Ideal Boilers VOGUE MAX SYSTEM 15, Installation & Servicing

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Installation and Servicing
CONTENTS
1 GENERAL .................................................................. 10
1.1 Introduction ................................................................ 10
1.2 Operation ................................................................... 10
1.3 Safe Handling ............................................................. 10
1.4 Optional Extra Kits ..................................................... 10
1.5 Safety ......................................................................... 10
1.6 Safe Handling Of Substances .................................... 10
1.7 Location Of Boiler ...................................................... 11
1.8 Gas Supply ................................................................. 11
1.9 Flue Installation .......................................................... 11
1.10 Terminal ...................................................................... 12
1.11 Air Supply ................................................................... 12
1.12 Water Circulation System ........................................... 12
1.13 Boiler Control Interlocks ............................................. 12
1.14 Electrical Supply ......................................................... 12
1.15 Condensate Drain .................................................... 12
1.16 Boiler Dimensions, Services & Clearances ................ 13
1.17 System Requirements ............................................... 14
1.18 System Balancing ...................................................... 15
1.19 Water Treatment......................................................... 15
2 INSTALLATION ......................................................... 16
2.1 Boiler Assembly - Exploded View ............................... 16
2.2 Unpacking .................................................................. 17
2.3 Front Panel Removal ................................................. 18
2.4 Wall Mounting Template ............................................. 19
2.5 Preparing The Wall ..................................................... 19
2.6 Fitting The Wall Mounting Plate ................................. 19
2.7 Mounting The Boiler ................................................... 19
2.8 Determining The Flue Length & Flue Packs Req’d ... 20
2.9 Cutting & Setting The Flue Length ............................. 22
2.10 Installing The Flue ...................................................... 23
2.11 Condensate Drain ...................................................... 24
2.12 Fitting The Optional Roof Flue Kit (Flat Or Pitched) ... 26
2.13 Flue Terminal Position ................................................ 27
2.14 Assembling The Roof Flue Kit .................................... 28
2.15 Connections & Filling ................................................. 29
2.16 Electrical Connections ................................................ 30
2.17 Installer Wiring - Mains ............................................... 30
2.18 Optional System Controls Kits ................................... 31
2.19 Internal Wiring - External Controls ............................. 31
2.20 System Control Wiring ............................................... 32
2.21 External Electrical Controls ........................................ 33
2.22 Wiring Diagram .......................................................... 34
2.23 Commissioning And Testing ....................................... 35
2.24 Initial Lighting ............................................................. 36
2.25 Check CH & HW Cylinder Operation ......................... 37
2.26 Display Functions In Normal Operation ..................... 38
2.27 Changing Settings ...................................................... 38
2.28 Menu Operation ......................................................... 39
2.29 General Checks ......................................................... 44
2.30 Handing Over ............................................................. 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
3.5 Removal Of Injector ................................................... 47
3.6 Burner Removal And Cleaning ................................... 48
3.7 Cleaning The Condensate Trap / Siphon ................... 48
3.8 Cleaning The Heat Exchanger ................................... 49
3.9 Re-Assembly .............................................................. 49
3.10 Replacement Of Components .................................... 50
3.11 Fan Replacement ....................................................... 50
3.12 Burner Injector Replacement ..................................... 51
3.13 Burner/Door Assembly Replacement ......................... 51
3.14 Return Thermistor Renewal ....................................... 51
3.15 Ignition Electrode Replacement ................................. 52
3.16 Flame Detection Electrode Replacement ................... 52
3.17 Spark Generator Replacement .................................. 53
3.18 Gas Control Valve Replacement ................................ 53
3.19 Condensate Trap Replacement ................................. 53
3.20 PCB Replacement ...................................................... 54
3.21 User PCB Replacement ............................................. 55
3.22 Draining The Boiler .................................................... 55
3.23 Pressure Gauge Renewal .......................................... 55
3.24 Safety Pressure Relief Valve Renewal ....................... 56
3.25 Pump Auto Air Vent Replacement .............................. 56
3.26 Pump Head Replacement .......................................... 57
3.27 CH Water Pressure Sensor Replacement.................. 57
3.28 Flow Thermistor Replacement ................................... 57
3.29 Heat Exchanger Replacement ................................... 58
3.30 Expansion Vessel Recharging And Replacement ...... 59
3.31 Boiler Sealing Panel Replacement ............................. 59
3.32 External System Filter Cleaning Guide.......................59
4 FAULT FINDING ........................................................ 60
4.1 Fault Finding Chart Main Menu .................................. 60
4.2 Overheat Lockout ....................................................... 61
4.3 Ignition Lockout .......................................................... 61
4.4 Flame Loss ................................................................. 62
4.5 Thermal Fuse Lockout ............................................... 62
4.6 Flame On Before Gas Valve On ................................. 63
4.7 Flow Thermistor Fault ................................................ 63
4.8 Outside Sensor Fault ................................................. 63
4.9 Return Thermistor Fault ............................................. 64
4.10 Fan Fault .................................................................... 64
4.11 Low Water Pressure ................................................... 64
4.12 No Water Flow............................................................ 64
4.13 No Connection To Primary Pcb .................................. 65
4.14 No CH But Cylinder Temperature Ok ......................... 65
4.15 No HW But CH Ok ..................................................... 66
4.16 Blank Display ............................................................. 66
5 SPARE PARTS .......................................................... 67
6 BENCHMARK & COMMISSIONING ......................... 68