Ideal Boilers VOGUE MAX SYSTEM 15 Installation & Servicing Download Page 4

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Installation and Servicing

Summary of Contents for VOGUE MAX SYSTEM 15

Page 1: ...Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers For the very latest copy of literature for specification and maintenance practices visit our website ideal...

Page 2: ...ting Full Load P4 kW 15 18 26 32 Part Load P1 kW 4 9 5 9 8 5 10 5 Auxiliary Electricity Consumption Full Load elmax kW 0 025 0 040 0 045 0 049 Part Load elmin kW 0 005 0 004 0 011 0 012 Standby PSB kW...

Page 3: ...s VII Class VIII 1 2 1 5 2 3 4 3 5 5 PRODUCT FICHE The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installed in a...

Page 4: ...4 Installation and Servicing...

Page 5: ...FOR ANY TECHNICAL QUERIES PLEASE RING THE INSTALLER HELPLINE 01482 498663 NOTE BOILER RESTART PROCEDURE To restart boiler press RESTART button on the control panel The boiler will repeat the ignition...

Page 6: ...6 Installation and Servicing...

Page 7: ...r 44 3 SERVICING 45 3 1 Servicing Schedule 45 3 2 Boiler Front Panel Removal Replacement 46 3 3 Lowering Controls Panel Accessing Mains Wiring 46 3 4 Fan And Venturi Assembly Removal And Cleaning 47 3...

Page 8: ...the gross C V of the gas Btu ft3 c For m3 h multiply l s by 3 6 Key to symbols GB United Kingdom IE Ireland Countries of destination PMS Maximum operating pressure of water C13 C33 C53 A room sealed a...

Page 9: ...cord Cold water inlet temp measure record Hot water outlet temp measure record Water flow rate at max setting measure record For condensing boilers only Condensate drain 24 25 For all boilers complete...

Page 10: ...Keep back straight Avoid twisting at the waist Avoid upper body top heavy bending Always grip with the palm of the hand Use designated hand holds Keep load as close to the body as possible Always use...

Page 11: ...quent service see the wall mounting template and Section 1 16 In addition sufficient space may be required to allow lifting access to the wall mounting plate 1 8 GAS SUPPLY The local gas supplier shou...

Page 12: ...lve control of temperature in individual 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 ra...

Page 13: ...imum 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...

Page 14: ...ume for the boiler expansion vessel If the capacity of the vessel is not considered sufficient for this or for any other reason an additional vessel MUST be installed on the return to the boiler Guida...

Page 15: ...ment is also recommended by Ideal Boilers Ideal Boilers recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems If water treatment is us...

Page 16: ...04 Gas Valve 205 Injector Gas 207 Venturi 208 Fan 209 Gasket Fan Venturi 210 Fan Adaptor 211 Venturi Deflector 212 Condensate Hose 213 Flue Turret Clamp 214 Siphon trap 217 Gas Cock 218 Flue Manifold...

Page 17: ...Template located on internal protective packaging F Turret Clamp G Pressure Relief Valve Drain Pipe H Boiler Guarantee Registration Pack I Ideal System Filter C A D F G B E H Boiler Guarantee I Gas V...

Page 18: ...oosen the 2 screws retaining the front panel at the underside of the boiler 2 Release catches at rear of door by pulling downwards 3 Pull the underside front panel forward then lift upwards to remove...

Page 19: ...y with a 5 core boring tool ensuring that the hole is square to the wall Both wall faces immediately around the cut hole should be flat 2 Drill 2 mounting holes marked from template with a 7 5mm 8mm m...

Page 20: ...itted 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 a...

Page 21: ...copic Horizontal Flue Terminal 1000mm long B Pack Telescopic Cut 75mm Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum B Pack Standard 233 602 340 553 652 869 577 794 Plus 1 1m D pack 1...

Page 22: ...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 SHOU...

Page 23: ...from its mounting and will need to be refitted 9 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...

Page 24: ...ler 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 Ext...

Page 25: ...ipe Water Weather proof insulation Max 3m external pipework Limestone chippings 500 300 25 75 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house Minimu...

Page 26: ...g 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 Unive...

Page 27: ...enetrate the shaded area of the roof Note The equivalent flue length resistance of the elbow kits are 90o elbow kit 1m 45o elbow kit 0 6m If chimney penetrates dotted area such that A is less than 300...

Page 28: ...ded with the vertical connector kit 3 Secure the vertical connector by applying downward pressure on the connector 4 Position the clamp on the top face of the flue manifold and push it horizontally ba...

Page 29: ...propriate IMPORTANT Be sure to follow the Ideal system filter installation and maintenance guide for correct method of installation Failure to install the system filter correctly will affect boiler wa...

Page 30: ...ER WIRING MAINS The Vogue boiler comes pre fitted with 1 8m of mains cable This must be connected to a permanent live supply and NOT switched by thermostats programmers If the supply cord is damaged i...

Page 31: ...ermostat Timer For 230V remove the SL1 link for PELV remove the OpenTherm link 2 19 INTERNAL WIRING EXTERNAL CONTROLS To add wired external Room Thermostats Timers or Programmers proceed as follows 1...

Page 32: ...C S HW ON HW OFF C S ON IN L IN L FUSED SPUR TIMER CH ON L N HW ON HW OFF Y PLAN VALVE SYSTEM BOILER WITH Y PLAN SYSTEM br br o g y b b g y g g L N E L N E CH ON R S ON HW ON HW OFF C S ON FUSED SPUR...

Page 33: ...If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system The frost thermostat should be sited...

Page 34: ...RX NC CHIP COM BUS GND CHIP COM BUS 5V CHIP COM BUS TX CHIP COM BUS RX CHIP COM BUS 24V CHIP COM BUS GND CHIP COM BUS 5V CHIP COM BUS RX MAINS LIVE MAINS NEUTRAL AUXILIARY LIVE IONISATION FLOW DHW DH...

Page 35: ...s refer to Gas Supply Section 1 8 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Gas Supply Gas Pressure Test Point ATTENTION IT IS A CONDITION O...

Page 36: ...knob E to the off position 7 Slacken the screw in the inlet pressure test point H and connect a gas pressure gauge via a flexible tube INITIAL IGNITION 1 Switch the electricity supply ON and check al...

Page 37: ...tablished the following screen will be displayed MENU 60O C TO CYLINDER ON 60 C ON 60 C 15 C The temperature shown will be the actual Flow temperature At full output check the gas rate at the gas mete...

Page 38: ...FF Cylinder Demand On CH Demand On MENU 60O C TO CYLINDER ON 60 C ON 60 C 15 C Cylinder Demand Off CH Demand On MENU ON 60 C 15 C READY TIMER OR CYLINDER THERMOSTAT OFF Boiler Frost Protection occurs...

Page 39: ...NAME MAX OFF MAX OFF SELECT EXIT on the next screen to show the following EXIT SELECT MENU SERVICE COMPANY PHONE NUMBER CHANGE SERVICE INTERVAL FAULT HISTORY SERVICE COMPANY NAME Press SELECT and a s...

Page 40: ...SELECT MENU VENT SYSTEM SENSOR READINGS FAULT HELP FAULT HISTORY Press SELECT and the following screen will be displayed EXIT SELECT FAULT HELP IGNITION LOCKOUT NO WATER FLOW LOW WATER PRESSURE Press...

Page 41: ...OW EFFICIENCY LEVEL HOT WATER PREHEAT ON OFF SERVICE COMPANY PHONE NUMBER SERVICE COMPANY NAME MAX OFF MAX OFF SELECT EXIT until the following screen is displayed EXIT SELECT MENU MAXIMUM FLOW TEMPERA...

Page 42: ...OFF SELECT EXIT until the following screen is displayed EXIT SELECT MENU PUMP MODULATION PLOT GRAPHS SERVICE MODE MAXIMUM FLOW TEMPERATURE Press SELECT and the following screen will be displayed EXIT...

Page 43: ...he desired setting is displayed Press SET followed by EXIT to return to normal operation PLOT GRAPHS To plot graphs of Water Pressure Switch Live DHW Flow Rate DHW Temperature Flow Return Temperature...

Page 44: ...lted 9 Explain boiler restart procedure 10 After installation and commissioning please complete the Commissioning Checklist before handover to the customer For IE its is necessary to complete a Declar...

Page 45: ...s soundness check up to the gas control valve 6 When work is complete the front panel MUST be correctly refitted ensuring that a good seal is made Do NOT OPERATE the boiler if the front panel is not f...

Page 46: ...into a lower position 3 To gain access to the mains wiring connections remove retaining screw press the retaining lug to the left and lift off the cover Position 1 2 Position 2 Clip REMOVAL 1 Loosen t...

Page 47: ...9 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 32 model only 10 Remove the fan fro...

Page 48: ...Replace as necessary Replacement of burner door sealing gasket 5b Remove the silicon seal from around the burner door location groove 6 Re new the seal and replace in reverse order 4 5 1 Refer to Sec...

Page 49: ...he heat exchanger connected 3 Refit the fan to the burner assembly Refer to Section 3 4 4 Refit the venturi to the fan and burner assembly Refer to Section 3 4 5 Refit the burner fan venturi assembly...

Page 50: ...it 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 the 32kW models Note a mounting space...

Page 51: ...peration of the boiler Refer to Sections 2 24 2 27 8 3 14 RETURN THERMISTOR RENEWAL 1 Refer to Sections 3 2 to 3 3 2 Unclip the return thermistor 3 Disconnect the electrical lead from the thermistor 4...

Page 52: ...nto the burner door assembly and secure with the 2 screws ensuring correct orientation 7 Reconnect the ignition lead and earth 8 Check the operation of the boiler Refer to Sections 2 24 2 27 1 Refer t...

Page 53: ...3 5 Remove the 2 securing screws in the underside of the boiler casing and remove the valve 6 Remove brass injector from gas valve outlet and re fit into replacement valve 7 Replace in reverse order e...

Page 54: ...rder 8 Turn power on and follow the on screen instrucitons as shown Installer Initialise PCB YES Press YES Installer Switch mains off wait 5s then switch mains on Installer Processing Select boiler mo...

Page 55: ...ntrols housing lid Refer to Section 3 20 4 Remove the electrical cover at the clips indicated Refer to Section 3 20 5 Disconnect the 2 electrical connectors carefully 6 Remove PCB from mounting posts...

Page 56: ...e boiler Refer to Sections 2 24 2 27 3 25 PUMP AUTO AIR VENT REPLACEMENT 1 Refer to Sections 3 2 3 3 2 Close the isolating service valves and drain the CH boiler Refer to Section 3 22 3 Remove the bur...

Page 57: ...e CH boiler Refer to Section 3 22 3 Remove the condensate trap Refer to Section 3 19 4 Remove the retaining clip to the rear of the housing 5 Pull out the sensor and disconnect the electrical connecti...

Page 58: ...use lead 8 Remove the horseshoe bracket and lift up the flue turret 9 Remove the securing screws and disconnect the flue outlet 10 Remove the 4 screws securing the heat exchanger fixing brackets 11 Re...

Page 59: ...ws from the top of the casing at the same time holding the ignitor bracket to prevent movement 5 Hold the expansion vessel and move the ignition assembly bracket carefully to one side 6 Pull the botto...

Page 60: ...ction 4 13 No Connection to Primary PCB 5 Restarts within 15 minutes Turn power off and on Go to Section 4 6 Flame On before Gas Valve On Go to Section 4 7 Flow Thermistor Fault Go to Section 4 8 Outs...

Page 61: ...position refer to Section 3 17 Are these functioning correctly Check ignition electrode and associated harness for continuity visual condition and position refer to Section 3 15 Are these functioning...

Page 62: ...sociated harness for continuity visual condition and position Check if the condensate pipe is blocked Check if the flue is blocked Replace as necessary Check gas supply and rectify fault Check wiring...

Page 63: ...Flame Sense Electrode Is there continuity between the Electrode and earth Is there continuity in the wiring from the primary PCB to the Thermistor 8 way connector connections 3 and 4 black and pink D...

Page 64: ...and 6 black and red Is there 240Vac at the blue and brown connections to the 3 way connection on the Fan Does the wiring from the Water Pressure Switch to the PCB have continuity and is it securely co...

Page 65: ...es the fault disappear Are the Radiator Valves open Does the zone valve move to the appropriate position Is an Ideal Electronic Programmable Room Stat connected Is there 240Vac at A Is there a lin pro...

Page 66: ...from the main PCB to the user interface PCB have continuity and is it un damaged Is the Fuse on the main PCB OK Replace the user interface PCB still no display No No No No No No Yes Yes Yes Yes Yes Y...

Page 67: ...ils 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...

Page 68: ...68 SHORT LIST OF PARTS Installation and Servicing...

Page 69: ...ommissioning 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...

Page 70: ...priate Building Regulations and then handed to the customer to keep for future reference GAS BOILER SYSTEM COMMISSIONING CHECKLIST CONTROLS Programmable room thermostat Optimum start control Combinati...

Page 71: ...larly and that the appropriate Service Interval Record is completed Service Provider SERVICE RECORD SERVICE 01 AND Where Possible AND Signature SERVICE 02 AND Where Possible AND Signature SERVICE 03 A...

Page 72: ...ITTED 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 flu...

Page 73: ...bled fixed and supported as per instructions Check that flue and flue terminal are not obstructed Check that no seals e g Those on flue extensions have been displaced during installation Rectify if ne...

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Page 80: ...he code of practice for the installation commissioning servicing of central heating systems Ideal Boilers Ltd PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 01482 492251 Fax 01482 448858 Re...

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Summary of Contents for VOGUE MAX SYSTEM 15

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