracket.
Reductioninmaximumfluelengthfor each bend
Reduction for bends
Bend
45°bend
90°bend
1,0 metre
1,0 metre
Twin flue accessories
Part No. Description Length
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)
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 OFTWIN ADAPTOR KIT (see fig.9)
●Discardtherestrictorring (suppliedwith thetwin
adapter kit).
●Inserttheexhaustconnectionmanifoldontothe
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.
4.5.3.2 HORIZONTALTERMINATION (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.
Dependingon siteconditionsit may bepreferable
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
isa 1°fallbackto theboiler (17mmper1000mm).
Insert the terminal assembly into the flue hole.
Push-fitthetwinfluepipesontotheconcentricto
twinconverter boxensuring thattheexhaustpipe
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
havebeen madeforconnectionontothe 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.
Whencutting an extension to therequired length,
you should ensure that the excess is cut from

Supplied By www.heating spares.co Tel. [phone]
11
Fig. 10
Fig. 11
theplain endofthe extension.Removeany burrs,
and check that both seals are located properly.
Seal the flue terminal assembly to the wall using
cement or a suitable alternative that will provide
satisfactory weatherproofing. The interior and
exterior trim can now be fitted.
4.5.3.3 VERTICALTERMINATION (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
theconcentricterminalthrough theceilingand/
or roof.
Dependingon siteconditionsit may bepreferable
to install the terminal assembly prior to fitting the
twin flue pipes.
Fit the appropriate flashing plate to the roof and
insert the vertical flue terminal through the
flashing plate from the outside, ensuring that the
collar on the flue terminal fits over the flashing.
Push-fitthetwinfluepipesontotheconcentricto
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
ontothe previous pieceand onto theconcentric
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.
●Ensurethatany horizontalsectionsofpipehave
a 1°fall towards the appliance (17mm per
1000mm).
●The convertor box on the vertical terminal will
haveto be temporarilyremovedwheninserting
the terminal through the flashing.
4.6 CONNECTINGTHE GAS AND WATER
The appliance is supplied with an accessories
pack that contains sealing washers and service
valves.
Whenconnectingpipeworktothevalves,tighten
thecompression end first,theninsert the sealing
washersbeforetighteningthevalveorconnection
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
servicevalve,connectthesupplypipetotheinlet
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
valvesfortheflowandreturnconnections,connect
a22mmpipetotheinletofeachvalveandtighten
both nuts.
4.6.3 SAFETY VALVE (see fig. 12)
Connect a suitable coupling and 15mm pipe to
thesafetyvalveoutletandtighten.Thedischarge
pipe must have a continuous fall away from the
applianceto outsideand allowany watertodrain
awaytherebyeliminatingthepossibilityoffreezing.
The discharge pipe must terminate in a position
where any water - possibly boiling - discharges
safely without causing damage or injury, but is
still visible.
convertor box
convertor box

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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
15mmpipetothesuppliedconnectorandtighten
the nut.
4.7 CONDENSATE OUTLET (see fig. 12)
During normal operation the boiler produces
condensatewhichis collectedina traplocatedin
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
shouldbeinsulatedtopreventtheriskoffreezing.
CONNECTING THE CONDENSATE OUTLET
Gentlypullthecondensateoutletpipedownfrom
its location inside the boiler until approximately
250mmprotrudesfromtheundersideoftheboiler.
Connect a suitable pipe (no less than 20mm
diameter) to the outlet pipe and ensure it
dischargesinaccordancewithbuildingregulations
or other rules in force.
4.8 ELECTRICAL CONNECTIONS
The electrical supply must be as specified in 3.7.
Aqualifiedelectricianshould connect the electri-
cal supply to the appliance. If controls - external
to the appliance - are required, a competent
personmustundertakethedesignofanyexternal
electrical circuits, please refer to section 8 for
detailed instructions.
ANYEXTERNALCONTROLORWIRINGMUST
BE SERVED FROM THE SAME ISOLATOR AS
THAT OF THE APPLIANCE.
Thesupplycablefromtheisolatortotheappliance
mustbe3-coreflexiblesized0,75mmtoBS6500.
Wiring to the appliance must be rated for opera-
tion in contact with surfaces up to 90°C.
Fig. 12
4.8.1 CASING REMOVAL
To gain access to the appliance electrical con-
nections you must first remove the casing, pro-
ceed as follows:
●locate and remove the 2 screws that secure the
controlsfasciatotheappliancecasing(seefig.13).
●locate and remove the 2 screws that secure the
casingtothebackframeoftheboiler(seefig.13).
●gentlypullonesideofthecasingthentheother
to disengage it from the retaining clips.
●lift the casing upward to disengage it from the
top locating hooks and then remove.
●storethecasingandscrewssafelyuntilrequired.
Re-fit in the reverse order.
4.8.2 ELECTRICAL INPUT BOARD
The appliance electrical input board is
locatedbehindthecontrolfascia(seefig.14).
Locate and remove the 4 screws securing
the input board cover.
NOTE
The appliance comes with a factory fitted link to
allowbasicoperationoftheboilerviathekeypad.
If it is anticipated that external controls will be
required please refer to the wiring diagrams in
section 8 for more detailed information.
Fig.13
Fig.14
Safety valve
outlet
Condensate
outlet pipe Hot water
outlet
Flow
Cold water
inlet
Return Gas
Cable
entries

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13
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
cableanchorage (see fig.6).Connect the supply
cable wires (earth, live, & neutral) to their
corresponding terminals on the electrical input
board.Ensure thatthe EARTHwireis leftslightly
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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5.1 GAS SUPPLY INSTALLATION
Inspect the entire installation including the gas
meter,testforsoundnessandpurge.RefertoBS
6891 for specific instruction.
5.2 THE HEATING SYSTEM
The appliance contains components that may
becomedamagedorrenderedinoperablebyoils
and/or debris that are residual from the installa-
tion of the system, consequently it is essential
thatthesystembeflushedinaccordancewiththe
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,identifytheautomaticairreleasevalveand
loosenthedustcapbyturningcapanti-clockwise
one full turn. IMPORTANT, THERE ARE NO
MANUAL AIR RELEASE VALVES LOCATED
ON THE APPLIANCE. Ensure all manual air
releasevalveslocatedontheheatingsystemare
closed.Usingthemethodoffillingasdescribedin
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
benecessarytogobackandtop-upthepressure
untiltheentiresystemhasbeenfilled.Inspectthe
systemforwatersoundness,rectifyinganyleaks.
5.4 INITIAL FLUSHING OF THE SYSTEM
Thewholeoftheheatingsystemmustbeflushed
both cold and hot as detailed in 5.8. Open all
radiatororheatingvalvesandtheapplianceflow
& 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 stop-
cockon(anti-clockwise),slowlyopeneachoutlet
until all air has been expelled and clear water is
discharged. Check pipe-work etc. for water
soundness.
5.6 PRE-OPERATION CHECKS
Before attempting to initial lighting of the appli-
ance, the following checks must be carried out:
●ensureallgasservicevalvesfromthemeterto
theapplianceareopenandthesupplypipehas
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;
SECTION 5 COMMISSIONING
●ensurethe systemhasbeen filled,vented, and
the pressure set to 1 bar;
●ensurethefluesystemhasbeenfittedproperly
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
switchedon.Switchthetimeclockorprogrammer
toan‘on’positionandensureallexternalcontrols
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
operateinthecentralheatingmodeasdescribed
in 1.4. Should the appliance fail to ignite, refer to
5.6 and/or section 7 (fault finding).
5.8 FINALFLUSHINGOFTHE 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.
*BothSentinelandFernoxmanufactureproducts
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
procedurecanbeusedifanyparametersrequire
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).
●PresstheSTOREbuttontosavethenewvalue.
●Press the MODE button until no decimal point
is shown.
Fig.16

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15
5.10 FUNCTIONAL PARAMETERS
These parameters should only be changed or
adjustedbythecommissioningengineerorservice
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).
●PresstheSTEPbuttonuntilitshowsthedesired
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
Theoutputoftheboilerisautomaticallyadjusted
by a continuous air/gas modulation system. The
systemiscontrolledbytheNTCthermistors(flow
& return temperature sensors) which ensures
stability of temperature irrespective of load
conditions. However the appliance also has a
rangeratingfacilitywhich canbeusedtolimitthe
maximumoutput - to central heating-ifrequired.
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
theappliance(uptothemaximumof1,5bartotal).
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,pullleveronheadofsafetyvalvetorelease
water until the required figure registers on the
pressure gauge (see fig. 1).
STEP OPERATING PARAMETER
1
2
3
4
VALUE DEFAULT SETTING
Variable between 40°-65°C
02 = 5°C
03 = 10°C
04 = 20°C
05 = 30°C
00 = off
01 = on
Variable between 20°90°C
60°C
04 = 20°C
01 = on
75°C
Hot water outlet temperature
Pre-heat temperature drop
Central heating mode
Central heating flow temperature
STEP OPERATING PARAMETER
A
b
I
J
L
n
o
VALUE DEFAULT SETTING
Variable between 0-30
(where 1=10,2 seconds)
Variable between 3-99
(where 1=1 minute)
Variable between 0-30
(where 1=10,2 seconds)
Variable between 17-55
(where 1=100 RPM)
Fixed
Variable between 16-55
(where 1=100 RPM)
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 (%)
Anty-cycle
Pump over-run
CH delay after HW request
CH fan speed (maximum)
DHW fan speed (maximum)
Minimum fan speed (CH & DHW)
Soft-light fan speed
Fig. 17

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5.13 REGULATING THE CENTRAL HEATING
SYSTEM
Fully open all radiator and circuit valves and run
theappliance forboth heatingand hotwateruntil
heatedwateriscirculating.Ifconditionsarewarm
remove any thermostatic heads. Adjust radiator
returnvalvesandanybranchcircuitreturnvalves
untiltheindividualreturntemperaturesarecorrect
and are approximately equal.
5.14 FINAL CHECKS
●ENSURE ALL TEST NIPPLES ON THE AP-
PLIANCEGASVALVEARETIGHTANDHAVE
BEEN CHECKED FOR SOUNDNESS.
●ENSURETHEAPPLIANCEFLUESYSTEMIS
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, installa-
tion 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.
Showthe userthelocation ofthefilling valveand
howtotop-upthesystempressurecorrectly,and
showthelocationofallmanualairreleasepoints.
Explain to the user how to turn off the appliance
forbothlongandshortperiods,andadviseonthe
necessary precautions to prevent frost damage.

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SECTION 6 SERVICING INSTRUCTIONS
6.1 GENERAL
Toensurethecontinuedsafeandefficientopera-
tion 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
byacompetentpersonsuchasaVokeraengineer,
an approved service agent, British Gas, or other
CORGI registered personnel.
The following instructions apply to the appliance
andits controls,butit shouldberemembered that
the central heating system will also require
attention from time to time.
6.2 ROUTINE ANNUAL SERVICING
●Checktheoperationoftheapplianceand 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).
●Ensureboththeburnerandheatexchangerare
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.Anydeteriorationinperformance
must be identified and rectified without delay.
●Inspectalljointsforsignsofleakage andrepair
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
giveyearsofreliable,troublefreeservice,thelife
spanofcomponentswillbedeterminedbyfactors
such as operating conditions and usage. Should
the appliance develop a fault, the fault finding
sectionwillassistindeterminingwhichcomponent
is malfunctioning.
6.4 COMPONENT REMOVAL PROCEDURE
Toremoveacomponent,accesstotheinteriorof
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
describedinsection4.8.1.Drainthewatercontent
from the appliance via the safety valve. Ensure
some water absorbent cloths are available to
catch any residual water that may drip from the
appliance or removed component. Undertake a
complete commissioning check as detailed in
section 5, after replacing any component.
ALWAYS TEST FOR GAS SOUNDNESS IF
ANY GAS CARRYING COMPONENTS HAVE
BEEN REMOVED OR DISTURBED.
6.5 PUMP HEAD (see fig. 18)
Carry out component removal procedure as de-
scribed in 6.4.
Using a 4mm Allen key or ‘T’ bar, unscrew and
remove the four Allen screws that hold the pump
inposition,pullfirmlyonthepumpheadtorelease
it from the base. Disconnect the electrical leads.
Replace in the reverse order.
6.6 SAFETY VALVE (see fig. 19)
Carry out component removal procedure as de-
scribed 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 de-
scribed in 6.4.
Usinga suitable pair of pumppliers,unscrewthe
AAV from its position.
Replace in the reverse order.
Fig. 18
Fig. 19
Pump
head
Safety valve
Locking screw

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6.8 PRESSURE GAUGE (see fig. 20)
Carry out component removal procedure as de-
scribed 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.
6.9 NTC THERMISTORS (temperature sensors)
Carry out component removal procedure as de-
scribed in 6.4.
Cold water inlet sensor (see fig. 21)
Disconnet thermistor electrical plug. Using a
13mmspannerslackenandremovethethermistor
and sealing washer.
Replace in the reverse order.
Flow & return sensors (see fig. 1 & 22)
Pullbackprotectivebootandremovethe2spade
connectors. Slacken and remove the 2 securing
screws.
Replace in the reverse order.
6.10 PRINTEDCIRCUIT BOARD (PCB)(see fig. 23)
Carry out component removal procedure as de-
scribed 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.
6.11 GAS VALVE (see fig. 24)
Carry out component removal procedure as de-
scribed in 6.4.
Thegasvalvemustbechangedascompleteunit.
Unclip and remove the air chamber cover.
Disconnecttheelectricalplugfromthegasvalve.
Disconnectsiliconetubefromgasvalveregulator.
Slacken and unscrew gas valve inlet and outlet
connections. Please note, the sealing washers
mustbediscardedandreplacedwithnewsealing
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
thegasvalve.WARNING,AGASSOUNDNESS
CHECK MUST BE CARRIED OUT.
Fig. 22
Fig. 23
Fig. 21
Cold water
inlet sensor
Actuator
locking pin
Actuator
Housing
P.C.B.
Cover
Fig. 20
Manifold
Screw
Screw
Pressure gauge
connection
Locking screw