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Installation Manual - all about gas

1. C Use of general Live for system Controls Room Stat 1 Remove the link wire between the Room Stat Timer terminals N O 2 The live feed to the Room Stat must be isolated by the same isolator that supplies the boiler OPTIONAL OPTIONAL ROOM STAT HEATING FROST TIMER ZONE 2 STAT 1010101010 dcogagogg D Frost Thermostat If parts of the system are vulnerable to freezing or the system controls are likely to be left off during cold weather then a frost stat should be fitted in conjunction with a pipe thermostat Position the frost thermostat in the area that is vulnerable hae onna MAINS AN to freezing and then connect it as shown in the diagram If the boiler is installed Armen cones eos in a garage it may be necessary to fit a pipe thermostat preferably on the return pipe work OOD E Weather Compensation 7 Timer Outside 1 Connect the Outside Sensor across the terminals as shown in the o Sensor Diagram DO nOT COnnECT 230V TO THESE TErMinaLS Or THE BOiLEr ELECTrOniCS WiLL BE DaMagED room stat mamno most MAINS IN ZONE 2 STAT JABS e85858 ABBE ggggg OUTSIDE OPEN SENSOR THERM Q O oggo Q Q F OpENTh
2. Check the Flow and Return Thermistors refer to Frames 87 amp 89 83 IgNITION LOCKOUT Check the Detection Electrode and associated Harness for MARE Boier IS Meset AoeS Gnas Tora shorttime continuity visual condition and position refer to Frame 59 and then Extinguish Check if the Condensate Pipe is Blocked No Is the Gas Pressure available at the boiler gt 18mBar Yes Is 215Vdc available at the Gas Valve during ignition See note Check Gas Supply and rectify fault Check wiring from Gas Valve to PCB and replace if necessary otherwise replace the main PCB y Yes Unplug the Gas Valve is the resistance between the Replace Gas Valve pins between 1kW and 10kW y Yes Check Spark Generator and associated Harness for continuity visual condition and position refer to Replace Spark Generator and Harness Frame 60 Are these functioning correctly as necessary Yes Check Ignition Electrode and associated Harness Replace Ignition Electrode and for continuity visual condition and position refer to associated Harness as necessary Frame 58 Are these functioning correctly Yes Check Syphon and condensate drain pipework for blockage and rectify if necessary Boiler now working OK Replace Gas Valve FAULT FINDINg FAULT FINDINg FAULT FINDI
3. hARDWARE pACK CONTENTs gas Valve pack 1 Pipe Gas Inlet gas Valve pack DhW pack 2 Washer Gas blue 3 Gas Cock a Filling Loop pack 1 3 8 Top Hat Washer x2 Plastic Chain x2 3 8 Blanking Cap x1 Valve Dbl Check Filling Loop x1 a7 3 8 Fibre Washer x2 3 8 Blanking Cap Extended x1 Filling Loop ae Valve Filling Loop x1 O Filling Loop with 3 8 Nuts x1 mO Return Valve pack 1 Pipe CH Return 2 Washer CH 3 Valve Return D Accessory pack DhW pack 1 Pipe DHW Inlet 2 Valve Return DHW 3 Washer DHW x2 4 Pipe DHW Outlet 5 Nut 1 2 Accessory pack 1 Screw x2 2 Wallplug x2 Flow Valve pack 1 Pipe CH Flow 2 Washer CH 3 Valve Flow with gauge continued 14 vogue combination boiler Installation and Servicing INSTALLATION 8 UNpACKINg CONT D pack B Contents Telescopic Telescopic Flue Terminal Flue Turret Rubber Terminal Wall Seal Screw Sealing Tape Wall Seal White pack B Contents Non Telescopic A Flue Terminal Flue Turret Rubber Terminal Wall Seal Cutting Aid Wall Seal Whi
4. KEY CO carbon monoxide CO carbon dioxide 02 oxygen Combustion Ratio The CO reading measured in ppm divided by the CO2 reading first converted to ppm ppm parts per million gs I amp U R Gas Safety Installation and Use Regulations vogue combination boiler Installation and Servicing set Boiler to Maximum gas Rate In accordance with boiler instructions set boiler to operate at maximum rate full load condition Allow sufficient time for combustion to stabilise Note Do not insert analyser probe during this period to avoid possible flooding of sensor Carry Out Flue Integrity Check Using Analyser Insert analyser probe into air inlet test point where available and allow readings to stabilise Note Where no air inlet test point is provided then a flue integrity check with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the prior to CO level and combustion ratio check see opposite page before proceeding to the check CO level and combustion ratio at maximum rate stage below Verify Flue Integrity Analyser readings indicate that combustion products and inlet air must be mixing Further investigation of the flue is therefore required Check that flue components are assembled fixed and supported as per instructions Check that flue and flue terminal are not obstructed equ
5. Fill and vent the system and open all Isolation Valves i Yes Does the wiring from the Water Pressure Sensor to the PCB have continuity and is it securely connected l Yes Replace Water Pressure Sensor 92 NO WATER FLOW 64 Ensure wiring has continuity and is securely connected Are the boiler and CH system filled with water and all Isolation and Radiator Valves open Fill and vent the system and open all Isolation Valves Yes Does the mains wiring from the Pump to the main PCB have continuity and is it securely connected 3 way connector x1C l Yes Ensure wiring has continuity and is securely connected Is there 230V to the Pump Replace Main PCB Yes Replace Pump vogue combination boiler Installation and Servicing SPARE pARTs 93 NO CONNECTION TO pRIMARy pCB Check the wiring from the Primary PCB to the User interface PCB is securely connected at both ends Yes Replace the wiring from the Primary PCB to the User Interface PCB Turn power Off and On does the fault disappear 94 NO Ch BUT DhW OK Press Enter Il g f ne DEMAND Turn im dial for Heating Is the above screen shown Turn Central Heating Dial Clockwise l Yes Ensure that the Timer and Room Thermostat are calling for heat Are the Timer and R
6. Refit the fan to the burner assembly Refer to Frame 47 Refit the venturi to the fan and burner assembly Refer to Frame 57 Refit the burner fan venturi assembly into the heat exchanger and secure Refer to Frame 51 Refit the gas pipe and secure with the 2 clips Refer to Frame 47 Reconnect the ignition detection earth fan leads Swing the control panel back into its working position Refer to Frame 46 Refit the front panel ensuring that a good seal is made Refer to 10 ti 12 Frame 45 Turn on the gas supply at the gas service cock Refer to Frame 33 Reconnect the electrical supply Check the operation of the boiler vogue combination boiler Installation and Servicing 47 SERVICING SERVICING sERVICINg 53 REpLACEMENT OF COMpONENTs When replacing ANY component iMPOr TanT when work is complete the front panel must be correctly refitted ensuring that a 1 Isolate the electrical supply good seal is made Isolate the water connections ThE BOILER MUsT NOT BE OpERATED WIThOUT ThE FRONT p ANEL FITTED Turn off the gas supply Remove the front panel 2 3 4 5 Swing the control panel down into the service position After replacing ANY component check operation of the boiler including gas tightness gas rate and combustion test 54 FAN REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Remove the ignition detection and earth leads
7. measure amp record Boller inte rloCk ss scici cicidassegctacesadeccccssaiesacdjetebscntajgenea sce 9 Cold water inlet temp ee measure amp record FOP vesacescensecessicessantecdsoncasesnvanvausedeatenevacnsersentsvens all boilers Hot water outlet temp eee measure amp record Flushing to BS 7593 essseseesseeeeseeteeeeeeeeneeetsees 12 Water flow rate at max setting measure amp record Fola olol E thse cease betes ET 12 For condensing boilers only Central heating mode Condensate Crain eccecceeceeeceeeteeseeeeneeeeeeees 21 22 Heat INpUt esinen to be calculated For all boilers complete sign amp hand over to customer For assistance see Technical Helpline on the back page NOTE TO ThE INSTALLER COMpLETE ThE BENChMARK COMMIssIONINg J enchmar ChECKLIsT AND LEAVE ThEsE COLLECTIVE MARK INSTRUCTIONs WITh App LIANCE THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS vogue combination boiler Installation and Servicing 5 gENERAL INTRODUCTION The Vogue range of boilers are wall mounted full sequence automatic spark ignition low water content fanned flue high efficiency condensing combination gas boilers Note Due to the high efficiency of the boiler a plume of water vapour will form at the terminal during operation Central heating CH output is fully modulating with a range of 26 3 7 to 18 0
8. Slacken the screw in the inlet pressure test point N and connect a gas pressure gauge via a flexible tube INITIAL IgNITION 1 Switch the electricity supply ON and check all internal and external controls are calling for heat Set the CH Temperature Control G to max and set the DHW Temperature Control H to max The boiler will now go through its ignition sequence until the burner is established If the boiler has not lit after 5 ignition attempts the following screen will be displayed Ignition Lockout Check other Gas Appliances work If not re instate gas supply Reset boiler by pressing r If fault persists contact installer 4 Reset the boiler and the ignition sequence will be repeated If reset occurs 5 times within 15 minutes then the following screen will be displayed Too Many Resets Contact Installer If power is removed this will be reset vogue combination boiler Installation and Servicing INSTALLATION 34 ChECK Ch amp DhW OpERATION CENTRAL hEATINg When the burner is established the following screen will be displayed The temperature shown will be the actual Flow Temperature Set the timer or Programmable Room Stat to be off The burner will go off and the fan and pump continue to run for 2 minutes The following screen will be displayed Press Enter for MENU NO DEMAND Timer or Room Stat Off Check the correct operation of all the system controls by operatin
9. Remove the 2 clips securing the gas inlet pipe and remove the pipe Remove the fan leads Remove the 4 securing nuts retaining the burner fan assembly Remove the assembly from the heat exchanger 8 To remove the venturi release the 2 securing screws 9 To remove the fan release the 3 screws securing the fan to the burner Replace the fan and refit the venturi checking the sealing gasket is undamaged or replace as necessary and secure with the 2 screws Note a noise damper is fitted to the venturi inlet on c40 and c32 models Note a mounting spacer is fitted to the fan outlet on c40 Check the operation of the boiler Refer to Frames 33 36 Mounting Spacer Fitted only to c40 Noise Damper Fitted only to c40 amp C32 models 48 vogue combination boiler Installation and Servicing sSERVICINg 55 BURNER INJECTOR REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Remove the 2 clips securing the gas inlet pipe and remove the pipe Carefully ease the injector out of the gas valve Replace injector O ring Re fit in reverse order ensuring the sealing o ring is in good condition or replace if necessary Refit the gas pipe ensuring the seals are in good condition and correctly located Secure with the clips Check the operation of the boiler Refer to Frames 33 36 56 BURNER DOOR AssEMBL y REpLACEMENT O 0o N OU e OMN Refer to F
10. 38 MENU OpERATION OUTsIDE sENSOR sLOpE This feature is only accessible if an Outside Sensor has been fitted to the boiler Boiler performance can be adjusted relative to the insulation level of the building To change the slope press ENTER and the following screen will be displayed MENU A Vent System Vv Maximum Flow Temperature Outside Sensor Slope oo Press until the following screen is displayed MENU Maximum Flow Temperature Outside Sensor Slope Fault Help 4 y Fault History Press ENTER and the following screen will be displayed Outside Sensor Slope 80 C 4 Flow Ge ere Press and until the desired setting is displayed Press ENTER followed by ExIT to return to normal operation FAULT hELp This feature provides a list of potential corrective actions at an installer level for all faults detectable by the boiler electronics Press ENTER and the following screen will be displayed MENU Vent System Vv Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope oy Press until the following screen is displayed MENU Outside Sensor Slope y Fault Help Fault History State of Inputs Press ENTER and the following screen will be displayed Overheat Lockout Fill System to 1 0 Bar Vent System Refill System Check Pump Spins Freely Check 240V to Pump o Press and to scroll through the information Press ExIT
11. What type of scale reducer has been fitted DOMEsTIC hOT WATER MODE Measure and Record Gas rate OR Burner operating pressure at maximum rate OR Gas inlet pressure at maximum rate Cold water inlet temperature Hot water has been checked at all outlets Yes Temperature Water flow rate CONDENsINg BOILERs ONL y The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 ALL INSTALLATIONS At max rate CO ppm CO CO At min rate where possible co ppm CO CO Record the following The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature Allinstallations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a enchmar Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer T
12. the appliance must be installed beyond Zone 2 as detailed in BS 7671 Ceiling Recessed window zone 2 3G8913a Compartment Installations Acompartment used to enclose the boiler should be designed and constructed specially for this purpose An existing cupboard or compartment may be used provided that it is modified for the purpose In both cases details of essential features of cupboard compartment design including airing cupboard installation are to conform to the following BS 6798 No cupboard ventilation is required see Air Supply for details e The position selected for installation MUST allow adequate space for servicing in front of the boiler e For the minimum clearances required for safety and subsequent service see the wall mounting template and Frame 1 In addition sufficient space may be required to allow lifting access to the wall mounting plate gAs sUppL y The local gas supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must NOT be used without prior consultation with the local gas supplier The boiler MUST be installed on a gas supply with a governed meter only A gas meter can only be connected by the local gas supplier or by a Gas Safe Registered Engineer In IE by a Registered Gas Installer RGII An existing meter sho
13. heating system In hard water areas treatment to prevent lime scale may be necessary however the use of artificially softened water is NOT permitted Under no circumstances should the boiler be fired before the system has been thoroughly flushed 12 could completely cut off the flow through the system must also include a bypass BALANCINg 1 Set the programmer to ON Close the manual or thermostatic valves on all radiators leaving the twin lockshield valves on the radiators referred to above in the OPEN position Turn up the room thermostat and adjust the lockshield valve to give an uninterrupted flow through the radiator These valves should now be left as set Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators to give around 20 C temperature drop at each radiator Adjust the room thermostat and programmer to NORMAL settings DOMEsTIC hOT WATER In hard water areas where mains water can exceed 200ppm Total Hardness as defined by BS 7593 2006 Table 2 a scale reducing device should be fitted into the boiler cold supply within the requirements of the local water company The use of artificially softened water however is not permitted Ideal stelrad group recommend the use of Fernox Quantomat Sentinel Combiguard and Calmag CalPhos scale reducing devices or Scalemaster Inline Scale Inhibitor branded Ideal which must be used in accordance wit
14. transfer to new turbine sensor 5 Reassemble in reverse order 6 Check operation of the boiler Refer to Frames 33 36 67 DRAININg ThE BOILER Filling Loop CENTRAL hEATINg CIRCUIT Close all the CH water isolating valves on the boiler inlet To drain the primary heat exchanger circuit Open the drain point by unscrewing using a flat blade screw driver and attach a length of drain hose After replacing any component on the boiler remove the hose close the drain valve and open all system isolating valves re pressurise as appropriate by re connecting the filling loop refer to Frame 24 before proceeding to check operation of the boiler Disconnect filling loop Refer to Frame 24 Check operation of the boiler Refer to Frames 33 36 5 Drain DOMEsTIC hOT WATER CIRCUIT f Circuit a DHW Gas DHW 1 Close the DHW water isolating valve on the DHW inlet Outlet Inlet Return 2 To drain the domestic hot water circuit As there is no direct drain for the domestic hot water circuit depending on the location of the boiler opening the lowest hot water tap may drain this circuit However it must be noted that some residual water will be experienced during replacement of components After replacing any component on the boiler open the DHW inlet isolating valve and vent the DHW system by opening all hot taps and ensuring wat
15. 2 It is important that the position of the terminal allows the free passage of air across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 4 4 Where the lowest part of the terminal is fitted less than 2m 6 6 above a balcony above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard Terminal guards are available from boiler suppliers Ask for TFC flue guard model no K6 round plastic coated In case of difficulty contact TFC Group Ltd Tower House Vale Rise Tonbridge Kent TN9 1TB Ensure that the guard is fitted centrally Tel 44 0 01732 351 680 Fax 44 0 01732 354 445 www tfc group co uk vogue combination boiler Installation and Servicing gENERAL 5 The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of any building 6 The air inlet products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm 1 to combustible material Detailed recommendations on the protection of combustible material are given in BS 5440 1 2008 IMpORTANT It is essential to ensure in practice that products of combustion discharging from the terminal cannot re enter the building or buildings through any openings into the building such as ventilators windows doors or other sources of natural air infiltration
16. 6 aym M MOJA yud d p r J um moq q yoe q yq nq q AJA 8x 9x x Lx EIX o aex Hirr H elzlilslrleleliley EJZ Jaa ee ee ee ee ee ORN U D D D S E E E A A yq id ee eee q yq 1q vogue combination boiler Installation and Servicing 4 yea uoo uuog sisseyo abeyo suey uoljoauu0D JOU eu1a u abelon 1M Moq if mol4 Josuas 19eM INSS Jd 18M way J wIL p01 29 3 reuua u Josuag awe 4 ep Bnid yun y JOWLL sate P w yuado a jeusa xy Se og L Jo 98UU0D M M ag maS JOHAL anen Sep WIRINg DIAgRAM 31 30 NOIL TIVLSNI INSTALLATION 32 COMMIssIONINg AND TEsTINg A Electrical Installation gas Installation 1 Checks to ensure electrical safety should be carried out bya 1 The whole of the gas installation including the meter competent person should be inspected and tested for tightness and purged in 2 ALWAYS carry out the preliminary electrical system checks accordance with ine recommendations or BS 6991 ek 4 In IE refer to IS 813 2002 i e earth continuity polarity resistance to earth and short circuit using a suitable test meter Purge air from the gas installation by the approved methods 3 After wiring the boiler all grommets in the bottom panel only MUST be in place to ensure that boiler case sealing is maintained Warning Whilst effecting the required gas tightness test and purging a
17. A CONDITION OF ThE MANUFACTURERs WARRANTY ThAT ThE BENChMARK COMMIssIONINg ChECKLIsT Is FULL y COMpLETED AND LEFT WITh ThE AppLIANCE vogue combination boiler Installation and Servicing 31 INSTALLATION INSTALLATION INSTALLATION 33 INITIAL LIghTINg Legend Boiler Status Exit Button Down Button Up Button Enter Button TAMM7 MWVO DW D J K L M N P Q R S 32 CH Temperature Control DHW Temperature Control and Off Pressure Gauge Boiler in Full Condensing Mode CH Flow Isolating Valve Gas Inlet Pressure Test Point Gas Service Cock DHW Inlet Valve CH Return Isolating Valve DHW Outlet Reset Button Switch Burner On indication pREpARATION FOR IgNITION Check that the electrical supply is OFF Check that the system has been filled and that the boiler is not air locked Ensure that the automatic air vent cap is open Refer to Frame 70 To assist with venting the air from the system refer to Frame 37 Vent System This function operates the boiler to ensure efficient venting of the boiler and system Refit the boiler front panel Refer to Frame 45 Check that the drain cock is closed and that the CH M amp R and DHW Q isolating valves are OPEN Check that the DHW Temperature Control Knob H is turned fully anti clockwise into the off position Check that the gas service cock P is OPEN
18. Arrangement 21 ROOF FLUE KIT CONTENTS OpTIONs l a I l Flue Terminal Flue seal Collar Flat Roof 90 elbow UIN 203132 i UIN 152259 UIN 203130 45 elbow UIN 203131 I Flue seal Collar Universal UIN 152258 n Roof Flue Extension Duct UIN 203129 l FLUE OUTLET 3G9626a vogue combination boiler Installation and Servicing 23 INSTALLATION 22 FLUE TERMINAL pOsITION The terminal should be positioned so that products of combustion can safely disperse at all times pluming may occur at the termination so where possible terminal positions where this could cause a nuisance should be avoided Minimum dimensions are shown below mM oe Aluminium 300mm min shield min oco Pitched Roof with structure Flat roof with structure The flue terminal shall not penetrate the shaded area of the roof arefcewinaoweree omm air brick windows etc 300 mm 300 mm The equivalent flue length resistance of the elbow kits are Below velux windows 2000mm 90 elbow kit 1m Above or side of velux windows 45 elbow kit 0 6m FLUE OUTLET Below eaves or balcony 24 vogue combination boiler Installation and Servicing INSTALLATION 23 AssEMBLINg ThE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof If after calculating or measuring the overall flue heigh
19. Cond Drain Gas Inlet 2 kG N yo amp cs a Min Top Clearance A 165mm REAR flue type Min Top Clearance 167 193 219 245 A SIDE flue type 26 52 l i i 271 Distange from Horizontal mm required to achieve 1 5deg fall to the appliance 104 297 Q sl See inset Front clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required with the cupboard door open to allow for servicing Bottom clearance Bottom clearance after installation can be reduced to 5mm This must be obtained with an easily removable panel to enable the consumer to access the filling loop and to provide the 100mm clearance required for servicing 323 349 375 401 427 mm 13 156 182 20 23 26 mm Top Clearance Bae A ma Oy 4 j 1 5 degree ax e eee T E 9 0 10 0 Max 26kW Distance in metres from edge of turret to side wall Dimension H 1 If the wall thickness is greater than 305mm then dimension H must be reduced by the difference in wall thickness 2 For flue lengths requiring D pack extentions the flue must incline by 26mm per 1 Metre of flue length No flue length greater that the maximum flue length shown above should be exceeded 10 vogue combination boiler Installation and Servicing gENERAL 2 sysTEM REqUIREMENTs Cen
20. Electronic Programmable Room Thermostat 7 day kit e Weather Compensation Kit e Adjustable Flue Support Bracket e DHW Expansion Vessel Kit e Balcony Flue Kit e Security Bracket Kit e Flue Support Bracket Kit vogue combination boiler Installation and Servicing sAFETy Current gas safety installation and use regulations or rules in force The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation must be carried out by a Gas Safe Registered Engineer It must be carried out in accordance with the relevant requirements of the e Gas Safety Installation and Use Regulations e The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland e The Water Fittings Regulations or Water byelaws in Scotland e The Current I E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a Registered Gas Installer RGII and installed in accordance with the current edition of S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice Bs 54
21. ExIT twice to return to normal operation 40 sET ZONE 2 FLOW TEMpERATURE If a second switched live is connected to the boiler for a second zone see Frame 30 then the flow temperature target for this zone can be set independently Press ENTER and the following screen will be displayed MENU A Vent System Vv Maximum Flow Temperature Outside Sensor Slope Press until the following screen is displayed MENU Test Condensate Anti Freeze 7 Set Zone 2 Flow Temperature Press ENTER and the following screen will be displayed Press amp to change the temperature to the require setting and then ENTER Press ExIT to return to normal operation pUMp MODULATION The boiler is factory set for pump operation to give maximum reliability If the CH system has been fully balanced then pump modulation can be increased to reduce electrical energy consumption to do so press ENTER and the following screen is displayed MENU Vent System 7 Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope Press until the following screen is displayed MENU A Set Zone 2 Flow Temperature Vv Pump Modulation Press ENTER and the following screen will be displayed Pump Modulation For minimum press v to save press Press to change the setting and then ENTER Press Exit to return to normal operation vogue combination boiler Installation and Servicing INSTALLATI
22. INSTALLATION INSTALLATION INSTALLATION 41 MENU OpERATION INSTALLER s DETAILs The service required message which is displayed after 12 months can be customised to show the installer s telephone number To record your telephone number press ENTER and the following screen will be displayed MENU Vent System Vv Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope oy Press until the following screen is displayed MENU Maximum Flow Temperature Vv Installer s Details Test Condensate Anti Freeze Set Zone 2 Flow Temperature Press ENTER and a screen similar to the following will be displayed Installer s Details A y 01482 498704 No shown when service due Press and to change the number and ENTER to accept Press ExIT twice to return to normal operation TEsT CONDENSATE ANTI FREEZE If Ideal s optional condensate anti freeze kit has been fitted to the boiler then to test operation press ENTER and the following screen will be displayed MENU A Vent System Vv Maximum Flow Temperature Outside Sensor Slope oy Press until the following screen is displayed MENU Maximum Flow Temperature 7 Test Condensate Anti Freeze Set Zone 2 Flow Temperature Press ENTER and the following screen will be displayed Condensate Anti Freeze CD ON for 5mins press Only active if optional kit purchased Ext Press ENTER to activate Press
23. TIMER ZONE2 STAT IN OUT IN OUT IN ouT L N no 318181018818 Replace main PCB Q O g Q Q e Ql e Z Q Z T a m lt u o Z a Z T a m lt u o Z Q Z T m lt m o Z Q Z T m m lt u o Z a Z T m m 66 vogue combination boiler Installation and Servicing SPARE pARTs When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Failure to do so could affect safety or performance of this appliance Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www idealparts com Our parts team are also available to help with your Ideal spare parts enquiries on 01482 498665 When calling and to ensure we can provide you with the most accurate parts information please ensure you have the following to hand z Boiler Model Appliance GC Number Boiler Serial Number vogue combination boiler Installation and Servicing 67 Code Of Practice For the installation commissioning and servicing of domestic heating and hot water products Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed
24. a new outside sensor FAULT FINDINg FAULT FINDINg FAULT FINDINg FAULT FINDINg FAULT FINDINg vogue combination boiler Installation and Servicing 63 e Z Q Z T m m lt u o Z a Z T m m lt m o Z Q Z T m m lt u o Z a Z T m m lt u o Z a Z T m m FAULT FINDINg 89 RETURN ThERMIsTOR F AULT Disconnect the electrical connection to the Return Thermistor and check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 Q At 60 C expect 2 400 2 600 Q At 85 C expect 1 000 1 100 Q Is the thermistor value correct l Yes No m Fit a new thermistor Replace wiring from flow thermistor to primary PCB Is there continuity in the wiring from the primary PCB to the Thermistor 6 way connector connections 3 and 4 black and red 90 FAN FAULT Does the wiring from the Fan to the PCB have secure connections at both ends and has not deteriorated Does the wiring have continuity l Yes Is there 230Vac at the blue and brown connections to the 3 way connection on the Fan 91 LOW WATER pREssURE Are the boiler and CH system filled with water and all Isolation and Radiator Valves open Replace primary PCB Rectify wiring amp connections Replace main PCB Replace Fan
25. assembly Remove the assembly from the heat exchanger To remove the venturi release the 2 securing screws to gain access for cleaning When replacing check the sealing gasket is undamaged or replace as necessary and secure with the 2 screws Note a noise damper is fitted to the venturi inlet on c40 models To remove the fan first remove the venturi as above and release the 3 screws securing the fan to the burner Note a mounting spacer is fitted to the fan outlet on c40 model only Remove the fan from the burner assembly When replacing check the sealing gasket is undamaged or replace as necessary and secure with the 3 screws Mounting Spacer Fitted only to c40 Noise Damper Fitted only to c40 amp c32 models 48 REMOVAL OF INj ECTOR Refer to Frames 45 amp 46 Refer to Frame 53 Remove the 2 clips securing the gas inlet pipe and remove the pipe as point 3 above Carefully ease the injector out of the gas valve Examine or clean as necessary Re fit in reverse order ensuring the sealing o ring is in good condition or replace if necessary Refit the gas pipe ensuring the seals are in good condition and correctly located amp secure with clips vogue combination boiler Installation and Servicing 45 SERVICING sERVICINg 49 BURNER REMOVAL AND CLEANINg Remove Fan and Venturi Assembly Refer to Frame 46 Remove the ignition detection and earth leads Remov
26. ensure the terminal flue duct is cut longer than the air duct to ensure engagement in the final flue duct seal FLUE OUTLET 7 Finally ensure the roof flashing plate is correctly sealed to the roof vogue combination boiler Installation and Servicing 25 INSTALLATION INSTALLATION 24 CONNECTIONS amp FILLINg NOTEs Ensure all boss blanking plugs are removed before connecting hardware Each valve must be fitted to the correct boss as shown in the picture Ensure each union is fitted with fibre seals provided Do not subject any of the isolating valves to heat as the seals may be damaged WATER CONNECTIONs Ch Connect the CH flow service valve and copper tail provided in the hardware pack to the threaded boss connection provided at the lower rear of the boiler Connect the CH rtn valve black handle and copper tail If connecting the boiler to heating loads in excess of 17 6kW 60 000 Btu h connecting flow and return heating systems pipework must be sized in 28mm diameter at the point of pipe connection to the boiler tails use 22mm x 28mm pipe adaptors as appropriate WATER CONNECTIONs DhW 1 Fit the DHW inlet service valve blue handle and copper tail to the threaded boss connection ensuring the seal provided is correctly located Fit the DHW outlet pipe tail to DHW outlet connection ensuring the seal provided is correctly located Fit the filling loop provided between the DHW inlet valve an the CH r
27. protection still active Boiler Switched Off To switch the boiler On Rotate the DHW Temperature Knob A Q 60 c A clockwise the screen on the right will be shown Select Hot Water Temperature To change the Room Temperature set point N only if Outside Sensor 3 g 20 c A connected rotate the CH Temperature Knob the screen on the right will be Select Room Temperature shown vogue combination boiler Installation and Servicing 35 INSTALLATION INSTALLATION INSTALLATION 37 MENU OpERATION VENT sysTEM The Vent System feature aids removal of air from the heat exchanger The pump will be switched on for 50s and then off for 10s while the diverter valve is moved between DHW and CH every 30s The feature lasts for 5 minutes Press ENTER and the following screen will be displayed MENU A Vent System Vv Maximum Flow Temperature Outside Sensor Slope Press and the following screen will be displayed MENU y Vent System Switch Pre heat On Off Maximum Flow Temperature Press ENTER and the following screen will be displayed Vent System Pump will be pulsed On 60s Off 10s Diverter Valve alternates CH DHW Press ENTER and the following screen will be displayed Vent System The feature will end automatically after 5 minutes to end manually press ExIT Pump pulsed On 60s Off 10s Diverter Valve alternates CH DHW Exit 36 pRE hEAT If pre heat is switched on t
28. sense electrode Replace Flame Detection Electrode 87 FLOW ThERMIsTOR F AULT Disconnect the electrical connection to the Flow Thermistor and check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 Q At 60 C expect 2 400 2 600 Q At 85 C expect 1 000 1 100 Q Is the thermistor value correct Fit a new thermistor y Yes Is there continuity in the wiring from the primary PCB to Replace wiring from flow thermistor to the Thermistor 6 way connector connections 5 and primary PCB 6 black and pink y Yes Replace primary PCB 88 OUTsIDE sENSOR F AULT Is the wiring securely connected at both the boiler and Securely connect the wiring at both the Outside Sensor boiler and Outside Sensor Yes Disconnect the wires to the Outside Sensor Check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 Q At 60 C expect 2 400 2 600 Q At 85 C expect 1 000 1 100 Q Is the thermistor value correct Yes Does the Outside Sensor wiring between the boiler No Ensure the wiring has continuity and is terminal strip and the PCB have continuity and is securely connected securely connected 5 way low voltage connector connections 1 and 2 grey and black wires Yes Replace main PCB Fit
29. service should be carried out ANNUALLY Stress the importance of regular servicing by a Gas Safe Registered Engineer In IE servicing work must be carried out by a Registered Gas Installer RGII 12 Inform the householder of the guarantee registration found within the envelope pack and the requirement to register it to receive the full benefit of the warranty vogue combination boiler Installation and Servicing sSERVICINg 44 sERVICINg sChEDULE For the very latest copy of literature for specification amp maintenance practices visit our website www idealboilers com where you will be able to download the relevant information N B Technical Bulletins are also available on www idealboilers com Warning Always turn OFF the gas supply at the gas service cock and switch OFF and disconnect the electricity supply to the appliance before servicing Combustion testing must be carried out by a competent person using a combustion analyser conforming to Bs7927 To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually It is the law that any service work must be carried out by a Gas Safe Registered Engineer In IE service work must be carried out by a Registered Gas Installer RGII INSpECTION gENERAL 1 Light t
30. temperature can be controlled by the user via the draw off tap the lower the rate the higher the temperature and vice versa Explain the function of the boiler fault mode Emphasise that if a fault is indicated the boiler should be turned off and a Gas Safe Registered Engineer consulted In IE contact a Registered Gas Installer RGII Explain and demonstrate the function of time and temperature controls radiator valves etc for the economic use of the system Ifa timer is fitted draw attention to the timer Users Instructions and hand them to the householder 8 Loss of system water pressure Explain that the dial at the front RHS of the boiler indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated Explain the re pressurising procedure and if unable to re pressurise or if the pressure continues to drop a registered local heating installer should be consulted Explain boiler reset procedure refer to Frame 32 After installation and commissioning please complete benchmean THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC th e HEATING AND HOT WATER SYSTEMS Commissioning Checklist before handover to the customer For IE its is necessary to complete a Declaration of Conformity to indicate compliance to l S 813 2002 IMpORTANT 11 Acomprehensive
31. twice to return to normal operation vogue combination boiler Installation and Servicing FAULT hIsTOR y To view the Fault History of the boiler press ENTER and the following screen will be displayed MENU Vent System Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope Press until the following screen is displayed MENU Fault Help Fault History State of Inputs State of Outputs A y Press ENTER and a screen similar to the following will be displayed Fault History A Water Pressure 17 Minutes v Ignition Lockout 3 Days Ago Overheat Lockout 2 Months No Water Flow 1 Year Ago Press and to view the full list Press ExIT twice to return to normal operation sTATE OF INpUTs To view the current Water Pressure Switched Live Status DHW Flow Rate DHW Temperature Flow Temperature Return Temperature Flame Status Outside Temperature DHW Switched Live Status and OpenTherm Status press ENTER and the following screen will be displayed MENU Vent System Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope Press until the following screen is displayed MENU Fault History State of Inputs State of Outputs Service Mode Minimum Rate A y Press ENTER and a screen similar to following will be displayed State of Inputs Water Pressure 1 3 Bar CH Switched Live On Hot Water Flow Rat amp 0 l min Hot Water 60 C Pres
32. 0 300mm 12 300mm 12 300mm 12 300mm 12 300mm 12 2000mm 79 600mm 24 Only one reduction down to 25mm is allowable per installation otherwise BS5440 1 2008 dimensions must be followed vogue combination boiler Installation and Servicing TERMINAL The terminal assembly can be adapted to accommodate various wall thicknesses Refer to Frame 10 AIR sUppLy It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed due to the low surface temperatures of the boiler casing during operation therefore the requirements of BS 6798 Clause 12 and BS 5440 2 may be disregarded WATER CIRCULATION sysTEM IMpORTANT A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping The central heating system should be in accordance with BS 6798 and in addition for smallbore and microbore systems BS 5449 WATER TREATMENT see Frame 5 BOILER CONTROL INTERLOCKs Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating in compliance with Building Regulations Heating systems utilising full thermostatic radiator valve control of temperature in individual
33. 146 6 Table 3 performance Data Domestic hot Water Maximum DHW Input NettCV kW 32 1 40 2 Btu h 109 500 137 200 4 1 Boiler Output Maximum 32 0 40 0 Non Condensing kW 18 0 26 0 32 0 3 7 4 6 DHW Output 109 200 136 500 0 70 C wean Water temp Btu h 61 400 88 700 109 200 12 800 15 700 DHW Flow Rate iin Condensing kW 19 3 27 9 34 3 4 0 4 9 at 35 C temp rise gpm i 40 C Mean Water temp Btu h 65 900 95 300 117 200 13 600 16 700 20 900 Seasonal efficiency SEDBUK 2009 89 1 NOx Classification Class 5 The value is used in the UK Governments Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body Note Gas consumption is calculated using a Key to symbols calorific value of 38 7 MJ m 1038 Btu ft gross B i Ki IE Irel i f inati or 34 9 MJ m 935 Btu ft nett g United Kingdom reland Countries of destination pMs Maximum operating pressure of water To obtain the gas consumption at a different calorific value a For l s divide the gross heat input kW by the gross C V of the gas MJ m C C C A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which in this case are concentric The fan is up
34. 2 3 9 Pressure gauge covering a range of 0 to 4 bar A 10 litre expansion vessel with an initial charge pressure of 0 75 bar Make up Water The water connection and isolation valves incorporate an approved system for filling and topping up the water in the Thoroughly flush out the whole system with cold heating system Refer to Frame 24 for details of how to fill water SNOOP Up the system Fill and vent the system until the pressure gauge The maximum cold water capacity of the system should registers 1bar and examine for leaks Refer to Frame not exceed 159 litres if not pressurized However if the 24 for filling detail system is to be pressurized the efficiency of the expansion Check the operation of the safety valve by raising the vessel will be reduced and a larger vessel or smaller system water pressure until the valve lifts This should occur volume may be necessary If the capacity of the vessel is within 0 3bar of the preset lift pressure not considered sufficient for this or for any other reason an additional vessel MUST be installed on the return to the boiler Release water from the system until the minimum system design pressure is reached Guidance on vessel sizing is given in Table above 1 0 bar if the system is to be pre pressurised Filling The system may be filled by the following method Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling c
35. 210 Fan Adaptor 211 Venturi Deflector 212 Condensate Hose 213 Flue Turret Clamp 214 Siphon trap 218 Flue Manifold 219 Flue Manifold Seal 220 Fan Adaptor Seal 302 Primay PCB 303 CUI Board 304 Thermistor Flow amp Return 306 Electrode Ignition 307 Electrode Detection IFEN P 73 308 Ignitor Unit 317 Control Box Front 318 Control Box Lid 319 Programmer Blank Insert 320 Control Box Complete 321 Control Box Hinges 401 Heat Engine 403 Heat Engine Gasket 404 Burner Door 501 Front Panel Door 503 Wall Mounting Plate 504 Bracket Ignition Note that production boiler PCBs are factory pre set to operate for boiler range and output but when ordering Primary PCB as a spare an additional Boiler Chip Card BCC MUST also be purchased for your specific boiler range and output Check boiler serial letter code on data plate to obtain correct BCC 13 INSTALLATION INSTALLATION INSTALLATION 7 UNPACKINg The boiler is supplied fully assembled in Pack A A telescopic or non telescopic flue assembly for rear or side flue outlet in Pack B is supplied as a separate order Unpack and check the contents pack A Contents Boiler Hardware Pack Box Wall Mounting Plate These Installation Instructions Wall Mounting Template located on internal protective packaging Turret Clamp Pressure Relief Valve Drain Pipe Boiler Guarantee amp Registration Pack
36. 40 1 Flues for gas appliances of rated input not exceeding 70 kW Bs 5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW BsEN 12828 2003 Heating Systems in buildings Design for water based heating systems Heating Systems in buildings Method for calculation of the design heat load Heating Systems in buildings Installation and commissioning of water based heating systems BsEN 12831 2003 BsEN 14336 2004 Bs 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases Bs 6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW Bs 6891 Low pressure installation pipes health amp safety Document No 635 The Electricity at Work Regulations 1989 The manufacturer s notes must NOT be taken in any way as overriding statutory obligations IMpORTANT These appliances are CE certificated for safety and performance It is therefore important that no external control devices e g flue dampers economisers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Ideal stelrad group in writing If in doubt please enquire Any direct connection of a control device not approved by Ideal stelrad group could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations SAFE hANDLIN
37. C HEATING AND HOT WATER SYSTEMS www centralheating co uk 72 FLOWChART FOR CO LEVEL AND COMBUSTION RATIO ChECK ON COMMIssIONINg A CONDENsINg BOILER Important preliminary Information on Checks The air gas ratio valve is factory set and must not be adjusted DURING COMMISSIONING If the boiler requires conversion to operate with a different gas family e g conversion from natural gas to LPG sepa rate guidance is provided with the conversion kit supplied and this must be followed pRIOR TO CO LEVEL AND COMBUsTION RATIO ChECK The installation instructions must have been followed gas type verified and gas supply pressure gas rate checked as required prior to commissioning As part of the installation process ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that maximum flue lengths have not been exceeded and all guidance has been followed e g Gas Safe Register Technical Bulletin TB 008 where chimney flues are in voids The ECGA should be of the correct type as specified by BS 7967 Prior to its use the ECGA should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer s instructions
38. ERM pROgRAMMABLE ROOM sTAT OpenTherm Remove the link wire between the Room Stat Timer terminals Programmable Room Stat Connect the OpenTherm Programmable Room Stat across the terminals as shown in the Diagram Unclip the 3 way connector from the back of the internal timer plastics goomsrar Gmarine ukose MAINS IN OUTSIDE OPEN and connect to the 3 way connector adjacent to the plastics AMMER PORE STAT b No EE ee DO nOT COnnECT 230V TO THESE TErMinaLS Or THE BOiLEr O is ELECTrOniCS WiLL BE DaMagED O a Q Cy g heating zone 2 Programmable Programmable Room Stat 1 Room Stat 2 It is possible to set 2 different flow temperature targets for 2 different heating zones To do this Programmable Room Thermostats should be 9 T connected as shown in the Diagram The Flow Temperature target for zone 1 is set using the CH temperature Knob while the Flow Temperature target for Zone 2 is set using the boiler menu see Frame 41 Note that Com star OPTIONAL OPTIONAL MAINS m HEATING if there is a demand from both zones at the same time then the higher MMER zone2 stat u wN target temperature will be used CHOCO dogodggggo vogue combination boiler Installation and Servicing 29 INSTALLATION INSTALLATION uaasB mojyjah
39. HE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk sERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate service Interval Record is completed service provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls sERVICE 01 sERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature sERVICE 03 sERVICE 04 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 05 SERVICE 06 Engineer name Engineer name Company name Company name
40. INSTALLATION AND SERVICING VOGUE COMB C26 C32 C40 For details of document amendments refer to page 3 When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of literature for specification and maintenance practices visit our website www idealboilers com where you can download the relevant information in PDF format May 2014 UIN 208548 AO6 L vogue combination boiler Installation and Servicing NOTEs FOR ThE INsTALLER FOR ANy TECHNICAL qUERIEs pLEAsE RINg ThE INSTALLER hELpLINE 01482 498704 NOTE BOILER REsET pROCEDURE To reset boiler press button r on the control panel The boiler will repeat the ignition sequence if a heat demand is present DOCUMENT AMENDMENTs Relevant Installation changes implemented in this book from Mod Level A05 Jan 14 to A06 May 14 Cover page Re brand front cover Ideal Stelrad Group reserve the right to vary specification without notice vogue combination boiler Installation and Servicing 3 gENERAL Table 1 general Data Vogue 32 Gas supply 2H G20 20mbar Gas Supply Connection 22mm copper compression Injector Size mm 4 30 4 40 5 15 Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection Domestic Hot Water 15mm coppe
41. IRED CONT D Flg U R E 1 Edge of turret Edge of turret Edge of turret to outside face of wall plus to outside face of wall plus to outside face of wall plus 44mm flue length 44mm flue length 44mm flue length A Note Maximum permissible flue length is measured from centre line of appliance flue outlet to outside wall face to wall inc Stand off Frame Minimum clearance 2 5mm Flue length measured from outer terminal li to end of outer flue NOTES A 44mm Centre of turret to edge of turret 100mm Turret has a flue insertion of 30mm The distance from the outer wall face to the wall seal flue mounting point is 14mm ia Wall Mounted template amp Flue FIgURE 2 Actual maximum flue length requirements outside edge of turret to out side face of wall plus 44mm Cut Length Minimum amp Maximum finished flue lengths obtainable dimension A 44mm horizontal Flue Terminal Telescopic Flue B pack horizontal Flue horizontal Flue Terminal 600mm long B pack Terminal 1000mm long 1000mm long B pack B pack Telescopic Telescopic Cut 75mm Maximum 734 1744 2694 Plus 3 1m D pack 3644 Plus 4 1m D pack 4594 Plus 5 1m D pack 5544 Plus 6 1m D pack 6494 Plus 7 1m D pack 7444 Plus 8 1m D pack 8394 9344 Plus 10 1m D pack N A Max output 32 amp 40 kW Max output 26 kW Note Telescopic flue B Pack or attached D pack extensions do not need to be cut between minimu
42. Ng FAULT FINDINg FAULT FINDINg vogue combination boiler Installation and Servicing 61 FAULT FINDINg 84 FLAME LOss If the boiler is Reset does the boiler Ignite for a Check the Detection Electrode and associated Harness short time and then Extinguish gt for continuity visual condition and position Check if the Condensate Pipe is blocked Check if the Flue is blocked Replace as necessary No Is the Gas Pressure available at the boiler gt 18 mbar Check Gas Supply and rectify fault l Yes Is 215Vdc available at the Gas Valve during No Check wiring from Gas Valve to PCB and replace if ignition See note 7 necessary otherwise replace the main PCB Yes Check Spark Generator and associated Harness NO Replace Spark Generator and Harness for continuity visual condition and position refer to as necessary Frame 60 Are these functioning correctly l Yes Check Ignition Electrode and associated Harness for continuity visual condition and position refer to Frame 58 Are these functioning correctly Yes Check Syphon and condensate drain pipework Replace Gas Valve for blockage and rectify if necessary Boiler now working OK Replace Ignition Electrode and associated Harness as necessary Note due to the wave form of the rectified voltage the reading will vary depending on the type of meter used to measure the val
43. ON 42 gENERAL ChECKs WATER CIRCULATION sysTEM 1 With the system COLD check that the initial pressure is correct to the system design requirements Notes 1 If the pump has not operated in the last 24 hours it will run briefly to prevent seizure 8 Finally set the controls to the User s requirements For pre pressurised systems this should be 1 0 bar With the system HOT examine all water connections for soundness The system pressure will increase If the diverter valve has not operated in the last 24 hours with temperature rise but should not exceed 2 5 bar it will be operated briefly to prevent seizure These two With the system still hot turn off the gas water and operations will not occur at the same time electricity supplies to the boiler and drain down to complete the flushing process Note A flushing solution should be used during the flushing procedure Flushing solutions Fernox F3 or DS40 Sentinel X300 new systems or X400 existing systems Refill and vent the system add inhibitor see Frame 24 clear all air locks and again check for water WATER TEMpERATUREs soundness Temperatures can be selected using the CH and DHW thermostats Reset the system initial pressure to the design Knob setting Ch Flow Temp DhW Outlet Temp requirement C F C F Balance the system Refer to Frame 4 Check the condensate drain for leaks and check that ven 804178 634143 it is discharging
44. Refit in reverse order making sure the trap is engaged with the outlet connection Refill the condensate trap Check the operation of the boiler Refer to Frames 33 36 64 MAIN pCB REpLACEMENT 1 Refer to Frames 45 amp 46 Refer to Frame 53 2 3 Remove the electrical cover at the clips 4 Carefully disconnect all electrical connectors Remove pcb from mounting posts Take the new Primary PCB and attach the appropriate Boiler Chip Card BCC to it this should correspond to the output of the boiler 26kW 32kW or 40kW Note Ensure the correct orientation of BCC by placing TOP side up as shown Replace in reverse order Check the operation of the boiler Refer to Frames 33 36 52 vogue combination boiler Installation and Servicing sSERVICINg 65 UsER pCB REpLACEMENT 1 Refer to Frames 45 amp 46 2 Refer to Frame 53 3 Set both the user temperature selector knobs to the 12 o clock position Remove the electrical cover at the oe BM WW clips indicated Refer to Frame Cs 64 a fp Disconnect all electrical connectors carefully Remove pcb from mounting posts Replace the pcb in reverse order Check the operation of the boiler Refer to Frames 33 36 66 DhW FLOW TURBINE sENsOR REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Lift off the flow turbine sensor plastic retaining clip Unplug the electrical connection and
45. Super Etfidenc Boiler Frost protection occurs if Flow Temperature less than 5 C system Frost protection occurs if Outside Sensor connected amp Outside Temp lt 5 C amp System Frost Protection selected in Menu service Due shown after 12 months operation see Frame 33 to reset Boiler Frost Protection Switch Off Temperature 19 C System Frost Protection Go to MENU to disable Turn illl dial for Heating Press Enter for MENU Super Efficiency Press Enter for MENU Press Enter for MENU L Service Due Phone 01482 498660 vogue combination boiler Installation and Servicing INSTALLATION 36 ChANgINg sETTINgs To change the DhW Temperature set point Rotate the DHW l 60 c A Temperature Control Knob the screen on the right will be shown Select Hot Water Temperature To change the Flow Temperature set point Rotate the CH III n 70 c A Temperature Control aE Knob the screen on the right will be shown Select Radiator Temperature To switch Ch function ON Rotate the CH AT d 70 c A Cono Temperature Control Knob clockwise the screen on the right will be Select Radiator Temperature shown To switch the Ch function OFF Rotate the CH Temperature Control Knob fully anti clockwise the screen on the right will be shown To disable DhW and Ch Rotate the DHW Temperature Knob fully anti clockwise the screen on the right will be shown frost
46. Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 07 sERVICE 08 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature sERVICE 09 Signature SERVICE 10 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature Allinstallations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer Heating and Hotwater Industry Council HHIC Signature penchiman THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTI
47. al to 20 6 OR CO2 ess than or equal to Check CO level and Combustion Ratio y at Maximum gas Rate equal to 20 6 OR CO2 e3 less than or equal to gt With boiler still set at maximum gas rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Turn off appliance and call Ideal Technical helpline for advice The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with GSIUR CO level less han 350ppm AND CO COz2 ratio less than 0 0040 Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary set Boiler to Minimum gas Rate Refer to Frame 39 In accordance with boiler instructions set boiler to operate at minimum rate to minimum load condition Allow sufficient time for combustion to stabilise ratio less than 0 0040 Check CO and Combustion Ratio at Minimum gas Rate With boiler set at minimum rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Turn off Appliance and Call Ideal Technical helpline The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from t
48. arget 2000rpm Fan Actual 1950rpm Press ExIT twice to return to normal operation 38 sERVICE MODE MAxIMUM RATE This feature will run the burner at maximum rate Note that a CH demand has to already be present for the feature to be active Gas rate will reduce as flow temperature approached 80 C To activate the feature press ENTER and the following screen will be displayed MENU Vent Syst ent System 7 Maximum Flow Temperature Outside Sensor Slope Press until the following screen is displayed MENU Service Mode Minimum Rate Service Mode Maximum Rate Show Efficiency Level A y System Frost Protection Press ENTER and the following screen will be displayed Service Mode Maximum Rate D Fan Target 5000rpm Fan Actual 4950rpm Press ExIT twice to return to normal operation EFFICIENCy LEVEL To view the efficiency level of the boiler press ENTER and the following screen will be displayed MENU Vent System Switch Pre Heat Maximum Flow Temperature 4 y Outside Sensor Slope Press until the following screen is displayed MENU Service Mode Maximum Rate y Show Efficiency Level System Frost Protection Reset Service Time Press ENTER and a screen similar to following will be displayed Efficiency Level 1346 29260 Hours Hours High Super Efficiency Efficiency Press ExIT twice to return to normal operation vogue combination boiler Install
49. at is selected from the menu When there is a demand for CH the heating system is supplied at the selected temperature of between 30 C and 80 C until DHW is drawn off The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW draw off of 26 10 6 l min at 35 C temperature rise 32 13 1 l min at 35 C temperature rise 40 16 4 l min at 35 C temperature rise The DHW draw off rate specified above is the nominal that the boiler flow regulator will give Due to system variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap At low DHW draw off rate the maximum temperature is limited to 65 C by the modulating gas control The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating and performance of key components to aid commissioning and fault finding SAFE hANDLINg This boiler may require 2 or more operatives to move it to its installation site remove it from its packaging base and during movement into its installation location Manoeuvring the boiler may include the use of a sack truck and involve lifting pushing and pulling Caution should be exercised during these operations Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered G
50. ation and Servicing INSTALLATION 40 MENU OpERATION sysTEM FROsT pROTECTION This feature can only be accessed if an outside sensor has been connected The pump will run continuously if the outside temperature is less than 5 C MENU A Vent System y Maximum Flow Temperature Outside Sensor Slope oy Press until the following screen is displayed MENU Show Efficiency Level Vv System Frost Protection Reset Service Time Plot Graphs Press ENTER and a screen similar to the following will be displayed System Frost Protection a Com SAVE press Enter Pump may run during night oo Press to activate or to de activate Press ExIT twice to return to normal operation REsET sERVICE TIME If the boiler has not been serviced within the last 12 months then a message will be displayed indicating this To reset this timing proceed as follows MENU Vent Syst A ent System y Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope oo Press until the following screen is displayed MENU System Frost Protection y Reset Service Time Plot Graphs Bus Address Press ENTER and the following screen will be displayed Reset Service Time days Service Reset press due Press ENTER to reset Press ExIT to return to normal operation vogue combination boiler Installation and Servicing pLOT gRAphs To plot graphs of Water Pressure Switche
51. commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations Installers are required to carry out work in accordance with the following penchmani THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The use of the word installer is not limited to installation itself and covers those carrying out installation commissioning and or servicing of heating and hot water products or the use of supporting products such as water treatment or test equipment Customer includes householders landlords and tenants Heating and Hotwater Industry Council HHIC Standards of Work Be competent and qualified to undertake the work required Install commission service and use products in accordance with the manufacturer s instructions provided Ensure that where there is responsibility for design work the installation is correctly sized and fit for purpose Meet the requirements of the appropriate Building Regulations Where this involves notifiable work be a member of a Competent Persons Scheme or confirm that the customer has notified Local Authority Building Control LABC prior to work commencing Complete all relevant sections of the Benchmark Checklist Service Record when carrying out commissioning or servicing of a product or system En
52. correctly Min 30 86 40 104 vogue combination boiler Installation and Servicing 41 INSTALLATION INSTALLATION INSTALLATION 43 hANDINg OVER After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions 42 Make the householder aware that the user instructions are located in the pocket in the drop down door and explain his her responsibilities under the relevant national regulations Explain and demonstrate the lighting and shutting down procedures The operation of the boiler and the use and adjustment of all system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions Explain the function and the use of the boiler heating and domestic hot water controls Explain that due to system variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap It is therefore necessary to draw the users attention to the section in the Users Instructions titled Control of Water Temperature and the following statement Additionally the
53. d Live DHW Flow Rate DHW Temperature Flow Return Temperature Flame Status Outside Temperature or DHW Switched Live press ENTER and the following screen will be displayed MENU Vent System Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope Press until the following screen is displayed MENU Reset Service Ti eset Service Time v Bus Address Maximum Flow Temperature Press ENTER and the following screen will be displayed Plot Graphs Select Water P ater Pressure y CH Switched Live Hot Water Flow Rate Hot Water Press amp to highlight the desired input and then ENTER to select Press ExIT 3 times to return to normal operation BUs ADDREss This feature is only required if the boiler is connected to an Ideal Cascade Manager available 2014 Each boiler in the cascade should be configured to a different bus address To change the bus address press ENTER MENU Vent Syst amp ent System y Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope Press until the following screen is displayed MENU Plot Graph ot Graphs x Maximum Flow Temperature Installer s Details Press ENTER and a screen similar to following will be displayed Bus Address A y Only changed for Multiple Boiler Installations Press or to change the address Press ENTER and then ExIT to return to normal operation 39
54. e local water company IMpORTANT Provision must be made to accomodate the expansion of DHW contained within the appliance If the DHW inlet contains a back flow prevention device or non return valve e g a water meter then a mini expansion vessel should be fitted between the device and the boiler in the cold inlet pipe Cold water rising main amp pipework in exposed areas need to be suitably lagged to prevent freezing Note DHW Expansion Vessel kit available from Ideal 5 WATER TREATMENT CENTRAL hEATINg The Vogue range of boilers have a stainless steel heat exchanger IMpORTANT The application of any other treatment to this product may render the guarantee of Ideal stelrad group Invalid Ideal stelrad group recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems If water treatment is used Ideal stelrad group recommend only the use of SCALEMASTER GOLD 100 FERNOx MBI ADEY MC1 or SENTINEL x100 inhibitors and associated water treatment products which must be used in accordance with the manufacturers instructions Notes 1 Itis most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers instructions If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing BS 7593 2006 details the steps necessary to clean a domestic
55. e the 2 clips securing the gas inlet pipe and remove the pipe Remove the fan leads Remove the 4 securing nuts from the heat exchanger Remove the assembly from the heat exchanger Brush off any deposits with a SOFT brush 8a Inspect the burner door sealing gaskets and insulation for signs of damage Replace as necessary Replacement of burner door sealing gasket 8b Remove the silicon seal from around the burner door location 9 SERVICING groove Re new the seal and replace in reverse order 50 CLEANINg ThE CONDENSATE TRAp siphON 1 46 Remove the rubber condensate pipe from the top of the trap Rotate the trap clockwise to disengage the trap and lift clear of the outlet connection Flush out any debris under running water Refit in reverse order making sure the trap is engaged with the outlet connection Fill the trap with water before operating the boiler vogue combination boiler Installation and Servicing sSERVICINg 51 CLEANINg ThE hEAT ExChANgER 1 1 Remove Fan and Venturi Assembly Refer to Frame 47 Once the front of the heat exchanger is open the heat exchanger may be cleaned with a hand brush and vacuum cleaner to remove any debris 52 RE AssEMBLy Reassemble the boiler in the following order Ensure the condensate trap is engaged in the base of the boiler and connected to the outlet with the pipe from the heat exchanger connected
56. e water as a lubricant during assembly The B pack terminal is classed as part of the maximum flue length This flue system incorporates a removable flue outlet nose that utilises a push fit location system This enables the installation of deflector high level or balcony flue kits without the removal of the whole B pack terminal The appliance must not be operated without the desired outlet nose correctly fitted in place ensuring the side location dimples are in line with the mounting face allowing the correct sealing of the components It is IMPORTANT that all attachments are fitted in accordance to the installation instructions provided with them The TURRET supplied in the B Pack has an upper combustion sample point with a screw cap seal and a lower air sample point with an air stopper seal Ensure all caps amp seals are in place Additional Termination Kits available for use with these B packs Flue Deflector Kit The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from any maximum flue length High Level Flue Outlet Kit The maximum permissible concentric flue length when using a standard 500mm kit is 4 5 metres Balcony Flue Outlet Kit The maximum permissible concentric flue length when using this kit is dependant on the length of the balcony flue outlet run which combined with the concentric run must not exceed the maximum flue length requirement of the appliance it is to be fit
57. ealed condensate trap Min 30mm Internal pipe Water Weather proof insulation Min 19mm Internal pipe Max 3m external pipework ire N N A Limestone chippings Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house 22 vogue combination boiler Installation and Servicing INSTALLATION 20 FITTINg ThE OpTIONAL ROOF FLUE KIT Flat or pitched Note A flat or pitched roof flashing plate not supplied is required before proceeding with the installation of this kit This kit is suitable for both flat and pitched roof terminations using a concentric flue to run vertically from the top of the boiler and terminating above roof level Connection to the top of the boiler is made using a separately supplied vertical connector WEAThER pROOFINg Where the flue passes through the roof line an adequate seal must be made This is achieved by using either Flat roof weather collar or Universal weather collar ACCEssORIEs Flue Duct Extension Kits are available for flue lengths extending beyond 1m These packs contain 1m extension ducts and may be cut to the desired length If the offset vertical option is used an elbow Kit is required For a full accessories list refer to page 7 Optional Extras and Frame 21 Flue
58. ecure the spark generator assy using 2 screws in the top of the case Check the operation of the boiler Refer to Frames 33 36 61 gAs CONTROL VALVE REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Remove the gas inlet pipe Refer to Frame 54 Unplug the electrical connection Disconnect the earth lead at the rear of the gas valve Disconnect the gas service valve Remove the 2 securing screws in the underside of the boiler casing and remove the valve Remove brass injector from gas valve outlet and re fit into replacement valve Replace in reverse order ensuring all seals are in good condition and the assembly is gas sound 10 Check the operation of the boiler Refer to Frames 33 36 62 DIVERTER VALVE ACTUATOR REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Remove the condense trap Refer to Frame 50 Disconnect the electrical cable connection Withdraw the securing clip Lift the valve actuator clear of the valve body Replace in reverse order Check the operation of the boiler Refer to Frames 33 36 vogue combination boiler Installation and Servicing 51 SERVICING SERVICING sERVICINg 63 CONDENSATE TRAp REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Remove the rubber condensate pipe from the top of the trap Rotate the trap clockwise to disengage the trap and lift clear of the outlet connection
59. egister number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLs tick the appropriate boxes Room thermostat and programmer timer Programmable room thermostat Time and temperature control to heating Load weather compensation Optimum start control Time and temperature control to hot water Cylinder thermostat and programmer timer Combination Boiler Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL sysTEMs The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions What system cleaner was used What inhibitor was used Quantity Has a primary water system filter been installed CENTRAL hEATINg MODE measure and record Gas rate OR Burner operating pressure if applicable OR Gas inlet pressure Central heating flow temperature Central heating return temperature COMBINATION BOILERs ONLy Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted
60. er flows from each tap Disconnect filling loop Refer to Frame 24 Check operation of the boiler Refer to Frames 33 36 QO I vogue combination boiler Installation and Servicing 53 SERVICING SERVICING sSERVICINg 68 pREssURE gAUgE RENEWAL Refer to Frames 45 amp 46 Refer to Frame 53 Close the isolating service valves and drain the CH boiler Remove the clip retaining the pressure sensor Remove the sensor Remove the electrical cover at the clips indicated Refer to Frame 64 Remove the clip retaining the pressure gauge and remove the gauge drawing the capillary carefully out of the boiler Refit in reverse sequence Refill the CH system Refer to Frame 67 Check the operation of the boiler Refer to Frames 33 36 69 pREssURE RELIEF V ALVE RENEWAL Refer to Frames 45 amp 46 Refer to Frame 53 Close the isolating service valves and drain the CH boiler Refer to Frame 67 Remove the burner amp Fan assembly Refer to Frame 47 Remove the CH Water Pressure Sensor Refer to Frame 75 Undo the PRV outlet retaining nut retaining the washer Remove the securing clip at the rear of the valve body Withdraw the valve vertically Renew the valve and refit in reverse order Refill the CH system Refer to Frame 67 Check the operation of the boiler Refer to Frames 33 36 54 vogue combination boiler Installation and Servicin
61. ermination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc fig 3 External Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose designed soak away If an external system is chosen then the following measures must be adopted The external pipe run should be kept to a minimum using the most direct and most vertical route possible to the discharge point with no horizontal sections in which condensate might collect For connections to an external soil vent stack see Fig 4 Insulation measures as described should be used When a rainwater downpipe is used an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse flow of rainwater into the boiler should the downpipe become flooded or frozen see Fig 5 Where the condensate drain pipe terminates over an open foul drain or gully the pipe should terminate below the grating level but above water level to minimise wind chil
62. ernal pipe Min 19mm Internal pipes Soil amp vent stack Min 19mm Internal pipe Minimum connection height up to 3 storeys Ta Condensate pump Install in accordance with manufacturers instructions Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break Figure 6 Connection of Condensate Drainage Pipe Upstream of a Sink Basin Bath or Shower Waste Trap to External Drain Gulley or Ranwater Hopper Figure 5 Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe only combined foul rainwater drain Boiler with 75mm sealed condensate trap Boiler with 75mm sealed condensate Water trap weather proof i ml insulation combined foul J rain water drain Min 19mm Visible air break at plug hole Water weather proof insulation Min 19mm Internal pipe Min 30mm Internal pipe External air break _ Air gap Internal pipe i Sink basin bath or shower with integral overflow and 75mm trap a Minimum 30mm internal pipe Terminated and cut at 45 2 25 Below grate L j m 45 pipe termination 43mm 90 male female bend 68mm PVCU Strap on fitting Figure 7 Connection of a Condensate Drainage Pipe to an External Purpose Made Soak Away Boiler with 75mm s
63. essure and gas rate have been verified then contact Ideal Complete the service section in the Benchmark Commissioning Checklist vogue combination boiler Installation and Servicing 43 SERVICING sERVICING sERVICINg 45 BOILER FRONT pANEL REMOVAL REpLACEMENT REMOVAL Loosen the 2 screws retaining the front panel at the bottom Release catches at rear of door by pulling downwards Pull the underside front panel forward then lift upwards to remove REpLACEMENT 3 Engage the top of the front panel on the locating lugs and push the panel back into position engaging the securing screws 4 Re tighten the securing screws 46 LOWERINg ThE CONTROLs p ANEL 1 Once the front panel has been removed Position 1 the controls panel can be hinged down to access the wiring and electronics or the internal components of the boiler To lower the panel further position 2 squeeze the 2 clips inward and hinge the panel into a lower position To gain access to the mains wiring connection squeeze the 2 lugs together and remove the cover 44 vogue combination boiler Installation and Servicing sSERVICINg 47 FAN AND VENTURI AssEMBLy REMOVAL AND CLEANINg Refer to Frame 45 amp 46 Remove the ignition detection and earth leads Remove the 2 clips securing the gas inlet pipe and remove the pipe Remove the fan leads Remove the 4 securing nuts retaining the burner fan
64. eturn valve gAs CONNECTION IMpORTANT The gas service cock is sealed with a non metallic blue fibre washer which must not be overheated when making capillary connections Refer to Frame 1 for details of the position of the gas connection For additional gas supply info refer to Gas Supply on page 8 pREssURE RELIEF VALVE DRAIN The pressure relief valve connection located at the bottom right hand side of the boiler comprises a 15mm diameter stub pipe The Installer to provide a compression joint on the end of the stub pipe This assists with pipe removal when servicing The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring CH Flow A purpose made pressure relief valve drain pipe is provided with the boiler to allow safe discharge through a wall to the outside of the building This is particularly relevant to high rise installations but can be used for all installations Pressure Relief Valve Drain Connection 15mm elbow or fittings not supplied Pressure Relief Valve Drain Pipe 26 Note The domestic hot water flow rate is automatically regulated to a maximum 26 10 7 l m 2 2 gpm 32 13 1 Vm 2 8 gpm 40 16 4 l m 3 2 gpm FILLINg IMpORTANT when filling When filling there may be a slight water leak from the air vent therefore elec
65. g sSERVICINg 70 pUMp AUTO AIR VENT REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Close the isolating service valves and drain the CH boiler Refer to Frame 67 Remove the burner amp Fan assembly Refer to Frame 47 Remove return pipe connected at top of pump and heat exchanger The auto air vent is retained in the pump body with a bayonet connection The air vent and float assembly is removed by turning the head anti clockwise viewed from above and pulling upwards Reassemble in reverse order Ensure the air vent head o ring seal is in place when refitting and the seal is in place at the pump outlet connection Refill the CH system Refer to Frame 67 10 Loosen the cap of the air vent 11 Check the operation of the boiler Refer to Frames 33 36 71 DhW FLOW TURBINE sENsOR REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Lift off the flow turbine sensor plastic retaining clip Unplug the electrical connection and transfer to new turbine sensor Reassemble in reverse order Check operation of the boiler Refer to Frames 33 36 72 DIVERTER VALVE INTERNAL CARTRIDgE REpLACEMENT 1 Refer to Frames 45 amp 46 2 Refer to Frame 53 3 Close the isolating service valves and drain the CH boiler Refer to Frame 67 Remove the Condense trap Refer to Frame 50 5 Disconnect the diverter valve head cable 6 Remove the diverter head retaining cli
66. g OF sUBsTANCEs No asbestos mercury or CFCs are included in any part of the boiler or its manufacture gENERAL LOCATION OF BOILER The boiler must be installed on a flat and vertical internal wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by the local authority For electrical safety reasons there must be no access available from the back of the boiler The boiler must not be fitted outside Timber Framed Buildings If the boiler is to be fitted in a timber Framed building it should be fitted in accordance with the Institute of Gas Engineering document IGE UP 7 2006 Edition 2 Bathroom Installations This appliance is rated Ip20 The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current IEE BS 7671 Wiring Regulations and the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower For IE reference should be made to the current ETCI rules for electrical installations and l S 813 2002 If the appliance is to be installed in a room containing a bath or shower then providing water jets are not going to be used for cleaning purposes as in communal baths showers
67. g each control separately and check that the main burner responds vogue combination boiler Installation and Servicing DOMEsTIC hOT W ATER Fully open a DHW tap The boiler will continue to run and the following screen will be displayed mi NO DEMAND Timer or Room Stat Off The temperature shown will be the actual DHW temperature Close all taps except the largest draw off bath and check that the boiler is firing in DHW This is factory set to give a DHW temperature rise of approximately 35 C at the flow rate stated on page 6 under operation At full DHW output check the gas rate at the gas meter with no other appliances in use Refer to page 9 for gas rates Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output Refer to Table 1 note to achieve maximum output in DHW operation all taps may need to be opened Fully open all DHW taps in turn and ensure that water flows freely Reduce the DHW draw off rate to about 3 l min 0 7gpm and check that the boiler modulates to deliver DHW at approximately 64 C with the DHW temperature control knob set to maximum Close the DHW tap and check that the main burner extinguishes The pump will overrun for 60 seconds while the fan overruns for 2 minutes The following screen will be displayed m NO NO DEMAND DEMAND Timer or Room Stat Off IMpORTANT The gas input to the burner is regulated by the gas valve accordin
68. g to the air flow produced by the fan Itis NOT user adjustable Any interference to sealed settings on the gas valve will adversely affect operation and render warranty void For additional information refer to Gas Supply on page 8 Note on systems in excess of 2 bar inlet pressure a water pressure governor may be required to prevent water noise 33 INSTALLATION INSTALLATION INSTALLATION 35 DispLAy FUNCTIONs IN NORMAL OpERATION Boiler switched Off DHW Knob in Off Position DhW Demand Off CH Knob in Off Position DhW Demand On CH Knob in Off Position DhW Demand Off Ch Demand Off DhW Demand On Ch Demand Off DhW Demand On Ch Demand On DhW Demand Off Ch Demand On pre heat Demand On 34 Turn A dial for Heating or H gt oad DEMAND Turn llll dial for Heating E ad a o o fo Turnilill dial for Heating Mi DEMAND DEMAND Timer or Room Stat Off Ed 2 o z fo Al Timer or Room Stat Off 2 o Sell Jer Z T Bs Priority a Sel Je a e z H So 27 re z o ad Pre Heat 50 C Turn lll dial for Heating Press Enter for MENU ot Water Press Enter for MENU Press Enter for MENU Super Effidency Press Enter for MENU Press Enter for MENU Super Effickency Press Enter for MENU Press Enter for MENU Super Efficiency Press Enter for MENU
69. gap on the replacement ignition electrode is 4 5 0 5mm Ensure the sealing gasket is fitted and in good condition Carefully feed the electrode into the burner door assembly and secure with the 2 screws ensuring correct orientation Reconnect the lead and earth Check the operation of the boiler Refer to Frames 33 36 63 FLAME DETECTION ELECTRODE REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Disconnect the detection lead Release the 2 securing screws and withdraw the probe Ensure the sealing gasket is fitted to the replacement electrode and in good condition Carefully feed the electrode into the burner door assembly and secure with the 2 screws ensuring correct orientation Reconnect the lead Check the operation of the boiler Refer to 50 Frames 33 36 vogue combination boiler Installation and Servicing sSERVICINg 60 spARK gENERATOR REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Remove the 2 securing screws at the top of the casing ensuring the expansion vessel is safely supported and withdraw the spark generator assy 4 Disconnect the leads from the generator Remove 2 securing screws To replace connect all wiring and then fix the generator in position using the 2 securing screws ensuring the earth lead is firmly fixed under the lower securing screw and the expansion vessel is correctly located S
70. h the manufacturers instructions For further information contact Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ 44 0 8706 015000 Sentinel Performance Solutions The Heath Business amp Technical Park Runcorn Cheshire WA7 4Qx Tel 0800 389 4670 Scalemaster Water Treatment Products Emerald Way Stone Staffordshire ST15 OSR Tel 44 0 1785 811636 Calmag Ltd Unit 3 6 Crown Works Bradford Road Sandbeds Keighley West Yorkshire BD20 5LN Tel 44 0 1535 210320 Adey Professional Heating Solutions Gloucester Road Cheltenham GL51 8NR Tel 44 0 1242 546700 vogue combination boiler Installation and Servicing INSTALLATION 6 BOILER AssEMBLy Exploded View Note that item numbers are linked to the spares list 104 CH Return Valve 105 CH Flow Valve 106 DHW Outlet 107 Filling Loop 108 Pump Head 111 Divertor Valve Head 112 Divertor Valve Cartridge 113 Pressure Relief Valve 114 Pipe PRV Outlet 115 Pipe Flow 116 Pipe Return 117 Pipe Expansion Vessel 118 Expansion Vessel 119 Return Group Manifold 120 Flow Group Manifold 121 Plate Heat Exchanger 123 Flow Sensor Hall Effect 124 Flow Turbine Cartridge 125 Water Pressure Transducer 127 Pressure Gauge 203 Pipe Gas Inlet 204 Gas Valve 205 Injector Gas 207 Venturi 208 Fan 209 Gasket Fan Venturi Model shown c40 vogue combination boiler Installation and Servicing
71. he boiler and carry out a pre service check noting any Please note During routine servicing and after any operational faults maintenance or change of part of the combustion 2 Check the flue terminal and terminal guard if fitted is undamaged circuit the following must be checked and clear of any obstruction The integrity of the flue system and the flue seals 3 Check all water and gas joints for signs of leakage Remake any suspect joints ensuring a gas tightness check is carried out if applicable and the water system is correctly refilled vented and re pressurised The operational working gas inlet pressure at maximum rate CLEANINg pROCEDURE The gas rate Note In order to carry out either servicing or replacement of The combustion performance components the boiler front panel must be removed Refer to COMpETENCE TO CARRy OUT ThE ChECK Frame 45 OF COMBUsTION pERFORMANCE Clean the main burner Refer to Frame 49 f Please note BS 6798 2009 Specification for Clean the heat exchanger amp condensate trap siphon Refer to installation and maintenance of gas fired boilers of Frames 50 amp 51 rated input not exceeding 70kW net advises that Check the main injector for blockage or damage Refer to Frame i 48 The person carrying out a combustion oe measurement should have been assessed as Check that the flue terminal is unobstructed and that the flue competent in the use of a flue gas analyser and system is sea
72. he gas supply in accordance with GS I amp U R NOTE Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ideal CO level less han 350ppm AND CO CO ratio less than 0 0040 Boiler is Operating satisfactorily No further actions required Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed Complete Benchmark Checklist recording CO and combustion ratio readings as required vogue combination boiler Installation and Servicing 73 74 NOTES vogue combination boiler Installation and Servicing NOTES vogue combination boiler Installation and Servicing 75 For additional fault finding advice please visit our website www idealboilers com Technical Training The Ideal Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers 4 CNCHIIG 01482 498 432 COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The code of practice for the installation Manufactured unae ana commissioning amp servicing of central heating systems registered quality management system FM 59915 Ideal P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No Londo
73. he outer flue place a mark at the RINg top of the flue approximately 20mm wide amp write stop the terminal side of the line Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure its cut square Remove all burrs and place a chamfer on the outer edge to aid assembly Re assemble telescopic section sETTINg TELESCOpIC FLUE B pACK 1 Measure the required flue length A 44mm Drill hole 2 Measure from the outer terminal lip to end of outer flue Pull apart flue until N ll desired length is achieved ENSURE THE STOP MARK IS NOT VISIBLE IF IT IS THE FLUE IS TOO SHORT AND SHOULD NOT BE USED Adhere sealing tape 3 Check that both flue seams are at the top and the outlet terminal is upper most Drill a 3 5mm hole through one of the 2 outer side holes into the inserted outer flue Take care not to pierce the inner plastic flue 5 Seal the joint on the outer air duct with the tape provided Fit internal and external wall seals see installing flue CUTTINg hORIZONTAL FLUE TERMINAL 600MM LONg B p ACK 1 Measure the required cut flue length A 44mm If inside the dimensions shown in Figure 2 1 Piece 600mm proceed Measure from the outer terminal lip to end of outer flue Mark the required cut length A 44 around the circumference of the outer flue and cut following the mark to ensure its cut square Dress the cut end to ma
74. hen the boiler will periodically fire the burner thereby reducing the time taken to provide hot water If pre heat is switched off the response time will be reduced although gas consumption will also be reduced Press ENTER and the following screen will be displayed MENU Vent System y Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope Press ENTER and a screen similar to the following will be displayed Switch Pre Heat To switch Pre heat off press OFF press y SAVE press o To switch Pre heat on press To return to normal operation press ExIT twice MAxIMUM FLOW TEMpERATURE It is possible to limit the maximum flow temperature that can be set from the CH Flow Temperature knob using this feature Note that this could prevent adequate room temperature being achieved in winter Press ENTER and the following screen will be displayed MENU Vent System y Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope Press until the following screen is displayed MENU Switch Pre Heat 4 witch Pre Hea y Maximum Flow Temperature Outside Sensor Slope Fault Help Press ENTER and a screen similar to following will be displayed Set Maximum Flow Temperature Press and until the desired temperature is displayed and then ENTER followed by ExIT to return to normal operation vogue combination boiler Installation and Servicing INSTALLATION
75. icing INSTALLATION 14 DETERMININg ThE FLUE LENgTh AND FLUE pACKs REqUIRED IMPORTANT The boiler must be installed in a vertical position in accordance to the installation instructions FLUE KITs Telescopic Flue B pack contains Flue turret telescopic flue incorporating a terminal rubber wall seal and instructions horizontal Flue Terminal 600mm long B pack contains Flue turret non telescopic single piece flue incorporating a terminal rubber wall seal and instructions horizontal Flue Terminal 1000mm long B pack Flue turret telescopic flue incorporating a terminal rubber wall seal and instructions Note If B packs are used on their own either 1 piece or telescopic then they can be fitted horizontally as the flue inside is designed to slope 1 5 degrees D pack contains 1 metre length of flue pipe Functional length 950mm 1 support bracket and instructions When extension D Packs are used the flue duct must incline 1 5 degrees away from the appliance to allow the condensate to drain back to the boiler and out of the condensate drain It is recommended that a support bracket is fitted on every 1 metre of pipe work used and the bracket is located as close to the collar as possible The bracketing must ensure a 1 5 degree fall back to the appliance Optional Flue Finishing Kit UIN 155988 amp Concentric Flue Screw Retaining Kit Optional Kit of mechanical fixing of flue joints Only us
76. ing r Ignition Lockout Check other Gas Appliances work If not re instate gas supply Reset Boiler by pressing r If fault persists contact installer Flame Loss Check other gas appliances work If not re instate gas supply If fault persists contact installer Thermal Fuse Lockout Reset Boiler If fault persists contact installer Too Many Resets Contact Installer Flame on before Gas Valve on Contact Installer Flow Thermistor Fault Contact Installer Outside Sensor Fault Contact Installer Return Thermistor Fault Contact Installer Fan Fault Contact Installer PCB Replaced Incorrectly Contact Installer 60 FAULT FINDINg 81 FAULT FINDINg ChART MAIN MENU Go to Frame 82 Overheat Lockout Go to Frame 83 Ignition Lockout Go to Frame 84 Flame Loss Go to Frame 85 Flame Loss 5 Resets within 15 minutes Turn power off and on Go to Frame 86 Flame On before Gas Valve On Go to Frame 87 Flow Thermistor Fault Go to Frame 88 Outside Sensor Fault Go to Frame 89 Return Thermistor Fault Go to Frame 90 Fan Fault Ensure BCC fitted correctly Ensure correct BCC fitted Less than 160V to boiler Check voltage at boiler mains in Check if local generator 10V Contact Electricity Provider Go to Frame 91 Low Water Pressure Check if Flow Thermistor correctly clipped to pipe Replace Flow Thermistor Go to Frame 92 No Water Flow Fault Low Mains Voltage Low Water Pressure Fil
77. injury 1 Cut the flue hole preferably with a 5 core boring tool ensuring that the hole is square to the wall Rear flue only Side flue only Both wall faces immediately around the cut hole should be 5 diameter hole 5 diameter hole o flat 2 Drill 2 mounting holes marked from template with a 7 5mm 8mm masonry drill and insert the plastic plugs provided Section for the wall mounting plate through wall 3 Locate 2 No 14 x 50mm screws in the wall mounting plate f Note Check all of the hole one at each side in any of the 3 holes provided at each positions before drilling side and screw home Ensure mounting bracket is level Le 12 FITTINg ThE W ALL MOUNTING pLATE 13 MOUNTINg ThE BOILER Screw the wall mounting plate to the wall using 2 wall plugs 1 Ensure the plastic plugs are removed from both the CH previously fitted with the 2 screws provided and DHW connections before mounting the boiler Choose one of the 2 sets of slots in left and right bank Note boiler may contain residual water Ensuring that at least one of the screws is fitted into a top slot and the mounting bracket is level Lift the boiler onto the wall mounting plate refer to the Introduction section for safe handling advice locating it over the two tabs Example of fixing oe on Se ee DS Oe ee ee oe 16 vogue combination boiler Installation and Serv
78. ion marks re level with Correctly sealed wall the internal face of the wall 5 Cored drilled S Mark 1 Flush with inter wall hele Note If the 2 location marks are not visible then the flue is not pulled back far enough to obtain the correct seal If the 1st location mark has passed the face of the wall the flue has been pulled to far back and the outer wall seal will have been dislodged from its mounting and will need to be refitted When 1st mark is in line with the wall whilst holding the flue firmly push the white wall sealing flange to the wall until the 2nd of the two marks is just visible If the last location mark is clearly passed the white inner wall seal then the outer wall seal will have been dislodged from its mounting and will need to be re fitted 10 Ensure the seam and the outlet terminal are at the top and fitted as shown Note If less than 50 of the length of the flue is internal the flue should be fitted from outside Wall Seal Lip ae Step Rubber Location Location ii Terminal mark 2 mark 1 o f D a Wall Seal f Ensure lip of wall seal is positioned m Fig 1 over step on plastic nose of flue terminal note seal is cut away for clarity isfu9783 FITTINg ThE TURRET Ensure the rubber seal is fitted correctly on the appliance manifold and that all flue seals are undamaged Hold the flue firmly and push the turret on until it has travelled 30m
79. ir from the gas installation open all windows and doors extinguish naked lights and DO nOT SMOKE gENERAL Please note The combustion for this appliance has been checked adjusted and preset at the factory for operation on the gas type defined on the appliance data plate DO NOT adjust the air gas ratio valve Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals as described in the Flue Installation section Proceed to put the boiler into operation as follows ChECK ThE OpERATIONAL WORKINg gAs INLET pRESSURE Set up the boiler to operate at maximum rate by referring to Frame 39 Service Mode Maximum Rate this mode will operate the boiler at maximum heat output but in Gas Supply central heating mode to ensure the boiler is operating at maximum this must be carred out when the system is cool With the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point complies with the requirements refer to Gas Gas Pressure Supply on page 8 Test Point Ensure that this inlet pressure can be obtained with all other gas appliances in the property working As part of the commissioning process the combustion of this appliance must be checked and the Benchmark Checklist completed A flow chart to assist is provided on page 73 ATTENTION IT Is
80. kW 12 800 to 61 400 Btu h 32 4 6 to 26 0kW 15 700 to 88 700 Btu h 40 5 7 to 32 0kW 19 600 to 109 200 Btu h Instantaneous domestic hot water DHW output is also fully modulating with a maximum of 26 26kW 88 700 Btu h 32 32kW 109 200 Btu h 40 40kW 136 500 Btu h The boiler is supplied fully assembled with DHW plate heat exchanger diverter valve circulating pump pressure gauge pressure relief valve and CH expansion vessel Variable CH and DHW temperature controls are fitted on the user control and the boiler features a DHW preheat facility The boiler includes as standard Automatic bypass Boiler frost protection Daily pump and diverter valve exercise The boiler casing is of white painted mild steel with a white polymer front panel The boiler temperature controls are located behind the lower panel on the front of the boiler The heat exchanger is manufactured from stainless steel The boiler is suitable for connection to fully pumped sealed heating systems ONLY Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework The standard configuration of pipework from the boiler is routed downwards OpERATION With no demand for CH the boiler fires only when DHW is drawn off or periodically for a few seconds without any DHW draw off in order to maintain the DHW calorifier in a heated condition This only occurs if pre he
81. ke sure all burr are removed and the cut edge is in its original shape Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure its cut square Remove all burrs and place a light chamfer on the outer edge to aid assembly FLUE OUTLET vogue combination boiler Installation and Servicing 19 INSTALLATION 17 INsTALLINg ThE FLUE FITTINg FLUE ThROUgh ThE W ALL 14mm fe Measure wall thickness and add 14mm aon F Wall Thickness Measure from the outer terminal lip towards outer flue place a small location mark at the dimension acquired at point 1 Add a further 14mm to the dimension obtain at item 1 and place an additional small location mark Fit external black wall seal ensuring the outer lip is in contact with Mark 2 Lines the lip you have been measuring from see fig 1 Fit the internal wall seal approximately 65mm before the outer of the 2 location marks Mark 2 Flush with For an internal fit place flue terminal in the centre of the 5 drilled the inner wall seal hole in the wall Apply pressure and lightly move the flue left to right or up and down This will cause the outer flange to fold in and allow the flue to pass through the wall Push through a further 65mm or until the inner flange is press against the inner wall This will allow the outer flange to return to its original shape TM Pull back the flue until the first of the 2 locat
82. l at the open end The use of a drain cover as used to prevent blockage by leaves may offer further prevention from wind chill See Fig 6 Where the condensate drain pipe terminates in a purpose designed soak away see BS 6798 any above ground condensate drain pipe sections should be run and insulated as described above See Fig 7 Unheated Internal Areas Internal condensate drain pipes run in unheated areas e g lofts basements and garages should be treated as external pipe Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual Figure 2 Connection of a Condensate Drainage Pipe Downstream of a Sink Basin Bath or Shower Water Trap to Internal Soil Vent Stack Boiler with 75mm sealed condensate Min 19mm we Internal pipe Sink basin Internal soil amp vent stack Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break continued 21 TALLATION o INSTALLATION INSTALLATION 19 CONDENSATE DRAIN CONT D Figure 4 Connection of condensate Drainage Pipe to External Soil amp Vent Stack Figure 3 Connection of a Condensate Pump Typical Method see manufacturers detailed instructions Boiler Water weather Visible air break with 75mm proof insulation sealed Boiler with 75mm condensate sealed trap condensate Min 30mm trap Int
83. l System to 1 Bar Bleed Radiators Refill System to 1 Bar Flow Return Reversed Contact Installer No Water Flow Fault Fill System to 1 Bar Bleed Radiators Refill System If Fault persists contact installer PCB Replaced Reset boiler by pressing r Reset boiler by pressing r Pump Rotor Blocked If fault persists contact installer Unblock Pump Go to Frame 93 No Connection to Primary PCB No Connection to Primary PCB Turn power off and on Contact Installer NO CH BUT DHW OK NO DHW BUT CH OK BLANK DISPLAY FLOW TEMPERATURE SETPOINT CANNOT BE INCREASED TO 80 C Go to Frame 94 No CH but DHW OK Go to Frame 95 No DHW but CH OK Go to Frame 96 Blank Display Ensure Flow Temperature is not limited within Installer Mode see Frame 37 Ensure System Frost Protection Temperature Setpoint is not set too high see Frame 40 PUMP RUNS DURING THE NIGHT vogue combination boiler Installation and Servicing FAULT FINDINg 82 OVERhHEAT LOCKOUT Has PCB just been replaced Reset Boiler ce Are the Boiler and CH DHW system filled with water Fill and vent the system and open all and are all Isolation Valves and Radiator Valves open Isolation Valves then Reset the Boiler Yes Is the Flow Return Differential across the boiler in excess of 30 C i Yes Check that the Pump is rotating freely Is the Replace the Pump then Reset the Boiler Differential now below 20 C Yes Reset boiler
84. lacement Refer to Frame 45 amp 46 Refer to Frame 53 Close the isolating service valves and drain the CH boiler Remove the clip securing the flexible connecting hose and disconnect Remove the two securing screws from the top of the casing at the same time holding the ignitor bracket to prevent movement a e Hold the expansion vessel and move the ignition assembly b bracket carefully to one side 13 Pull the bottom of the expansion vessel forward when free pull vessel downwards and remove 14 Refit in reverse order 15 Open the isolating valves and refill the CH system 16 Check the operation of the boiler Refer to Frames 33 36 58 vogue combination boiler Installation and Servicing SERVICINg 80 BOILER sEALINg pANEL REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Remove the old seal from the casing Fit the new seal ensuring correct location over the fixing pins and the material is fully located within the casing Reassemble in reverse order Check the operation of the boiler Refer to Frames 33 36 vogue combination boiler Installation and Servicing 59 SERVICING e Z Q Z T m m lt m o Z a Z T m m lt u o Z a Z T m m lt u o Z Q Z T m m lt u o Z a Z T m lt M Overheat Lockout Fill System to 1 Bar Bleed Radiators Refill System Check Radiator Valves are Open Reset Boiler by press
85. led correctly the interpretation of the results ALSO IF THE DHW FLOW RATE IS IN QUESTION The flue gas analyser used should be one 5 Check the DHW filter for blockage Refer to Frame 76 meeting the requirements of BS7927 or BS The cleaning procedures are covered more fully in Frames 45 51 and EN50379 3 and be calibrated in accordance with MUST be carried out in sequence the analyser manufacturers requirements and The integrity of the boiler combustion circuit and the relevant seals IMpORTANT Competence can be demonstrated by satisfactory 6 After completing the servicing or exchange of components always completion of the CPA1 ACS assessment which test for gas tightness covers the use of electronic portable combustion 7 When work is complete the front panel MUST be correctly refitted gas analysers in accordance with BS7967 Parts ensuring that a good seal is made 1 to 4 Do nOT OPEra TE the boiler if the front panel is not fitted lf for any reason the condensate trap siphon has been removed ensure the trap is refilled with water before reassembling Flue Check the gas consumption Sampling Point Check combustion by connecting the flue gas analyser to the flue ensure cap is gas sampling point as shown in the diagram and measure CO amp secured after CO If the CO CO ratio is greater than 0 004 AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pr
86. ly and NOT switched by thermostats programmers For installers wishing to change this cable proceed as follows Replacement wiring should comply with the notes in Frame 28 amp 29 1 Isolate the mains supply to the boiler 2 Remove the front panel refer to Frame 9 3 Swing the control box down into the service position refer to Frame 46 vogue combination boiler Installation and Servicing Wiring should be 3 core PVC insulated cable not less than 0 75mm 24 x 0 2mm and to BS 6500 Table 16 For IE reference should be made to the current ETCI rules for electrical installations Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm 1 8 contact separation in both poles The means of isolation must be accessible to the user after installation Remove the Live Neutral and Earth wires from the terminal block Loosen the cable clamp and withdraw the mains cable Route the replacement cable back through the cable clamp and grommet and re tighten to provide cord anchorage Connect the Live Neutral and Earth wires to the terminal strip When making the mains electrical connections to the boiler it is important that the wires are prepared in such a way that the earth conductor is longer than the current carrying conductors such that if the cord anchorage should slip the current carrying conductors become taut before the earthing c
87. m and maximum values shown above except where specified Horizontal Flue Terminal 600mm long B Pack flue will require cutting on values below maximum values shown above m u Oe a Se a a 18 vogue combination boiler Installation and Servicing INSTALLATION 16 CUTTINg amp sETTINg ThE FLUE LENgTh TELEsCOpIiC FLUEs TELEsCOpIC FLUE B pACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT hORIZONTAL FLUE TERMINAL 1000MM LONg B pACK TELESCOpIC MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 amp 652MM THIS WILL REQUIRE 75MM TO BE CUT OFF THE TERMINAL END OF THE 1000MM TELESCOPIC FLUE ALL OTHER LENGTHS OBTAINED USING D PACK ExTENSIONS IN FLUE LENGTH TABLE 1 COLUMN HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK CUT 75MM TELESCOPIC SHOULD HAVE THE 75MM CUT OFF THE D PACK ExTENSION AND NOT TELESCOPIC FLUE CUT 75MM OFF hORIZONTAL FLUE TERMINAL 1000MM LONg B pACK TELEsCOpIc 1 Measure cut flue length A 44mm If required telescopic length is not between 658 and 708 then proceed to set flue 7b Remove telescopic end piece from the flue body and set aside Mark the circumference 75mm from the open end of the outer flue Cut along the 75mm mark cutting only the outer flue ensuring the cut is square M f Dress the cut end to make sure all burr is removed and the cut edge is in its caste WONN original shape this Measure 20mm from the newly cut edge of t
88. m on to the flue pipe and is fully engaged Make sure the flue has not rotated or moved forward during fitting and the flue seam is upper most Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold Fully engage the clamp location section into the manifold location holes Rotate down on to turret flange Secure clamp to appliance using securing screw Ensure all sample points are accessible and all sample plugs and caps are fitted Retaining Clamp Lugs screw A Duct Assembly B Flue Turret C Turret Clamp D Seal FLUE OUTLET 20 vogue combination boiler Installation and Servicing INSTALLATION 18 CONDENSATE DRAIN Condensate Drain This appliance is fitted with a siphonic 75mm condensate trap system that requires filling before operating the appliance for the 1st time or after maintenance All condensate pipework should conform to the following a Where a new or replacement boiler is being installed access to an internal gravity discharge termination should be one of the main factors considered in determining boiler location Plastic with push fit or solvent connections Internal plastic pipe work a minimum of 19mm ID typically 22mm OD External plastic pipe must be a minimum of 30mm ID typically 32 OD before it passes through the sleeved wall All horizontal pi
89. me 9 3 Swing the control box down into the servicing position refer to Frame 46 Route incoming cables through the grommets in the bottom panel note grommets are blind and will require puncturing and secure using clamps and screws provided in the hardware pack 5 Remove terminal block cover 6 Connect wires to terminal block Re assemble in reverse order 29 INTERNAL WIRINg Room Stat or A Internal Timer with Room stat or programmable Room stat ze seat Remove the link wire between the Room Stat Timer terminals Connect the Room Stat or Programmable Room Stat across the terminals as OPTIONAL optionaL MAINS IN shown in the Diagram mane onea aor g N e continued neutral If the Room Stat has a neutral connection then connect this to the fused spur elses Q dgggo 28 vogue combination boiler Installation and Servicing INSTALLATION 30 sysTEM CONTROL WIRINg CONT D B External Timer and Room stat OO Remove the link wire between the Room Stat Timer terminals OPTIONAL OPTIONAL MAINS IN Connect the Room Stat and Timer across the terminals as shown in the Diagram ROOM STAT HEATING FROST TIMER ZONE 2 STAT T If the Room Stat has a neutral connection then connect this to the fused spur P Gann neutral ggg
90. n 322 137 Ideal stelrad group pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice Ideal Stelrad Group Ideal Technical Helpline 01482 498 663 www idealboilers com
91. ontinued 27 INSTALLATION INSTALLATION INSTALLATION 27 OpTIONAL sysTEM CONTROLs KITs Ideal offer 5 kits as follows see individual kits for installation instructions Combi Mechanical Timer 24 hr 24 hour mechanical CH timer fits into the control box of the boiler This can be fitted in conjunction with a Room Thermostat Combi Electronic Timer 7 day 7 day electronic CH timer fits into the control box of the boiler This can be fitted in conjunction with a room thermostat Features English language installation help messages Combi RF Electro Mechanical programmable Room Thermostat Kit 24 hr combined 24 hour mechanical timer and room thermostat with wireless communication to the receiver unit which fits into the control box of the boiler Combi RF Electro Mechanical Timer and RF Room Thermostat Kit 24 hr RF Room Thermostat with wireless communication to the RF 24 hour electro mechanical CH timer which fits into the control box of the boiler Weather Compensation Kit allows outside temperature sensing 28 INTERNAL WIRINg The Vogue Combi boiler comes pre fitted with a link wire between the Room Thermostat Timer connections on the terminal strip This creates a permanent call for heat and must be removed when adding a Room Thermostat Timer To add wired external Room Thermostats Timers or Programmers proceed as follows 1 Isolate the mains supply to the boiler 2 Remove the front panel refer to Fra
92. ontinued vogue combination boiler Installation and Servicing 11 gENERAL 3 sysTEM REqUIREMENTSs continued 4 DOMEsTIC hOT WATER 1 The domestic hot water service must be in accordance with BS 5546 and BS 6700 2 Refer to Table 1 for minimum and maximum working pressures In areas of low mains water pressures the domestic hot water regulator may be removed from the DHW flow turbine cartridge Refer to Frame 76 The boiler will require the flow rate to be set to obtain a sysTEM BALANCINg The boiler does not normally need a bypass but at least some radiators on the heating circuit of load of at least 10 of the minimum boiler output must be provided with twin lockshield valves so that this minimum heating load is always available See note regarding thermostatic radiator valves on page 9 Note Systems incorporating zone valves which temperature rise of 35 C at the tap furthest from the boiler The boilers are suitable for connection to most types of washing machine and dishwasher appliances When connecting to suitable showers ensure that a The cold inlet to the boiler is fitted with an approved anti vacuum or syphon non return valve b Hot and cold water supplies to the shower are of equal pressure hard Water Areas Where the water hardness exceeds 200mg litre 200ppm it is recommended that a proprietary scale reducing device is fitted into the boiler cold supply within the requirements of th
93. oom Thermostat calling for Heat i Yes Are the Radiator Valves open Open the Radiator Valves i Yes Is an Ideal Electronic Programmable Room Stat Consult Electronic Programmable Room connected Stat Fault Finding Instructions No There is no voltage from the Timer Room Is there 230Vac at A Stat This is not a boiler fault Ensure voltage is supplied to the boiler by correcting external wiring l Yes Is there 230V between pins 2 and 3 at the diverter valve Replace Main PCB Yes Replace Diverter Valve ROOM OPTIONA OPTIONA STAT HEATING FROST TIMER ZONE2 STAT MAINS IN IN OUT IN OUT IN ouri L N Aoolblolodlb SISISISISISISIE vogue combination boiler Installation and Servicing FAULT FINDINg 95 NO DhW BUT Ch OK Does the display show ON underneath the tap No Is the red neon illuminated on the Ensure cold inlet and hot symbol DHW Turbine water outlet are not reversed l Yes Is the wiring connected between the Are the flow rates correct as per Table 3 Main PCB and the DHW Turbine Re connect wiring i Ws No Remove Turbine and clear any Fi bi debris is DHW OK it newturoime Does the wiring from the Main PCB to the Diverter Valve have continuity and is fully connected l Yes No Adjust flow rates to achieve 35 C Check diver
94. p and withdraw the diverter head Using a spanner unscrew the valve assembly from the body and lift out 8 Reassemble in reverse order 9 Refill the CH system Refer to Frame 67 Check the operation of the boiler Refer to Frames 33 36 vogue combination boiler Installation and Servicing 55 SERVICING sSsERVICING sERVICINg 73 DhW pLATE hEAT ExChANgER REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Close the isolating service valves and drain the heating and DHW systems Refer to Frame 67 Remove the burner amp Fan assembly Refer to Frame 47 Remove the 2 Allen screws securing the plate heat exchanger to the brass housings Ease the plate heat exchanger back to disengage and lift out Fit the new heat exchanger using the new o rings supplied Refit in reverse order Open the isolating service valves refill the CH and DHW systems and vent as necessary Refer to Frame 67 10 Check the operation of the boiler Refer to Frames 33 36 74 pUMp hEAD REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Close the isolating service valves and drain the CH boiler Refer to Frame 67 Disconnect both electrical leads to the pump Remove the 4 Allen screws securing the pump head and remove Refit in reverse order Open the isolating valves and refill the CH system Refer to Frame 67 Check the operation of the boiler Refe
95. pe runs must fall a minimum of 45mm per metre away from the Boiler External amp unheated pipe work should be kept to a minimum and insulated with Class O waterproof pipe insulation All installations must be carried out in accordance to the relevant connection methods as shown in the Condensate installation diagrams amp BS6798 2009 Pipe work must be installed so that it does not allow spillage into the dwelling in the event of a blockage through freezing All internal burrs should be removed from the pipe work and any fittings In order to minimise the risk of freezing during prolonged very cold spells one of the following methods of terminating condensate drainage pipe should be adopted Internal Drain Connections Wherever possible the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc See Figs 1 and 2 Figure 1 Connection of Condensate Drainage Pipe to Internal Soil amp Vent Stack Boiler with 75mm sealed condensate trap Min 19mm ne Internal pipe 1 Soil amp vent stack Minimum connection height up to 3 storeys Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break vogue combination boiler Installation and Servicing Condensate pump Where gravity discharge to an internal t
96. r to Frames 33 36 75 Ch WATER pREssURE sENsSOR REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Close the isolating service valves and drain the CH boiler Refer to Frame 67 Remove the retaining clip to the rear of the housing Lift out the sensor and disconnect the electrical connection 6 Refit in reverse order 7 Open the isolating valves and refill the CH system Refer to Frame 67 56 Check the operation of the boiler Refer to Frames 33 36 vogue combination boiler Installation and Servicing sSERVICINg 76 DhW FILTER AND FLOW REgULATOR CLEANINg REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Isolate the DHW supply to the boiler Drain the DHW system Refer to Frame 67 Remove the DHW Flow Turbine Sensor See Frame 71 Using a spanner remove the DHW flow turbine cartridge Unscrew the flow regulator housing Remove the filter Clean or replace as necessary Refit in reverse order ee SO ON GT A CO N Open the isolating valves and refill DHW system Refer to Frame 67 12 Check the operation of the boiler Refer to Frames 33 36 77 FLOW ThERMIsTOR REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Unclip the flow thermistor Disconnect the electrical lead from the thermistor Reconnect the electrical lead to the new thermistor and reassemble in reverse order ensuring that the thermistor is secu
97. r compression Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter mm in 100 4 Average Flue Temp Mass Flow Rate DHW C g s 73 C 11 g s 70 C 17 g s Maximum Working Pressure Sealed Systems bar Ib in 2 5 36 3 Maximum Domestic Hot Water Inlet Pressure bar Ib in 10 0 145 Minimum Domestic Hot Water Inlet Pressure bar Ib in 1 1 16 0 1 5 21 8 1 5 21 8 Electrical Supply 230 V 50 Hz Power Consumption W 108 Fuse Rating External 3A Internal 4A Time Delay Water content Central Heating litre gal 1 5 0 33 1 8 0 41 2 2 0 48 Domestic Hot Water litre gal 0 5 0 11 Packaged Weight 40 4 89 Maximum Installation Weight 35 0 77 Boiler Casing Size Height i 740 29 1 Width i 445 17 5 Depth i 330 13 Heat Exchanger Weight without Burner 8 2 Required for maximum flow rate Boiler operates down to 2 l min DHW delivery In areas of low water pressure the DHW restrictor can be removed Table 2 performance Data Central heating Boiler Input _ Max Min Boiler Input Q Nett CV kW 18 1 26 1 32 1 3 7 4 6 Btu h 61 800 89 100 109 500 12 700 15 600 Gross CV kw 20 1 29 0 35 6 5 1 Gross CV kW 35 6 44 6 Btu h FARAR TEER 21 600 Btu h 121 600 152 200 Gas Consumption m h 1 869 2 695 3 314 0 383 0 472 Gas Consumption m h 3 314 4 150 ft h ft h 117 1
98. rames 45 amp 46 Refer to Frame 53 Remove the ignition detection and earth leads Remove the 2 clips securing the gas inlet pipe and remove the pipe Remove the fan leads Remove the 4 securing nuts retaining the burner door fan assembly Remove the assembly from the heat exchanger To remove the venturi release the 2 securing screws To remove the fan release the 3 screws securing the fan to the burner door assembly Remove the ignition and detection probes Refit the fan venturi ignition probe and detection probe to the new burner door assembly 12 Refit in reverse order 13 Check the operation of the boiler Refer to Frames 33 36 57 RETURN ThERMIsTOR RENEWAL i 2 3 4 5 Refer to Frame 53 Refer to Frames 45 amp 46 Unclip the return thermistor Disconnect the electrical lead from the thermistor Reconnect the electrical lead to the new thermistor and reassemble in reverse order ensuring that the thermistor is securely fitted to the pipe on the thermistor locator tabs as shown Check the operation of the boiler Refer to Frames 33 36 vogue combination boiler Installation and Servicing 49 SERVICING SERVICING sSERVICINg 58 IgNITION ELECTRODE REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Disconnect the ignition lead and the earth connection Release the 2 securing screws and carefully withdraw the probe Check the
99. rely fitted to the pipe on the thermistor locator tabs as shown Check the operation of the boiler Refer to Frames 33 36 vogue combination boiler Installation and Servicing 57 SERVICING SERVICING sSERVICINg 78 hEAT ExChANgER REpLACEMENT Refer to Frames 45 amp 46 Refer to Frame 53 Close the isolating service valves and drain the CH boiler Refer to Frame 67 Remove the Burner amp Fan assembly Refer to Frame 47 Remove the securing clips to disconnect the flow and return pipes below the heat exchanger Disconnect the condensate pipe from the sump Disconnect the DRYFIRE ONE TIME sensor lead Remove the horseshoe bracket and lift up the flue turret Remove the securing screws and disconnect the flue outlet Remove the 4 screws securing the heat exchanger fixing brackets Remove the heat exchanger forwards lifting to clear the flow and return pipes Refit in reverse order Ensure all wires and harnesses are in their correct position in order to prevent damage to them 13 Open the isolating valves and refill the CH system Refer to Frame 67 14 Check the operation of the boiler Refer to Frames 33 36 79 ExpANsION VEssEL REChARgINg AND REpLACEMENT Recharging Refer to Frames 45 amp 46 Refer to Frame 53 Remove the charge point cover Recharge the tank pressure to 0 75bar Refit in reverse order Check the operat ion of the boiler Refer to Frames 33 36 Rep
100. rip the boiler at the base e Be physically capable e Use personal protective equipment as appropriate e g gloves safety footwear During all manoeuvres and handling actions every attempt should be made to ensure the following unless unavoidable and or the weight is light e Keep back straight e Avoid twisting at the waist e Avoid upper body top heavy bending e Always grip with the palm of the hand e Use designated hand holds Keep load as close to the body as possible e Always use assistance if required vogue combination boiler Installation and Servicing gENERAL OpTIONAL ExTRA KITs horizontal Flue Terminal 600mm long e Horizontal Flue Terminal 1000mm long e Flue Extension Ducts 1000mm long 26 up to 10m 32 up to 8m 40 up to 8m e Flue Finishing Kit 90 Elbow Kit maximum per installation 26 upto 6 elbows 32 upto 4 elbows 40 upto 4 elbows 45 Elbow Kit maximum per installation 26 upto 6 elbows 32 upto 4 elbows 40 upto 4 elbows e Roof Flue Kit to a maximum of 10m e Flue Vertical Connector Kit e Raised Horizontal Flue Outlet Kit e Flue Extension Kit 60 1m e Concentric Flue screw Retaining Kit e Weather Collar e Stand Off Kit e Stand Off Kit inc pipes e High Level Flue Outlet Kit e Flue Deflector Kit e Condensate Pump Kit e Mechanical Timer 24 hr Kit e Electronic Timer 7 day kit e RF Mechanical Programmable Room Thermostat 24 hr kit e RF
101. rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve When thermostatic radiator valves are used the space heating temperature control over a living dining area or hallway having a heating requirement of at least 10 of the minimum boiler heat output should be achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves However if the system employs thermostatic radiator valves on all radiators or two port valves then a bypass circuit external to the boiler must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position ELECTRICAL sUppLy Warning This appliance must be earthed Wiring external to the appliance MUST be in accordance with the current I E E BS 7671 Wiring Regulations and any local regulations which apply For IE reference should be made to the current ETCI rules for electrical installations The mains supply to the boiler and system wiring centre shall be through one common fused double pole isolator and for new heating systems and where practical replacement installations the isolator shall be situated adjacent to the appliance CONDENSATE DRAIN Refer to Frames 22 23 amp 54 A condensate drain is provided on the boiler This drain must be connected to a drainage point on site All pipework and fittings in the condensa
102. rssacceessosrcesaceess 12 Wiring Diagram sicscccsceccsscscccctscccrsnccrseansceccacecssanccrisaccees 30 For GB to comply with Building Regulations Part L1 Part 6 in Scotland the boiler should be fitted in accordance with the manufacturer s instructions Self certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist Before installing this boiler read the Code of Practice sheet at the rear of this book BENChMARK COMMIssIONINg ChECKLIsT DETAILs Boiler page page Make and mogel rsicicrurnii sasesana 5 Burner operating pressure ssssserirrrcrrenrrernrerna n a Appliance serial no on data badge Front Cover Central heating flow temp measure and record SEDBUK ING Yoweisiceitesceisscdeecdhe bi Wide arnoak nae Eai 4 Central heating return temp measure and record Controls For combination boilers only Time and temperature control to heating 29 SCale rOQucer iiisge iiriksi iian amiei 12 Time and temperature control to hot water 29 Hot water mode Heating Zone ValVeS c ccceseceeeeeeceeseeeeeseneeeesees n a Heat iNp t isisisi enasna to be calculated TAV Siena aide eehietenateeeeegee 9 Max operating burner pressure ceee n a Auto BYPASS wis escceciel chee aeesns ee eseeeentevtenciesicecaieecce 9 Max operating water pressure
103. s and to view the full list Press ExIT twice to return to normal operation 37 INSTALLATION INSTALLATION INSTALLATION 39 MENU OpERATION STATE OF OUTpUTs To view the current status of the Pump Diverter Valve Fan Spark Generator and Gas Valve press ENTER and the following screen will be displayed MENU A Vent System Vv Switch Pre Heat Maximum Flow Temperature Outside Sensor Slope oy Press until the following screen is displayed MENU State of Inputs Vv State of Outputs Service Mode Minimum Rate Service Mode Maximum Rate Press ENTER and a screen similar to the following will be displayed State of Outputs Diverter Valve CH Pump On Fan Target 3000 3000rpm Spark Generator Off Press and to view the full list Press ExIT twice to return to normal operation sERVICE MODE MINIMUM RATE This feature will run the burner at minimum rate Note that a CH demand has to already be present for the feature to be active To activate the feature press ENTER and the following screen will be displayed MENU A Vent System 7 Maximum Flow Temperature Outside Sensor Slope os Press until the following screen is displayed MENU A State of Outputs Vv Service Mode Minimum Rate Service Mode Maximum Rate Show Efficiency Level Press ENTER and the following screen will be displayed Service Mode Minimum Rate D Fan T
104. sioned to the manufacturers instructions and the data fields on the commissioning checklist completed in full To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed The service details should be recorded on the Benchmark Service Interval Record and left with the householder DCNCHIIG COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk Heating and Hotwater Industry Council HHIC gAs BOILER sysTEM COMMIssIONINg ChECKLIsT This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer name Telephone number Address Boiler make and model Boiler serial number Commissioned by PRINT NAME Gas Safe r
105. stream b For ft h divide the gross heat input Btu h of the combustion chamber Note C covers optional high level by the gross C V of the gas Btu ft and balconly flue kits only c For m h multiply s by 3 6 I An appliance designed for use on 2nd Family gas Group H only 4 vogue combination boiler Installation and Servicing gENERAL onie CONTENTS g Air SUPPLY iissccecccsscsersecccccacccessucersunceseraccereaacsestansseeasseevans 9 Natural gas only ee eta Benchmark Commissioning Checklist 22 0 70 Boiler size Boiler Clearances 0c eee ee 10 Benchmark No Boiler Exploded Diagram cccssessseesseeeseseenseees 13 86 CN 45 Condensate Drain s sscsseseseeeseseeees 9 21 22 46 86 CN 45 Electrical Connections sesers ainena 32 47 348 97 86 CN 45 Electricalsuppiy ca 9 FEWN LE NE aeeoe 60 66 Destination Country GB IE Flue Fitting e a ere ere 16 Flue Installation renere 16 25 gas Safety Regulations cseesseeeesseeeeeeeeeeeeeeeeeneee 7 CES SUN rnanera 8 IMStallcatl OM aeoeaiei 13 42 OAU ctosccereetnesnecenntees E O O T 55 sate handling manan 6 SErV C NG siccccccersccecsencrccasourseacccsveccesseanertsanccesraceerssss 43 59 Thermostatic Radiator Valves c ccsssseeenseeeees 9 Water and SySteMs _ 2 ccccssssseeteeeeeeseeeeeeeeeseeeees 9 11 12 Water amp gas Connections eecceeeceeeeeeeeeeeeeeeees 26 Water Treatment scciscscccccscerssscccssnccrreanse
106. such as forced ventilation openings etc If products of combustion re entry is identified or suspected this should be immediately investigated and corrected following the guidance provided in the current Gas Industry Unsafe Situation Procedure Table 4 Balanced Flue Terminal position Flue Terminal positions Min spacing Directly below above or alongside an opening window air vent or other ventilation opening Below guttering drain pipes or soil pipes BS5440 1 2008 300mm 12 25mm 1 75mm 3 25mm 1 200mm 8 25mm 1 200mm 8 25mm 1 150mm 6 25mm 1 300mm 12 300mm 12 600mm 24 1 200mm 48 Below eaves BS5440 1 2008 Below balconies or a car port roof BS5440 1 2008 From vertical drain pipes or soil pipes BS5440 1 2008 From an internal or external corner or to a boundary along side the terminal BS5440 1 2008 Above adjacent ground roof or balcony level From a surface or a boundary facing the terminal From a terminal facing a terminal From an opening in a car port e g door or window into dwelling Vertically from a terminal on the same wall Horizontally from a terminal on the wall Vertical Terminals Above the roof pitch with roof slope of all angles Above flat roof From a single wall face From corner walls Below velux window Above or side of velux window 1 200mm 48 1 500mm 6
107. sure that the product or system is left in a safe condition and whenever possible in good working order Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing work Refer to the manufacturer s helpline where assistance is needed Report product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Hand over the manufacturer s instructions including the Benchmark Checklist to the customer on completion of an installation Obtain the customer s signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of manufacturer s instructions Advise the customer that regular product servicing is needed in line with manufacturers recommendations to ensure that safety and efficiency is maintained Respond promptly to calls from a customer following completion of work providing advice and assistance by phone and if necessary visiting the customer Rectify any installation problems at no cost to the customer during the installers guarantee period www centralheating co uk Benchmark Commissioning and servicing section It is a requirement that the boiler is installed and commis
108. t from the top of the boiler it is necessary to cut both pipes of assembly A then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied Ensure the cut pipe ends are free from any burrs 1 Position the roof flashing plate Supplied separately over the hole cut in the roof and insert flue terminal from the roof end 5 eonen Fit the vertical connector supplied separately in accordance with heed ae the instructions provided with the vertical connector kit Flue Terminal Secure the vertical connector by applying downward pressure on AssEMBLy A the connector Position the clamp on the top face of the flue manifold and push it horizontally backwards Locate both clamp lugs into the flue manifold and secure to the flue manifold with the M5 retaining screw as shown in Frame 17 Push fit extension duct if required supplied separately into Pitched roof tile vertical connector Flat roof tile gt weather collar weather collar lt Extension Duct NS N N N Vertical connector 3G9557b If the last extension duct requires cutting measure x the distance outer ducts between the duct and the terminal and add 100 mm to this dimension This gives the length of the last extension duct Note Check the position of the inner flue duct relative to the outer duct on the assembled extension duct s and
109. te FRONT pANEL REMOVAL Loosen the 2 screws retaining the front panel at the bottom Release catches at rear of door by pulling downwards Pull the underside front panel forward then lift upwards to remove vogue combination boiler Installation and Servicing 15 INSTALLATION INSTALLATION 10 WALL MOUNTINg TEMpLATE Extended centre line 31 or 176 The wall mounting template is located on the internal protective Sa packaging The template shows the position of the fixing and rear n LESA See Diagram Bait flue centre holes for a standard installation kia ld Care MUST be taken to ensure the correct holes are drilled 7 L 1 Tape template into the required position ensuring its squareness ar E j by hanging a plumbline as shown p 2 If fitting a side flue extend the flue centreline onto the side by 131mm on a standard wall fix or 176mm if using a stand off bracket 3 Mark the following on to the wall a The selected group of wall mounting screw holes b The centre position of the flue duct Marking both the centre and the circumference of the flue duct Remove the template plate from the wall 11 pREpARINg ThE WALL 225 a 131 176 stand off distance IMpORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal
110. te drainage system MUST be made of plastic no other materials may be used IMpORTANT Installation must be in accordance with BS 6798 The drain outlet on the boiler is sized for standard 21 5mm 3 4 overflow pipe It is a universal fitting to allow use of different brands of pipework gENERAL 1 BOILER DIMENSIONS sERVICEs amp CLEARANCEs The boiler connections are made on the boiler connection tails Refer to Frame 24 The following minimum clearances must be maintained for operation and servicing Additional space will be required for installation depending upon site conditions side and Rear Flue a Provided that the flue hole is cut accurately e g with a core drill the flue can be installed from inside the building where CLEARANCES 25 from case all dimensions in mm wall thicknesses do not exceed 600mm 24 Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside Installation from inside ONLy b If a core boring tool is to be used inside the building the space in which the boiler is to be installed must be at least wide enough to accommodate the tool BOILER DIMENSIONS t Side flue dim A t deal fy Flue terminal 450 gt CH Return DHW Outlet 3 JE PRV Outlet Yo CH Flow gt DHW Inlet lt
111. ted to Total Maximum permissible horizontal Concentric Flue Length combining both B Packs and D Packs Measured from centreline of the turret to the outside of the wall terminal 26 kW appliances Total Maximum 10 metres minus any flue kit options or bends 32 amp 40kW Appliances Total Maximum 8 metres minus any flue kit options or bends Total Maximum permissible Vertical Flue Length combining both Roof Terminal and D Packs 26 32 amp 40kW Appliances Total Maximum 10 Metres minus any bends 90 Elbow Kit 60 100 Equivalent flue length resistance 1M 45 Elbow Kit 60 100 Equivalent flue length resistance 0 6M Minimum horizontal Flue Lengths Centre line of turret to outside of wall terminal Telescopic terminal 350mm One piece terminal 285mm Wall Thickness Std Metric Brick 102 5mm wide B Pack Flue Type Minimum permissible Wall Thickness Maximum permissible Wall Thickness Horizontal Flue Terminal 154 102 5 102 5 513 600mm long B Pack Telescopic Flue B Pack imi E agg 88k Horizontal Flue Terminal 1000mm long B Pack Horizontal Flue Terminal 1000mm long B Pack cut 75mm For Flue lengths between 658 amp 708 use a horizontal Flue Terminal 1000mm long B pack cut 75mm off the end of the terminal section of the telescopic flue only FLUE OUTLET vogue combination boiler Installation and Servicing 17 INSTALLATION 15 DETERMININg ThE FLUE LENgTh AND FLUE pACKs REqU
112. ter valve head fully engaged and clip gt temperature rise and check filter fitted in secured onto waterset turbine is not blocked with debris M Yes Is there 230V between pins 1 and 3 Replace or reconnect as appropriate Yes y Replace Diverter Valve head is DHW OK Re engage diverter valve head and secure clip to waterset Yes AA Replace Diverter Valve body Replace Main PCB 96 BLANK DispLAy Is there 230Vac to the boiler at A Supply power to the boiler Yes y Is the wiring from the boiler terminal block to the main Connect the wiring from the terminal PCB connected securely block to the main PCB securely y Yes Does the wiring from the boiler terminal block to the Replace the wiring from the boiler Main PCB have continuity terminal block to the Main PCB Yes Is the cable from the main PCB to the user interface Connect the cable from the main PCB to PCB connected securely gt the user interface PCB securely Yes Replace cable from main PCB to user Does the cable from the main PCB to the user interface PCB interface PCB have continuity and is un damaged l Yes Is the Fuse on the main PCB OK Replace Main PCB Yes ROOM OPTIONAL OPTIONAL STAT HEATING FROST MAINS Da Replace the user interface PCB still no display
113. tral heating Notes pressure relief valve setting bar 3 0 a The method of filling refilling topping up or flushing sealed Vessel charge pressure bar 0 5 to 0 75 primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water system pre charge pressure bar None 1 0 authority system volume Expansion vessel Antifreeze fluid corrosion and scale inhibitor fluids suitable for litres volume litres use with boilers having stainless steel heat exchangers may be 25 used in the central heating system 50 75 100 125 150 175 190 200 general 250 1 The installation must comply with all relevant national and local 300 regulations For other system volumes 2 The installation should be designed to work with flow multiply by the factor across temperatures of up to 86 C All components of the system must be suitable for a working pressure of 3 bar and temperature of 110 C Extra care should be taken in making all connections so that the risk of leakage is Moea z2 minimised Max CH output kW 18 26 32 Btu h 61400 88700 109200 The following components are incorporated within the appliance i Water flow rate l min 13 18 6 22 9 a Circulating pump 20 C differential gal min 2 9 4 1 5 0 b Pressure relief valve with a non adjustable preset lift Head available for m wg 4 4 2 5 1 2 pressure of 3 bar system ftwg 14 4 8
114. trical connections should be protected 1 Ensure Filling Loop is connected 2 Ensure dust cap on auto air vent is slackened off 3 Check all isolation handles on all water connections are in the open position Open handle on the filling loop then slowly open handle until pressure gauge reads between 1 to 1 5 bar Once pressure gauge dial reads between 1 1 5 bar turn the filling loop isolation valves back to the closed position Disconnect filling loop at the LH side ensuring top hat washer is retained and screw on blanking cap Connect extended blanking cap and top hat washer to filling loop pipe Note Fully open all DHW taps and ensure water is flowing freely Once satisfied close all taps Handle Shown in closed position Handle DHW Shown in closed position Outlet Note that all isolation handles are shown in the open postion Handle Filling Loop vogue combination boiler Installation and Servicing INSTALLATION 25 ELECTRICAL CONNECTIONS Warning This appliance MUST be earthed A mains supply of 230Vac 50 Hz is required The fuse rating should be 3A All external controls and wiring must be suitable for mains voltage Wiring external to the boiler MUST be in accordance with the current I E E BS 7671 Wiring Regulations and any local regulations 26 MAINs WIRINg The Vogue Combi boiler comes pre fitted with 1 8m of mains cable This must be connected to a permanent live supp
115. ue In general terms a reading of greater than 150V indicates that the correct voltage is supplied to the gas valve 85 ThERMAL FUsE LOCKOUT Isolate the electrical supply to the boiler and system Ensure that the electrical connection to the thermal fuse is pushed fully home and that the 6 way connector is properly connected to the primary PCB Press r is the fault still present l Yes Disconnect the 6 way connector to the thermal fuse Replace the primary PCB Is there continuity across the black and yellow wires a in pins 1 and 2 pa Disconnect the electrical connection to the thermal fuse Is there continuity across the fuse ie Replace the heat exchanger Replace the wiring from the PCB to the thermal fuse e Z a Z T m m lt u o Z Q Z T m m lt m o Z Q Z T m lt m o Z Q Z T m lt u o Z a Z T m m 62 vogue combination boiler Installation and Servicing FAULT FINDINg 86 FLAME ON BEFORE gAs V ALVE ON Check integrity of wiring from primary PCB to Flame Sense electrode replace if deteriorated Check condition of Flame Sense Electrode and replace if deteriorated No Reset the boiler does boiler work OK Disconnect the electrical connection to the Flame Sense Electrode Is there continuity between the Electrode and earth lie Replace wiring from primary PCB to flame
116. uld be checked preferably by the gas supplier to ensure that the meter is adequate to deal with the rate of gas supply required It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS6891 2005 Whilst the principle of the 1 1 gas valve ensures the Vogue range is able to deliver it s full output at inlet pressures as low as 14mb other gas appliances in the property may not be as tolerant When operating pressures are found to be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation Allowing for the acceptable pressure loss of 1mb across the installation pipework it can be assumed that a minimum permitted operating pressure of 18mb will be delivered to the inlet of the appliance Reference BS 6400 1 Clause 6 2 Pressure Absorption IMpORTANT Installation pipes must be fitted in accordance with BS 6891 In IE refer to 1S 813 2002 The complete installation MUST be tested for gas tightness and purged as described in the above code FLUE INSTALLATION Pluming will occur at the terminal so terminal positions where this could cause a nuisance should be avoided The flue must be installed in accordance with the recommendations of BS 5440 1 2008 In IE refer to I S 813 2002 The following notes are intended for general guidance 1 The boiler MUST be installed so that the terminal is exposed to external air

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