Ideal Boilers VOGUE MAX COMBI 26, Installation & Servicing

7

Installation and Servicing

CONTENTS

1 INTRODUCTION ........................................................ 10

1.1 Introduction ............................................................... .10

1.2 Operation .................................................................. .10

1.3 

Safe Handling ............................................................ .10

1.4 

Optional Extra Kits .................................................... .11

1.5 Safety ........................................................................ .11

1.6 

Safe Handling of Substances .................................... .11

1.7 

Location of Boiler  ..................................................... .12

1.8 

Gas Supply ................................................................ .12

1.9 

Flue Installation ......................................................... .12

1.10 Terminal ..................................................................... .13

1.11 

Air Supply .................................................................. .13

1.12 

Water Circulation System .......................................... .13

1.13 

Boiler Control Interlocks ............................................ .13

1.14 

Electrical Supply ........................................................ .13

1.15 

Condensate Drain   ................................................... .13

1.16 

Boiler Dimensions, Services & Clearances ............... .14

1.17 

System Requirements ............................................... .15

1.18 

System Balancing ..................................................... .16

1.19 

Water Treatment........................................................ .16

2 INSTALLATION ......................................................... 17

2.1 

Boiler Assembly - Exploded View .............................. .17

2.2 Unpacking ................................................................. .18

2.3 

Front Panel Removal ................................................ .19

2.4 

Wall Mounting Template ............................................ .20

2.5 

Preparing the Wall ..................................................... .20

2.6 

Fitting the Wall Mounting Plate.................................. .20

2.7 

Mounting the Boiler ................................................... .20

2.8 

Determining the Flue Length & Flue Packs Req’d  ... .21

2.9 

Cutting & Setting the Flue Length ............................. .23

2.10 

Installing the Flue ...................................................... .24

2.11 

Condensate Drain ..................................................... .25

2.12 

Fitting the Optional Roof Flue Kit (Flat or Pitched) .... .27

2.13 

Flue Terminal Position ............................................... .28

2.14 

Assembling the Roof Flue Kit .................................... .29

2.15 

Connections & Filling ................................................ .30

2.16 

Electrical Connections ............................................... .32

2.17 

Installer Wiring - Mains .............................................. .32

2.18 

Optional System Controls Kits .................................. .33

2.19 

Internal Wiring - External Controls ............................ .33

2.20 

External Wiring .......................................................... .34

2.21 

Replacing Pre-Fitted Mains Cable ............................ .34

2.22 

Wiring Diagram ......................................................... .35

2.23 

Commissioning And Testing ...................................... .36

2.24 

Initial Lighting ............................................................ .37

2.25 

Check CH & DHW Operation .................................... .38

2.26 

Display Functions In Normal Operation .................... .39

2.27 

Changing Settings ..................................................... .40

2.28 

Menu Operation ........................................................ .41

2.29 

General Checks ........................................................ .46

2.30 

Handing Over ............................................................ .47

3 SERVICING ............................................................... 48

3.1 

Servicing Schedule ................................................... .48

3.2 

Boiler Front Panel Removal / Replacement .............. .49

3.3 

Lowering the Controls Panel ..................................... .49

3.4 

Fan & Venturi Assembly Removal & Cleaning .......... .50

3.5 

Removal of Injector ................................................... .50

3.6 

Burner Removal & Cleaning ...................................... .51

3.7 

Cleaning the Condensate Trap / Siphon ................... .51

3.8 

Cleaning the Heat Exchanger ................................... .52

3.9 Re-Assembly ............................................................. .52

3.10 

Replacement of Components .................................... .53

3.11 

Fan Replacement ...................................................... .53

3.12 

Burner Injector Replacement .................................... .54

3.13 

Burner/Door Assembly Replacement ........................ .54

3.14 

Return Thermistor Renewal ...................................... .54

3.15 

Ignition Electrode Replacement ................................ .55

3.16 

Flame Detection Electrode Replacement .................. .55

3.17 

Spark Generator Replacement ................................. .56

3.18 

Gas Control Valve Replacement ............................... .56

3.19 

Diverter Valve Actuator Replacement ....................... .57

3.20 

Condensate Trap Replacement ................................ .57

3.21 

PCB Replacement ..................................................... .58

3.22 

User PCB Replacement ............................................ .59

3.23 

DHW Flow Turbine Sensor Replacement ................. .59

3.24 

Draining the Boiler ..................................................... .59

3.25 

Pressure Gauge Renewal ......................................... .60

3.26 

Pressure Relief Valve Renewal ................................. .60

3.27 

Pump Auto Air Vent Replacement ............................. .61

3.28 

Diverter Valve Internal Cartridge Replacement ......... .61

3.29 

DHW Plate Heat Exchanger Replacement ............... .62

3.30 

Pump Head Replacement ......................................... .62

3.31 

CH Water Pressure Sensor Replacement................. .62

3.32 

DHW Filter & Flow Regulator Cleaning/Replacement ... .63

3.33 

Flow Thermistor Replacement .................................. .63

3.34 

Heat Exchanger Replacement .................................. .64

3.35 

Expansion Vessel Recharging and Replacement ..... .65

3.36 

Boiler Sealing Panel Replacement ............................ .65

3.37 

External System Filter Cleaning Guide.......................65

4 

FAULT FINDING ........................................................ 66

4.1 

Fault Finding Chart Main Menu ................................. .66

4.2 

Overheat Lockout ...................................................... .67

4.3 

Ignition Lockout ......................................................... .67

4.4 

Flame Loss ................................................................ .68

4.5 

Thermal Fuse Lockout .............................................. .68

4.6 

Flame On Before Gas Valve On ................................ .69

4.7 

Flow Thermistor Fault ............................................... .69

4.8 

Outside Sensor Fault ................................................ .69

4.9 

Return Thermistor Fault ............................................ .70

4.10 

Fan Fault ................................................................... .70

4.11 

Low Water Pressure .................................................. .70

4.12 

No Water Flow........................................................... .70

4.13 

No Connection To Primary PCB ................................ .71

4.14 

No CH But DHW Ok .................................................. .71

4.15 

No DHW But CH Ok .................................................. .72

4.16 

Blank Display ............................................................ .72