s i m p ly a d va n c e d
installatioN
and servicing
combination boiler
c26, c32, c40
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 on PDF format.
For details of document amendments, refer to page 3
October 2013
UIN 208548 A04
2
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........A03 (May 13) to A04 (Sep 13)
Page 12 - Frame 5, Water Treatment
Addition of Adey Professional Heating Solutions
Page 31 - Frame 32, Commissioning and Testing
Electrical Installation - item no. 3 added
Page 40 - Frame 41, Menu Operation
Addition of Pump Modulation section
Ideal Stelrad Group reserve the right to vary specification without notice
vogue combination boiler - Installation and Servicing
3
general
Table 1 - General Data
Vogue
2632 40
2H - G20 - 20mbar
Gas supply 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 copper compression
Flow Connection
Central Heating
22mm copper compression
Return Connection
Central Heating
22mm copper compression
Flue Terminal Diameter
mm (in)
100 (4)
ºC (g/s)
73ºC (11 g/s)
73ºC (13 g/s)
70ºC (17 g/s)
Average Flue Temp-Mass Flow Rate (DHW)
Maximum Working Pressure (Sealed Systems)
bar (lb/in2)
2.5 (36.3)
bar (lb/in2)
Maximum Domestic Hot Water Inlet Pressure
10.0 (145)
2
Minimum Domestic Hot Water Inlet Pressure*
bar (lb/in )
1.1 (16.0)
1.5 (21.8)
1.5 (21.8)
230 V ~ 50 Hz.
Electrical Supply
Power Consumption
W
108
137
133
Fuse RatingExternal : 3A Internal : 4A Time Delay
Central Heating
litre (gal)
1.5 (0.33)
1.8 (0.41)
2.2 (0.48)
Water content
Domestic Hot Water litre (gal)
0.5 (0.11) Packaged Weight
Maximum Installation Weight
Height
Boiler Casing Size
Width
Depth
Heat Exchanger Weight without Burner
41.7 (92)
36.4 (80)
740 (29.1)
445 (17.5)
330 (13)
8.2
kg (lb)
40.4 (89)
kg (lb)
35.0 (77)
mm (in)
mm (in)
mm (in)
KG
7.3
43.7 (96)
38.0 (84)
9.5
*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 :
Boiler Input ‘Q’
Nett CV
kW
26
18.1
Table 3 - Performance Data - Domestic Hot Water
Max.
32
40
26.1
32.1
26
Min.
32
40
3.7
4.6
5.7
(Btu/h) 61,800 89,100 109,50012,700 15,600 19,500
Gross CV
kW
20.1
29.0
35.6
4.1
5.1
6.3
(Btu/h) 68,500 98,800 121,60014,100 17,300 21,600
Gas Consumption
m3/h 1.869 2.695 3.3140.383 0.472 0.590
3
(ft /h)66.0 95.2 117.113.6 16.7 20.8
Boiler Output :
Non Condensing
Nett CV
18.0
26.0
32.0
3.7
4.6
5.7
kW 19.3
27.9
34.3
4.0
4.9
6.1
40oC Mean Water temp. (Btu/h) 65,900 95,300 117,200 13,600 16,700 20,900
Seasonal efficiency* SEDBUK 2005
91.0
91.1
91.0
n/a
Seasonal efficiency* SEDBUK 2009
89.1
89.2
89.1
n/a
NOx Classification
kW
26
32
40
26.1
32.1
40.2
(Btu/h) 89,100 109,500 137,200
Gross CV
kW
29.0
35.6
44.6
(Btu/h) 98,800 121,600 152,200
Gas Consumption m3/h2.695 3.314 4.150
(ft3/h)95.2 117.1146.6
Maximum kW
70oC Mean Water temp. (Btu/h) 61,400 88,700 109,200 12,800 15,700 19,600
Condensing
Maximum DHW Input :
kW
26.0
32.0
40.0
DHW Output(Btu/h) 88,700 109,200 136,500
DHW Flow Rate
l/min
at 35°C temp. rise. (gpm)
10.6
2.3
13.1
2.9
16.4
3.6
DHW Specific Rate l/min
(gpm)
12.4
2.7
15.3
3.4
19.1
4.2
Class 5
* The value is used in the UK Government’s 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
calorific value of 38.7 MJ/m3 (1038 Btu/ft3) gross
or 34.9 MJ/m3 (935 Btu/ft3) nett
To obtain the gas consumption at a different
calorific value:
Key to symbols
GB = United Kingdom
IE = Ireland
(Countries of destination)
PMS=Maximum operating pressure of water
b. For ft3/h - divide the gross heat input (Btu/h)
by the gross C.V. of the gas (Btu/ft3)
C13 C33 C53* =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 stream
of the combustion chamber. (*Note. C53 covers optional high level
and balconly flue kits only.)
c. For m3/h - multiply l/s by 3.6
I2H
a. For l/s - divide the gross heat input (kW) by
the gross C.V. of the gas (MJ/m3)
4
=An appliance designed for use on 2nd Family gas, Group H only.
vogue combination boiler - Installation and Servicing
general
0
Air Supply .. ..................................................................... 9
Natural Gas only
Benchmark Commissioning Checklist ...................... 70
Boiler sizeG.C. Appliance No.PI No.
(Benchmark No.)
26
32
40
47-348-99
47-348-98
47-348-97
86 CN 45
86 CN 45
86 CN 45
Boiler Clearances ........................................................ 10
Boiler Exploded Diagram ............................................ 13
Condensate Drain ........................................ 9, 21, 22, 46
Electrical Connections ................................................ 32
Electrical Supply ........................................................... 9
Fault Finding ........................................................... 60-66
Destination Country:
GB, IE
Flue Fitting ................................................................... 16
Flue Installation ...................................................... 16-25
Gas Safety Regulations ................................................ 7
Gas Supply ..................................................................... 8
Installation ............................................................... 13-42
Pump ............................................................................ 55
Safe Handling .. ............................................................... 6
Servicing ................................................................. 43-59
Thermostatic Radiator Valves ...................................... 9
Water and Systems .............................................9,11,12
Water & Gas Connections .......................................... 26
Water Treatment ......................................................... 12
Wiring Diagram ............................................................ 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.
0
0
Contents
Vogue
Benchmark Commissioning Checklist Details
Boiler
Page
Make and model.......................................................... 5
Appliance serial no. on data badge ........... Front Cover
SEDBUK No. %........................................................... 4
Controls
Time and temperature control to heating.................. 29
Time and temperature control to hot water .............. 29
Heating zone valves................................................. n/a
TRV’s.......................................................................... 9
Auto bypass................................................................ 9
Boiler interlock............................................................. 9
For ..................................................................... all boilers
Flushing to BS.7593.................................................. 12
Inhibitor..................................................................... 12
Central heating mode
Heat input....................................................to be calculated
Page
Burner operating pressure....................................... n/a
Central heating flow temp.............measure and record
Central heating return temp..........measure and record
For combination boilers only
Scale reducer............................................................ 12
Hot water mode
Heat input.............................................to be calculated
Max. operating burner pressure............................... n/a
Max. operating water pressure......... measure & record
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.................................................21-22
For all boilers: complete, sign & hand over to customer
For assistance see Technical Helpline on the back page
NOTE TO THE INSTALLER: COMPLETE
THE BENCHMARK COMMISSIONING
CHECKLIST AND LEAVE THESE
INSTRUCTIONS WITH APPLIANCE
vogue combination boiler - Installation and Servicing
5
general
INTRODUCTION
operation
The Vogue range of boilers are wall mounted, full sequence,
automatic spark ignition, low water content, fanned flue, high
efficiency, condensing, combination gas boilers.
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-heat is selected from the menu.
Note. Due to the high efficiency of the boiler a plume of water
vapour will form at the terminal during operation.
26
3.7 to 18.0kW (12,800 to 61,400 Btu/h)
32
4.6 to 26.0kW (15,700 to 88,700 Btu/h)
When there is a demand for CH, the heating system is supplied at
the selected temperature of between 30oC and 80oC, 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
40
5.7 to 32.0kW (19,600 to 109,200 Btu/h)
26
10.6 l/min at 35 oC temperature rise.
Instantaneous domestic hot water (DHW) output is also fully
modulating with a maximum of :
32
13.1 l/min at 35 oC temperature rise.
40
16.4 l/min at 35 oC temperature rise.
26
26kW (88,700 Btu/h)
32
32kW (109,200 Btu/h)
40
40kW (136,500 Btu/h)
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.
Central heating (CH) output is fully modulating with a range of:
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.
At low DHW draw-off rate the maximum temperature is limited to
65 oC 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
The boiler temperature controls are located behind the lower
panel on the front of the boiler.
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.
The heat exchanger is manufactured from stainless steel.
Caution should be exercised during these operations.
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.
Operatives should be knowledgeable in handling techniques when
performing these tasks and the following precautions should be
considered:
The boiler casing is of white painted mild steel with a white
polymer front panel.
The standard configuration of pipework from the boiler is routed
downwards.
• Grip the boiler at the base.
• Be physically capable.
• 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.
•
•
•
•
•
•
•
6
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 assistance if required.
vogue combination boiler - Installation and Servicing
general
Optional extra kits
Safety
• Horizontal Flue Terminal (600mm long)
Current Gas Safety (installation and use) regulations or rules
in force:
• Horizontal Flue Terminal (1000mm long)
• Flue Extension Ducts (1000mm long)
26-up to 10m
32-up to 8m
40-up to 8m
• Flue Finishing Kit
• 90o Elbow Kit (maximum per installation)
26 - upto 6 elbows
32 - upto 4 elbows
40 - upto 4 elbows
• 45o Elbow Kit (maximum per installation)
26 - upto 6 elbows
32 - upto 4 elbows
40 - upto 4 elbows
• Roof Flue Kit (to a maximum of 10m)
• Flue Vertical Connector Kit
• Raised Horizontal Flue Outlet Kit
• Flue Extension Kit Ø60 (1m)
• Concentric Flue Screw Retaining Kit
• Weather Collar
• Stand-Off Kit
• Stand-Off Kit (inc. pipes)
• High Level Flue Outlet Kit
• Flue Deflector Kit
• Condensate Pump Kit
• Mechanical Timer (24 hr) Kit
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:
• Gas Safety (Installation and Use) Regulations
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
• The Water Fittings Regulations or Water byelaws in Scotland.
• 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 I.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. 5440:1 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.
BSEN 12831:2003 Heating Systems in buildings: Method for
calculation of the design heat load.
BSEN 14336:2004
• Electronic Timer (7 day) kit
Heating Systems in buildings: Installation
and commissioning of water based heating
systems.
• RF Mechanical Programmable Room Thermostat (24 hr) kit
BS. 5546
• RF Electronic Programmable Room Thermostat (7 day) kit
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.
• Weather Compensation Kit
• Adjustable Flue Support Bracket
BS. 6891
• DHW Expansion Vessel Kit
Health & Safety Document No. 635.
• Balcony Flue Kit
• Security Bracket Kit
• Flue Support Bracket Kit
Low pressure installation pipes.
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 HANDLING OF SUBSTANCES
No asbestos, mercury or CFCs are included in any part of the
boiler or its manufacture.
vogue combination boiler - Installation and Servicing
7
general
Location of boiler
GAS SUPPLY
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 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 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 I.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), the appliance
must be installed beyond Zone 2, as detailed in BS.7671.
Ceiling
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 should 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 IS.813:2002.
The complete installation MUST be tested for gas tightness and
purged as described in the above code.
Flue installation
2.25m
Zone 1
Pluming will occur at the terminal so terminal positions where this
could cause a nuisance should be avoided.
Recessed
window
Zone 2
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:
0.6m
1. The boiler MUST be installed so that the terminal is exposed to
external air.
Zone 0
3G8913a
Compartment Installations
A compartment 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.
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.
In both cases, details of essential features of cupboard /
compartment design, including airing cupboard installation, are to
conform to the following:
Terminal guards are available from boiler suppliers. (Ask for
TFC flue guard model no. K6 - round, plastic coated). In case of
difficulty contact:
• BS 6798 (No cupboard ventilation is required - see ‘Air Supply’
for details).
TFC Group Ltd.
Tel. + 44 (0) 01732 351 680
Tower House, Vale Rise
Fax. + 44 (0) 01732 354 445
Tonbridge. Kent TN9 1TB
www.tfc-group.co.uk
Ensure that the guard is fitted centrally.
• The position selected for installation MUST allow adequate
space for servicing in front of the boiler.
• 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.
8
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.
Terminal
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.
Air supply
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, such as forced ventilation openings etc.
The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frame 10 .
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.
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.
Water circulation system
Table 4 - Balanced Flue Terminal Position
The central heating system should be in accordance with BS.6798
and, in addition, for smallbore and microbore systems, BS.5449.
Flue Terminal Positions
Min. Spacing*
300mm (12”)
2. Below guttering, drain pipes or soil pipes.
BS5440-1 2008
25mm ( 1”)*
75mm (3”)
3. Below eaves.
BS5440-1 2008
25mm (1”)*
200mm (8”)
4. Below balconies or a car port roof.
BS5440-1 2008
25mm (1”)*
200mm (8”)
5. From vertical drain pipes or soil pipes.
BS5440-1 2008
25mm (1”)*
150mm (6”)
6. From an internal or external corner or to a boundary along side the terminal. BS5440-1 2008
25mm (1”)*
300mm (12”)
300mm (12”)
8. From a surface or a boundary facing the terminal.
600mm (24”)
9. From a terminal facing a terminal. 1,200mm (48”)
10. From an opening in a car port
(e.g. door or window) into dwelling. 1,200mm (48”)
11. Vertically from a terminal on the same wall. 1,500mm (60”)
12. Horizontally from a terminal on the wall.
300mm (12”)
Vertical Terminals
13. Above the roof pitch with roof slope of all angles.
Above flat roof.
300mm (12”)
300mm (12”)
14. From a single wall face.
From corner walls.
300mm (12”)
300mm (12”)
15. Below velux window 2000mm (79”)
16. Above or side of velux window
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.
Water treatment - see Frame 5
1. Directly below, above or alongside an opening
window, air vent or other ventilation opening.
7. Above adjacent ground, roof or balcony level.
Important.
600mm (24”)
* Only one reduction down to 25mm is allowable per installation
otherwise BS5440-1 2008 dimensions must be followed.
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 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 & 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 condensate 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.
vogue combination boiler - Installation and Servicing
9
general
1boiler dimensions, services & clearances
The boiler connections are made on the boiler connection tails.
Refer to Frame 24.
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.
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
2.5
from case
2.5
all dimensions in mm
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.
330
445
Side flue
dim. A
740
450
51 37.5
10
65
67
67
PRV Outlet
CH Return
DHW Inlet
Gas Inlet
DHW Outlet
CH Flow
Cond. Drain
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.
65
50
42.5
* 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..
vogue combination boiler - Installation and Servicing
general
2
system requirements - Central Heating
Notes
a. The method of filling, refilling, topping up or flushing sealed
primary hot water circuits from the mains via a temporary hose
connection is only allowed if acceptable to the local water
authority.
b. Antifreeze fluid, corrosion and scale inhibitor fluids suitable for
use with boilers having stainless steel heat exchangers may be
used in the central heating system.
General
1. The installation must comply with all relevant national and local
regulations.
2. The installation should be designed to work with flow
temperatures of up to 86 oC.
3. All components of the system must be suitable for a working
pressure of 3 bar and temperature of 110 oC. Extra care should
be taken in making all connections so that the risk of leakage is
minimised.
Pressure relief valve settingbar
Vessel charge pressure
bar
System pre-charge pressurebar
System volume
(litres)
3.0
0.5 to 0.75
None
1.0
Expansion vessel
volume (litres)
25
1.61.8
50
3.13.7
75
4.75.5
100
6.37.4
125
7.89.2
150
9.411.0
175
10.912.9
190
11.914.0
200
12.514.7
250
15.618.4
300
18.822.1
For other system volumes
multiply by the factor across
Model
Max CH output
The following components are incorporated within the appliance:
a. Circulating pump.
Water flow rate
@ 20ºC differential
b. Pressure relief valve, with a non-adjustable preset lift
pressure of 3 bar.
Head available for
system
c. Pressure gauge, covering a range of 0 to 4 bar.
d. A 10-litre expansion vessel, with an initial charge pressure
of 0.75 bar.
0.0630.074
26
32
40
18
61400
26
88700
32
109200
l/min
gal/min
13
2.9
18.6
4.1
22.9
5.0
m.wg
ft.wg
4.4
14.4
2.5
8.2
1.2
3.9
kW
Btu/h
4. ‘Make-up’ Water
The water connection and isolation valves incorporate an
approved system for filling and topping up the water in the
heating system. Refer to Frame 24 for details of how to fill
and top up the system.
a. Thoroughly flush out the whole system with cold
water.
The maximum cold water capacity of the system should
not exceed 159 litres, if not pressurized. However, if the
system is to be pressurized, the efficiency of the expansion
vessel will be reduced and a larger vessel (or smaller system
volume) may be necessary. 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.
c.
Check the operation of the safety valve by raising the
water pressure until the valve lifts. This should occur
within 0.3bar of the preset lift pressure.
Guidance on vessel sizing is given in Table above.
b.
Fill and vent the system until the pressure gauge
registers 1bar and examine for leaks. Refer to Frame
24 for filling detail.
d. Release water from the system until the minimum system design pressure is reached; 1.0 bar if the system is to be pre-pressurised.
5.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.
continued . . . . . .
vogue combination boiler - Installation and Servicing
11
general
3
system requirements - (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
temperature rise of 35oC at the tap furthest from the boiler.
3. The boilers are suitable for connection to most types of washing
machine and dishwasher appliances.
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
could completely cut off the flow through the
system must also include a bypass.
Balancing
4. 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.
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.
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.
These valves should now be left as set.
Cold water, rising main & pipework in exposed areas need to be suitably
lagged to prevent freezing.
3. Adjust the room thermostat and programmer
to normal settings.
5.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 the local water company.
2. Open all manual or thermostatic radiator
valves and adjust the lockshield valves on
the remaining radiators, to give around 20oC
temperature drop at each radiator.
Note. DHW Expansion Vessel kit available from Ideal.
5water treatment
Central Heating
Domestic Hot water
The Vogue range of boilers have a stainless steel heat
exchanger.
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 I
scale reducing devices or Scalemaster Inline Scale Inhibitor
branded Ideal, which must be used in accordance with the
manufacturers’ instructions.
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. It is most important that the correct concentration of the water
treatment products is maintained in accordance with the
manufacturers’ instructions.
2. 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
heating system.
3. In hard water areas, treatment to prevent lime scale may be
necessary - however the use of artificially softened water is
NOT permitted.
4. Under no circumstances should the boiler be fired before the
system has been thoroughly flushed.
12
For further information contact:
Fernox Cookson Electronics
Forsyth Road, Sheerwater, Woking, Surrey GU21 5RZ
+44 (0) 8706 015000
Sentinel Performance Solutions
The Heath Business & Technical Park
Runcorn, Cheshire WA7 4QX
Tel: 0800 389 4670
Scalemaster Water Treatment Products
Emerald Way, Stone, Staffordshire ST15 0SR
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
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
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 & Return)
306 Electrode Ignition
307 Electrode Detection
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.
Model shown - c40
vogue combination boiler - Installation and Servicing
13
INSTALLATION
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.
E
A
B
Pack A Contents
ABoiler
B Hardware Pack Box
C
C Wall Mounting Plate
D These Installation Instructions
E Wall Mounting Template
(located on internal protective packaging)
F
D
F
Turret Clamp
G Pressure Relief Valve Drain Pipe
G
H Boiler Guarantee & Registration Pack
H
Boiler Guarantee
HARDWARE PACK CONTENTS
Gas Valve Pack
1. Pipe - Gas Inlet
2. Washer - Gas (blue)
3. Gas Cock
Filling Loop Pack
1. 3/8" Top Hat Washer (x2)
2. Plastic Chain (x2)
3. 3/8" Blanking Cap (x1)
4. Valve - Dbl Check Filling Loop (x1)
5. 3/8" Fibre Washer (x2)
6. 3/8" Blanking Cap Extended (x1)
7. Valve Filling Loop (x1)
8. Filling Loop with 3/8" Nuts (x1)
Return Valve Pack
1. Pipe CH Return
2. Washer CH
3. Valve Return
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)
Gas Valve Pack
DHW Pack
2
3
1
1
2
3
Filling Loop
4
5
5
2
2
8
6
3
5
3
7
4
1
Accessory Pack
1
1
2
Return Valve Pack
Flow Valve Pack
3
3
1
2
1
2
continued . . . . .
14
vogue combination boiler - Installation and Servicing
INSTALLATION
unpacking Cont’d
INSTALLATION
8
Pack B Contents Telescopic
A
Telescopic Flue Terminal
B
Flue Turret
C
Rubber Terminal Wall Seal
DScrew
E
Sealing Tape
F
Wall Seal (White)
B
F
A
D
C
E
Pack B Contents Non-Telescopic
A
Flue Terminal
B
Flue Turret
C
Rubber Terminal Wall Seal
D
Cutting Aid
E
Wall Seal (White)
B
D
A
E
C
9front panel removal
1. Loosen the 2 screws retaining the front panel at the
bottom.
1
2. Release catches at rear of door by pulling
downwards.
3. Pull the underside front panel forward then lift
upwards to remove.
2
vogue combination boiler - Installation and Servicing
15
INSTALLATION
10 wall mounting template
Extended centre line
131(or 176)
The wall mounting template is located on the internal protective
packaging. The template shows the position of the fixing and rear
flue centre holes for a standard installation
V - See Diagram Below
Care MUST be taken to ensure the correct holes are drilled.
1. Tape template into the required position, ensuring its squareness
by hanging a plumbline as shown.
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.
4. Remove the template plate from the wall.
279a
nm9
11 preparing the wall
225
131 (176 sta
nd off distanc
e)
Important.
Ensure that, during the cutting operation, masonry falling
outside of the building does not cause damage or personal
injury.
1. Cut the flue hole (preferably 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.
Rear flue only
5" diameter hole
FLUE OUTLET
2. Drill 2 mounting holes (marked from template) with a 7.5mm
/ 8mm masonry drill and insert the plastic plugs, provided,
for the wall mounting plate.
X
Section
through wall
3. Locate 2 No.14 x 50mm screws in the wall mounting plate
(one at each side, in any of the 3 holes provided at each
side) and screw home. Ensure mounting bracket is level.
12 Fitting the Wall Mounting Plate
Side flue only
5" diameter hole
Note. Check all of the hole
positions before drilling.
13 Mounting the Boiler
Screw the wall mounting plate to the wall using 2 wall plugs
(previously fitted) with the 2 screws provided.
1. Ensure the plastic plugs are removed from both the CH
and DHW connections before mounting the boiler.
Choose one of the 2 sets of slots in left and right bank.
Ensuring that at least one of the screws is fitted into a top slot
and the mounting bracket is level.
16
Example of fixing
Note. boiler may contain residual water.
2. Lift the boiler onto the wall mounting plate (refer to the
Introduction section for safe handling advice), locating it
over the two tabs.
esp9496
vogue combination boiler - Installation and Servicing
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 & Concentric Flue Screw Retaining Kit (Optional Kit of mechanical fixing of flue joints)
Only use 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 & 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 fitted to
26 kW appliances
Total Maximum: 10 metres - minus any flue kit options or bends
32 & 40kW Appliances
Total Maximum:
FLUE OUTLET
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)
8 metres - minus any flue kit options or bends
Total Maximum permissible Vertical Flue Length combining both Roof Terminal and ‘D’ Packs
26, 32 & 40kW Appliances
Total Maximum: 10 Metres - minus any bends
90º Elbow Kit 60/100 - (Equivalent flue length resistance = 1M)
45º 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
‘B’ Pack Flue Type
Std Metric Brick 102.5mm wide
Minimum permissible Wall Thickness
Maximum permissible Wall Thickness
Side Flue Rear Flue Rear Flue + Std-Off
Side Flue
Rear Flue
Rear Flue + Std-Off
Horizontal Flue Terminal
(600mm long) B Pack
154
102.5
102.5
513
482
433
Telescopic Flue B Pack
265
220
171
464
433
384
Horizontal Flue Terminal
(1000mm long) B Pack
577
532
483
780
749
700
Horizontal Flue Terminal
(1000mm long) B Pack cut 75mm
522
457
498
705
674
625
For Flue lengths between 658 & 708 use a Horizontal Flue Terminal (1000mm long) B Pack, cut 75mm off the end of the
terminal section of the telescopic flue only.
vogue combination boiler - Installation and Servicing
17
INSTALLATION
15 DETERMINING THE FLUE LENGTH and flue packs required, cont’d
figure 1
100mm
Edge of turret
to outside face of wall plus
44mm = flue length
A
Edge of turret
to outside face of wall plus
44mm = flue length
A
Edge of turret
to outside face of wall plus
44mm = flue length
A
Note. Maximum permissible
flue length is measured from
centre line of appliance flue
outlet to outside wall face.
WALL
WALL
SIDE
Fit
to wall
WALL
REAR
Fit
to wall
inc. Stand
off Frame
REAR
Fit
to wall
Minimum clearance 5mm
NOTES
Centre of turret to edge of turret = 100mm
Turret has a flue insertion of 30mm
The compressed outer wall seal has protruding wall to seal mounting lip - 14mm
From centreline of turret to wall. Rear mount 131mm, side (including clearance) 225mm
Flue length measured from outer terminal lip
to end of outer flue
A + 44mm
figure 2
18
B Pack (Standard)
Plus 1 (1m D pack)
Plus 2 (1m D pack)
Plus 3 (1m D pack)
Plus 4 (1m D pack)
Plus 5 (1m D pack)
Plus 6 (1m D pack)
Plus 7 (1m D pack)
Plus 8 (1m D pack)
Plus 9 (1m D pack)
Plus 10 (1m D pack)
233
1183
2133
3083
4033
4983
5933
6883
7833
8783
9733
602
1552
2502
3452
4402
5352
6302
7252
8202
9152
N/A
340
1290
2240
3190
4140
5090
6040
6990
7940
8890
9840
553
1503
2453
3403
4353
5303
6253
7203
8153
9103
10000
652
1602
2552
3502
4452
5402
6352
7302
8252
9202
N/A
869
1819
2769
3719
4669
5619
6569
7519
8469
9419
N/A
577
1527
2477
3427
4377
5327
6277
7227
8177
9127
N/A
794
1744
2694
3644
4594
5544
6494
7444
8394
9344
N/A
Max output 26 kW
Minimum & 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
Minimum
Maximum
Minimum
Maximum
Minimum
Maximum
Minimum
Maximum
Max output 32 & 40 kW
FLUE OUTLET
Actual maximum flue length requirements
(outside edge of turret to out side face of wall plus 44mm (Cut Length))
Note; Telescopic flue B Pack or attached “D” pack extensions do not need to be cut between minimum 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.
vogue combination boiler - Installation and Servicing
INSTALLATION
16 Cutting & Setting the Flue Length
Telescopic 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 & 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).
2. Remove telescopic end piece from the flue body and set aside.
3. Mark the circumference 75mm from the open end of the outer flue.
4. Cut along the 75mm mark cutting only the outer flue ensuring the cut is
square.
mm
75
m
10m
Measure from
this
RING
5. Dress the cut end to make sure all burr is removed and the cut edge is in its
original shape.
6. Measure 20mm from the newly cut edge of the outer flue, place a mark at the
top of the flue approximately 20mm wide & write stop the terminal side of the
line.
7. Mark the inner tube 10mm longer than the outer tube around its
circumference and cut following the mark to ensure its cut square
8. Remove all burrs and place a chamfer on the outer edge to aid assembly.
9. Re-assemble telescopic section.
Setting Telescopic Flue B Pack
Adhere sealing tape
Drill hole
FLUE OUTLET
1. Measure the required flue length (A+44mm).
2. Measure from the outer terminal lip to end of outer flue. Pull apart flue until
desired length is achieved. ENSURE THE STOP MARK IS NOT VISIBLE, IF
IT IS, THE FLUE IS TOO SHORT AND SHOULD NOT BE USED.
3. Check that both flue seams are at the top and the outlet terminal is upper most.
4. 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.
6. Fit internal and external wall seals (see installing flue)
Cutting HORIZONTAL FLUE TERMINAL (600MM LONG) B PACK
1. Measure the required cut flue length (A+44mm). If inside the dimensions
shown in Figure 2 “1 Piece 600mm” proceed.
2. 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.
3. Dress the cut end to make sure all burr are removed and the cut edge is
in its original shape.
4. Mark the inner tube 10mm longer than the outer tube around its
circumference and cut following the mark to ensure its cut square.
5. Remove all burrs and place a light chamfer on the outer edge to aid
assembly.
vogue combination boiler - Installation and Servicing
m
75m
A+
mm
44
m
10m
19
INSTALLATION
17 Installing the Flue
Fitting Flue Through the Wall
1. Measure wall thickness and add 14mm.
2. Measure from the outer terminal lip towards outer flue, place a
small location mark at the dimension acquired at point 1.
3. Add a further 14mm to the dimension, obtain at item 1 and place an
additional small location mark.
4. Fit external black wall seal ensuring the outer lip is in contact with
the lip you have been measuring from (see fig 1)
5. Fit the internal wall seal approximately 65mm before the outer of
the 2 location marks.
6. For an internal fit place flue terminal in the centre of the 5” drilled
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.
7. 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.
8. Pull back the flue until the first of the 2 location marks re level with
the internal face of the wall.
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.
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 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
Fig 1
FLUE OUTLET
Step
20
Location
mark 2
Rubber
Terminal
Wall Seal
Location
mark 1
Ensure lip of wall seal is positioned
over step on plastic nose of flue terminal
(note, seal is cut away for clarity)
isfu9783
Fitting the Turret
1. Ensure the rubber seal is fitted correctly on the appliance manifold and that all flue seals are undamaged.
2. Hold the flue firmly and push the turret on until it has travelled 30mm 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.
3. Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold.
4. Fully engage the clamp location section into the manifold location holes. Rotate down on to turret flange.
5. Secure clamp to appliance using securing screw.
6. Ensure all sample points are accessible and all sample plugs and caps are fitted.
Retaining
screw
Sample points
Clamp Lugs
D
A
Flue Outlet
B
C
A - Duct Assembly
B - Flue Turret
C - Turret Clamp
D - Seal
vogue combination boiler - Installation and Servicing
18condensate drain
49
51
180
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.
b. Plastic with push fit or solvent connections.
c. Internal plastic pipe work a minimum of 19mm ID (typically
22mm OD)
d. External plastic pipe must be a minimum of 30mm ID (typically
32 OD) before it passes through the sleeved wall.
e. All horizontal pipe runs, must fall a minimum of 45mm per metre
away from the Boiler.
f. External & unheated pipe work should be kept to a minimum
and insulated with Class “O” waterproof pipe insulation.
g. All installations must be carried out in accordance to the
relevant connection methods as shown in the “Condensate
installation diagrams” & BS6798:2009
h. Pipe work must be installed so that it does not allow spillage
into the dwelling in the event of a blockage (through freezing)
i. All internal burrs should be removed from the pipe work and any
fittings.
Condensate Pump
Where gravity discharge to an internal termination 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 chill” 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
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.
Unheated Internal Areas
Internal condensate drain pipes run in unheated areas, e.g. lofts
basements and garages, should be treated as external pipe.
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.
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.
Minimum
connection
height up to 3
storeys
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
Min Ø 19mm
Internal pipe
75
Sink/basin/
bath or
shower
≥ 100
≥ 100
≥ 450
75
Min Ø 19mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
Soil & vent stack
Boiler
with 75mm
sealed
condensate
trap
Figure 2 - Connection of a Condensate Drainage Pipe
Downstream of a Sink, Basin, Bath or Shower Water Trap to
Internal Soil Vent Stack
Internal soil & vent stack
Figure 1 - Connection of Condensate Drainage Pipe to
Internal Soil & Vent Stack
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
continued . . . . .
vogue combination boiler - Installation and Servicing
21
INSTALLATION
INSTALLATION
19 Condensate drain - Cont’d.......
Boiler
with 75mm
sealed
condensate
trap
Min Ø 30mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
Water/
weather proof
insulation
Min Ø 19mm
Internal pipe
Min Ø 30mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
combined foul/
rain water drain
External air
break
Air gap
Terminated
and cut at 45º
43mm 90º male/
female bend
68mm Ø PVCU
Strap on fitting
Minimum
connection
height up to 3
storeys
Figure 6 - Connection of Condensate Drainage Pipe
Upstream of a Sink, Basin, Bath or Shower Waste Trap to
External Drain, Gulley or Ranwater Hopper
Visible air break
at plug hole
Min Ø 19mm
Internal pipe
Sink, basin, bath or
shower with integral
overflow and 75mm trap
75
Figure 5 - Connection of a Condensate Drainage Pipe to an
External Rainwater Downpipe (only combined foul/rainwater
drain)
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
≥ 100
Condensate pump
(Install in accordance with manufacturers instructions)
≥ 450
Min Ø 19mm
Internal pipe
Water/
weather proof
insulation
Minimum 30mm
internal pipe
45º pipe
termination
≥ 25 Below grate
75
Min Ø 19mm
Internal pipe
Water/weather
proof insulation
75
Visible air break
Boiler
with 75mm
sealed
condensate
trap
Figure 4 - Connection of condensate Drainage Pipe to
External Soil & Vent Stack
Soil & vent stack
Figure 3 - Connection of a Condensate Pump Typical
Method (see manufacturers detailed instructions)
Figure 7 - Connection of a Condensate Drainage Pipe to an
External Purpose Made Soak Away.
Boiler
with 75mm
sealed
condensate
trap
Min Ø 30mm
Internal pipe
Max 3m external
pipework
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
≥ 300
≥ 25
Min Ø 19mm
Internal pipe
Water/Weather
proof insulation
75
INSTALLATION
INSTALLATION
≥ 500
Limestone
chippings
2 rows of three Ø12mm 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 Arrangement.
nm8736
Flue Terminal
UIN 203132
Flue Seal Collar - Flat Roof
UIN 152259
Vertical connector
UIN 208175
FLUE OUTLET
21 Roof Flue Kit Contents / Options
90o elbow
UIN 203130
45o elbow
UIN 203131
Flue
duct
support
Flue Seal Collar - Universal
UIN 152258
Flue
duct
support
vogue combination boiler - Installation and Servicing
3G9626a
Roof Flue Extension Duct
UIN 203129
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.
rf8392
Minimum dimensions are shown below
m
0m
30
in
m
300mm
min
rf8393-1
625mm
Fixed
300mm
min
690mm
Fixed
A
A
B
07
98
24
A
RF
FLUE OUTLET
rf8394-1
Flat roof - with structure
A = 600mm
B = 2000mm
The flue terminal shall not penetrate the shaded area of the roof
Terminal Position
Minimum Dimension
Directly below an opening,
air brick, windows, etc.
300 mm
Below plastic / painted gutters
300 mm
Note.
Painted surface
300 mm
Below eaves or balcony
500 mm
The equivalent flue length resistance of the
elbow kits are:
Below velux windows
2000mm
90o elbow kit = 1m
600mm
45o elbow kit = 0.6m
Above or side of velux windows
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 height
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.
MAX LENGTH:
10m
o
1. Position the roof flashing plate (supplied separately) over the
hole cut in the roof and insert flue terminal from the roof end.
max 41
min 16
o
Ensure the cut pipe ends are free from any burrs.
1
BOILER
2. Fit the vertical connector (supplied separately) in accordance with
the instructions provided with the vertical connector kit.
Flue Terminal
aSSEMBLY a
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 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).
Flat roof tile
weather collar
Pitched roof tile
weather collar
5. “Push” fit extension duct (if required (supplied separately)) into
vertical connector.
5
Extension
Duct
4
FLUE OUTLET
nm8740
Vertical
connector
3G9557b
2
6. 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.
6
'X'
Note. Check the position of the inner flue duct relative to the outer duct
on the assembled extension duct(s) and ensure the terminal flue duct is
cut longer than the air duct to ensure engagement in the final flue duct
seal.
7. Finally ensure the roof flashing plate is correctly sealed to the roof.
vogue combination boiler - Installation and Servicing
25
INSTALLATION
INSTALLATION
24connections & 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.
Note. The domestic hot water flow rate is
automatically regulated to a maximum:
26 = 10.7 l/m
(2.2 gpm)
32 = 13.1
l/m
(2.8 gpm)
40 = 16.4
l/m
(3.2 gpm)
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
FILLING
1. 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.
Important - when filling:
When filling, there may be a slight water leak from the air vent
therefore electrical connections should be protected.
2. Connect the CH rtn. valve (black handle) and copper tail.
3. 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.
2. Fit the DHW outlet pipe tail to DHW outlet connection,
ensuring the seal provided is correctly located.
3. Fit the filling loop provided between the DHW inlet valve an
the CH return valve
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.
4. Open handle  on the filling loop, then slowly open handle
 until pressure gauge reads between 1 to 1.5 bar.
5. Once pressure gauge dial reads between 1 - 1.5 bar turn the
filling loop isolation valves back to the closed position.
6. Disconnect filling loop at the LH side, ensuring top hat
washer is retained and screw on blanking cap.
7. 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.
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.
Handle 
(Shown in closed position)
For additional gas supply info refer to “Gas Supply” on page 8.
The pressure relief valve connection, located at the bottom righthand 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.
Handle 
CH Flow
26
Gas
Supply
Black
Handle
Note that all isolation
handles are shown in
the open postion.
DHW
Inlet
CH
Return
Yellow
Handle
Blue
Handle
Pressure Relief Valve
Drain Connection
15mm elbow
or fittings
(not supplied)
(Shown in closed position)
DHW
Outlet
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.
3G9705
FLUE OUTLET
Pressure Relief valve Drain
Pressure Relief Valve
Drain Pipe
Filling
Loop
Black
Handle
Black
Handle
vogue combination boiler - Installation and Servicing
INSTALLATION
INSTALLATION
25electrical connections
Wiring should be 3 core PVC insulated cable, not less than
0.75mm2 (24 x 0.2mm), and to BS 6500 Table 16. For IE
reference should be made to the current ETCI rules for
electrical installations.
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.
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.
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
supply and NOT switched by thermostats/programmers.
For installers wishing to change this cable proceed as
follows.
4. Remove the Live, Neutral and Earth wires from the terminal block.
5. Loosen the cable clamp and withdraw the mains cable.
6. Route the replacement cable back through the cable clamp and
grommet and re-tighten to provide cord anchorage.
Replacement wiring should comply with the notes in
Frame 28 & 29.
7. 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
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).
6
4
L
N
E
continued . . . .
vogue combination boiler - Installation and Servicing
27
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 Frame 9).
3. Swing the control box down into the
servicing position (refer to Frame 46).
4. 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.
7. Re-assemble in reverse order.
29 Internal Wiring
Room Stat or
Programmable
Room Stat
(A) INTERNAL TIMER WITH ROOM STAT, OR
PROGRAMMABLERoom
ROOM Stat
STAT
(A) Internal Timer with Room Stat or Programmable
1. Remove
the link wire
between the Room Stat/Timer
1. Remove the link wire between the Room
Stat/Timer
terminals
terminals
2. Connect the Room Stat or Programmable Room Stat across the terminals as
2. Connect the Room Stat or Programmable Room Stat across
shown in the Diagram.
the terminals as shown in the Diagram.
ROOM STAT
/TIMER
OPTIONAL
HEATING
ZONE 2
OPTIONAL
FROST
STAT
MAINS IN
L
N
3. If the Room Stat has a neutral connection
then
connect
the fused
3. If the
Room
Stat has a this
neutraltoconnection
then spur
connect this
neutral.
to the fused spur neutral.
continued. . . . . .
28
vogue combination boiler - Installation and Servicing
INSTALLATION
(B) EXTERNAL TIMER AND ROOM STAT
Room
Stat
(B)External Timer and Room Stat
1. Remove the link wire between the Room
Timer
1. Remove the link wire between the Room Stat/Timer
terminals
Stat/Timer
terminals
Connect
the Roomas
Statshown
and Timerin
across
2. Connect the Room Stat and Timer across 2.
the
terminals
thethe terminals as
shown in the Diagram.
Diagram.
3. If the Room Stat has a neutral
neutral.
INSTALLATION
30System Control Wiring - cont’d
ROOM STAT
/TIMER
3. If the Room Stat has a neutral connection then connect this
the fused
spur neutral.
connection tothen
connect
this to the fused spur
OPTIONAL
HEATING
ZONE 2
OPTIONAL
FROST
STAT
MAINS IN
L
N
(C)Use of General Live for System Controls(C) USE OF GENERAL LIVE FOR SYSTEM CONTROLS
Room Stat
1. Remove the link wire between the Room Stat/Timer
1. Remove the link wire between the Room Stat/Timer
terminals
terminals
2. The live
the Room
Stat must be
isolated by the same
2. The live feed to the Room Stat must be isolated
by feed
thetosame
isolator
that
isolator that supplies the boiler.
supplies the boiler.
ROOM STAT
/TIMER
(D)Frost Thermostat
OPTIONAL OPTIONAL
HEATING
FROST
STAT
ZONE 2
(D) FROST THERMOSTAT
parts
of the
system arecontrols
vulnerable are
to freezing
If parts of the system are vulnerable to freezingIfcontrols
or the
system
likelyor the system
are likely to be left off during cold weather then a frost
to be left off during cold weather then a frost stat
should
be fitted
in conjunction
stat should
be fitted
in conjunction
with a pipe thermostat.
Position the
in theisarea
that is vulnerable to
with a pipe thermostat. Position the frost thermostat
infrost
thethermostat
area that
vulnerable
freezing and then connect it as shown in the diagram. If the
to freezing and then connect it as shown in theboiler
diagram.
If
the
boiler
is
installed
is installed in a garage it may be necessary to fit a pipe
thermostat, preferably
on the return
pipe work.
in a garage it may be necessary to fit a pipe thermostat,
preferably
on the
return
L
N
Frost
Stat
ROOM STAT
/TIMER
OPTIONAL OPTIONAL
HEATING
FROST
ZONE 2
STAT
MAINS IN
L
N
pipe work.
(E)Weather Compensation
(E) WEATHER COMPENSATION
Outside
Sensor
Timer
1. Connect the Outside Sensor across the terminals as shown in the
1. Connect the Outside Sensor across the terminals
Diagram.
as shown in the Diagram.
OR
THE
BOILER
DO NOT CONNECT 230V TO THESE TERMINALS
DO NOT CONNECT
230V
TO THESE
ELECTRONICS WILL BE DAMAGED TERMINALS OR THE BOILER ELECTRONICS
WILL BE DAMAGED
ROOM STAT
/TIMER
OPTIONAL
HEATING
ZONE 2
OPTIONAL
FROST
STAT
MAINS IN
L
N
OUTSIDE
SENSOR
OPEN
THERM
(F)OPENTHERM PROGRAMMABLE ROOM STAT
OpenTherm
Programmable
Room Stat
1. Remove the link wire between the Room Stat/Timer terminals
2. Connect the OpenTherm Programmable Room Stat across the
terminals as shown in the Diagram.
3. Unclip the 3 way connector from the back of the internal timer plastics
and connect to the 3 way connector adjacent to the plastics.
ROOM STAT
/TIMER
OPTIONAL OPTIONAL
FROST
HEATING
STAT
ZONE 2
MAINS IN
L
N
OUTSIDE
SENSOR
OPEN
THERM
DO NOT CONNECT 230V TO THESE TERMINALS OR THE BOILER
ELECTRONICS WILL BE DAMAGED
(G)Heating Zone 2
(G) HEATING ZONE 2
It is possible to set 2 different flow temperature targets for 2
different heating
To do this Programmable Room
It is possible to set 2 different flow temperature targets
for 2zones.
different
Thermostats should be connected as shown in the Diagram.
heating zones. To do this Programmable Room The
Thermostats
should
Flow Temperature
target forbe
zone 1 is set using the CH
temperature Knob, while
the Flow
connected as shown in the Diagram. The Flow Temperature
target
for Temperature target for Zone
2 is set using the boiler menu (see Frame XX). Note that if
zone 1 is set using the CH temperature Knob, while
Flow
Temperature
there isthe
a demand
from
both zones at the same time then the
higher
target temperature
will bethat
used.
target for Zone 2 is set using the boiler menu (see
Frame
41). Note
if there is a demand from both zones at the same time then the higher
target temperature will be used.
vogue combination boiler - Installation and Servicing
Programmable Programmable
Room Stat 1 Room Stat 2
ROOM STAT
/TIMER
OPTIONAL
HEATING
ZONE 2
OPTIONAL
FROST
STAT
MAINS IN
L
N
29
30
y
g
Fused
at 4AT
or
bk
Internal Timer
Mains Voltage
Connection
2
bk
X1A
1
r
r
1
br
r
r
2
b
X1B
Timer
Link Plug
br
3
y/g
b
1
br
2
X1C
b
y/g
Pump
3
1
br
3
b
4
y/g
1
b
Chassis
Earth
X1D
2
bk
Divertor
Valve
2
3
y/g
X2A
bk
4
Spark
Generator
Gas Valve
1
br
2
b
bk
X2B
3
y/g
y/g
4
bk
5
br
1
3
1
2
3
b bk
PCB
X3
2
Flame
Sensor
Electrode
Spark
Electrode
p
gy
bk
bk b
bk
r
y
r
p
b
y/g
br
Fan
p
bk
y
X13
X7
X5
X6
X8
bk
b
r
Water
Flow
Turbine
KEY
b - blue
bk - black
br - brown
r
- red
p - pink
y - yellow
w - white
y/g - yellow/green
g - grey
or - orange
v - violet
1 2 3 1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11
y
bk
bk
bk
Flow
Thermistor
Return
Thermistor
Thermal
Fuse
Service
Connector
Internal
Timer
wr
Low
Voltage
Connection
External
Opentherm
connection
or
bk
r
Water
Pressure
Sensor
INSTALLATION
INSTALLATION
31wiring diagram
vogue combination boiler - Installation and Servicing
32 Commissioning and Testing
A. Electrical Installation
B.Gas Installation
1. Checks to ensure electrical safety should be carried out by a
competent person.
1. The whole of the gas installation, including the meter,
should be inspected and tested for tightness and purged in
accordance with the recommendations of BS. 6891.
In IE refer to IS.813:2002.
2. Always carry out the preliminary electrical system checks,
i.e. earth continuity, polarity, resistance to earth and short
circuit, using a suitable test meter.
3. After wiring the boiler, all grommets in the bottom panel
MUST be in place to ensure that boiler case sealing is
maintained.
2. Purge air from the gas installation by the approved methods
only.
WARNING. Whilst effecting the required gas tightness test and purging air 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. No measurement of the combustion is
necessary. 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
CH Flow
inlet pressure
Outlet rate by
Set up the boiler to operate DHW
at maximum
referring to Frame 39, Service
Mode Maximum Rate. this mode
Gas Supply
will operate the boiler at maximum
heat output but in central heating
mode. to ensure the boiler is
operating at maximum this must
be carred out when the system is
Black
cool.
Handle
With the boiler operating in the Yellow
maximum rate condition check Handle
that the operational (working)
gas pressure at the inlet gas
Gas Pressure
pressure test point complies with
Test Point
the requirements - refer to “Gas
Supply” on page 8.
DHW Inlet
CH Return
Safety
Drain
Valve
Blue
Handle
Ensure that this inlet pressure can be obtained with all
other gas appliances in the property working.
Black
Handle
3G9927
ATTENTION !
IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE
BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED
AND LEFT WITH THE APPLIANCE
vogue combination boiler - Installation and Servicing
31
INSTALLATION
INSTALLATION
INSTALLATION
INSTALLATION
33initial lighting
A
Legend
J
G
L
A. Boiler Status
B. Exit Button
Press Enter
for MENU
K
C. Down Button
D. Up Button
ON
E. Enter Button
ON
60°C
2
Priority
F. Reset Button
1
0
G. CH Temperature Control
3
4
H. DHW Temperature Control and Off
Switch
J. Burner On indication
K. Pressure Gauge
L. Boiler in Full Condensing Mode
M. CH Flow Isolating Valve
B
N. Gas Inlet Pressure Test Point
C
F
D
E
H
P. Gas Service Cock
Q. DHW Inlet Valve
P
R. CH Return Isolating Valve
S. DHW Outlet
Q
R
M
S
N
PREPARATION FOR IGNITION
Initial IGNITION
1. Check that the electrical supply is OFF.
1. Switch the electricity supply ON and check all internal and
external controls are calling for heat.
2. Check that the system has been filled and that
the boiler is not air locked.
3. Ensure that the automatic air vent cap is open.
Refer to Frame 70.
4. 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.
5. Refit the boiler front panel. Refer to Frame 45.
6. Check that the drain cock is closed and that the
CH (M & R) and DHW (Q) isolating valves are
OPEN.
7. Check that the DHW Temperature Control Knob
(H) is turned fully anti-clockwise into the off
position.
8. Check that the gas service cock (P) is OPEN.
9. Slacken the screw in the inlet pressure test
point (N) and connect a gas pressure gauge via
a flexible tube.
2. 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.
3. 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.
32
vogue combination boiler - Installation and Servicing
INSTALLATION
Central Heating
Domestic Hot Water
When the burner is established the following screen will be
displayed.
Fully open a DHW tap. The boiler will continue to run and
the following screen will be displayed.
Press Enter
for MENU
ON
60°C
NO
DEMAND
INSTALLATION
34 Check CH & DHW Operation
Press Enter
for MENU
NO
DEMAND
ON
60°C
Timer or Room Stat Off
The temperature shown will be the actual Flow
Temperature.
The temperature shown will be the actual DHW
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.
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”.
Press Enter
for MENU
NO
DEMAND
NO
DEMAND
Timer or Room Stat Off
Check the correct operation of all the system controls by
operating each control separately and check that the main
burner responds.
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.
Press Enter
for MENU
NO
DEMAND
NO
DEMAND
Timer or Room Stat Off
IMPORTANT
The gas input to the burner is regulated by the gas valve
according to the air flow produced by the fan. It is 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.
vogue combination boiler - Installation and Servicing
33
INSTALLATION
INSTALLATION
INSTALLATION
35 Display Functions In Normal Operation
Press Enter
for MENU
Boiler Switched Off:
DHW Knob in Off Position
OFF
OFF
Boiler Frost Protection:
occurs if Flow
Temperature less than
5°C
Press Enter
for MENU
4°C
Boiler Frost Protection
Turn
dial for Heating or Hot Water
Press Enter
for MENU
DHW Demand Off:
CH Knob in Off Position
OFF
Turn
NO
DEMAND
dial for Heating
Press Enter
for MENU
DHW Demand On:
CH Knob in Off Position
OFF
Turn
ON
60°C
dial for Heating
Switch Off Temperature: 19°C
System Frost Protection:
occurs if
Outside Sensor connected
& Outside Temp’ < 5°C &
System Frost Protection
selected in Menu
Service Due:
shown after 12 months
operation, see Frame 33
to reset
Press Enter
for MENU
4°C
System Frost Protection
Go to MENU to disable
Press Enter
for MENU
OFF
Turn
ON
60°C
dial for Heating
Service Due
Phone
01482 498660
Press Enter
for MENU
DHW Demand Off,
CH Demand Off
NO
DEMAND
NO
DEMAND
Timer or Room Stat Off
Press Enter
for MENU
DHW Demand On,
CH Demand Off
NO
DEMAND
ON
60°C
Timer or Room Stat Off
Press Enter
for MENU
DHW Demand On,
CH Demand On
DEMAND
ON
ON
60°C
Priority
Press Enter
for MENU
DHW Demand Off,
CH Demand On
ON
60°C
NO
DEMAND
Press Enter
for MENU
Pre-heat Demand On
OFF
Turn
34
Pre-Heat
50°C
dial for Heating
vogue combination boiler - Installation and Servicing
INSTALLATION
INSTALLATION
To change the DHW
Temperature Set Point
Rotate the DHW
Temperature Control
Knob, the screen on the
right will be shown
To change the Flow
Temperature Set Point:
Rotate the CH
Temperature Control
Knob, the screen on the
right will be shown
To switch CH function
ON:
Rotate the CH
Temperature Control
Knob clockwise, the
screen on the right will be
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 protection still
active)
To switch the boiler On:
Rotate the DHW
Temperature Knob
clockwise, the screen on
the right will be shown
INSTALLATION
36changing settings
60°C
ON
Select Hot Water Temperature
70°C
ON
Select Radiator Temperature
70°C
ON
Select Radiator Temperature
OFF
Central Heating Switched Off
OFF
Boiler Switched Off
60°C
ON
Select Hot Water Temperature
To change the Room
Temperature Set Point
(only if Outside Sensor
connected): rotate the CH
Temperature Knob, the
screen on the right will be
shown
20°C
ON
Select Room Temperature
vogue combination boiler - Installation and Servicing
35
INSTALLATION
INSTALLATION
INSTALLATION
37 Menu Operation
Vent System
Pre-heat
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.
If pre-heat is switched on then 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
Press ENTER and the following screen will be displayed
MENU
MENU
Vent System
Vent System
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Switch Pre-Heat
Enter
Exit
Press “+” and the following screen will be displayed.
Maximum Flow Temperature
Outside Sensor Slope
Enter
Exit
Press ENTER and a screen similar to the following will be
displayed.
MENU
Switch Pre-Heat
Vent System
Switch Pre-heat On/Off
Maximum Flow Temperature
Enter
Exit
ON
OFF press
SAVE press
Enter
Exit
Press ENTER and the following screen will be displayed.
To switch Pre-heat off press “-“
Vent System
To switch Pre-heat on press “+”
Pump will be pulsed
OFF
To return to normal operation press EXIT twice.
On 60s, Off 10s
Diverter Valve
alternates CH/DHW
Enter
Exit
Press ENTER and the following screen will be displayed.
Vent System
Pump pulsed
ON
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.
On 60s, Off 10s
Diverter Valve
alternates CH/DHW
Exit
MENU
Vent System
The feature will end automatically after 5 minutes, to end
manually press EXIT.
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Enter
Exit
Press “-“ until the following screen is displayed.
MENU
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Fault Help
Enter
Exit
Press ENTER and a screen similar to following will be
displayed.
70°C
Enter
Set Maximum Flow Temperature
Exit
Press “+” and “-“ until the desired temperature is displayed and
then ENTER followed by EXIT to return to normal operation.
36
vogue combination boiler - Installation and Servicing
INSTALLATION
Outside Sensor Slope
Fault History
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
To view the Fault History of the boiler press ENTER and the
following screen will be displayed
INSTALLATION
38 Menu Operation
MENU
Vent System
MENU
Switch Pre-Heat
Maximum Flow Temperature
Vent System
Outside Sensor Slope
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Enter
Exit
Enter
Exit
Press “-” until the following screen is displayed.
Press “-“ until the following screen is displayed.
MENU
Fault Help
MENU
Fault History
State of Inputs
Maximum Flow Temperature
State of Outputs
Outside Sensor Slope
Fault Help
Fault History
Enter
Exit
Enter
Exit
Press ENTER and the following screen will be displayed.
Outside Sensor Slope
Press ENTER and a screen similar to the following will be displayed.
Fault History
Water Pressure: 17 Minutes
Ago
Ignition Lockout: 3 Days Ago
80°C
Overheat Lockout: 2 Months
Ago
No Water Flow:
1 Year Ago
Flow
Exit
Enter
30°C
-15°C Out’ 20°C
1.6
Exit
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
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
Vent System
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Switch Pre-Heat
Enter
Exit
Press “-” until the following screen is displayed.
MENU
Maximum Flow Temperature
Outside Sensor Slope
MENU
Fault History
Fault Help
Fault History
State of Inputs
Enter
Exit
Press ENTER and the following screen will be displayed.
Overheat Lockout
State of Outputs
Service Mode Minimum Rate
Enter
Exit
Press ENTER and a screen similar to following will be displayed.
State of Inputs
Fill System to 1.0 Bar
Water Pressure:
1.3 Bar
Vent System, Refill System
CH Switched Live:
Check Pump Spins Freely
Hot Water Flow Rate:
5.0 l/min
Check 240V to Pump
Exit
Press “-“ until the following screen is displayed.
Outside Sensor Slope
State of Inputs
Enter
Exit
Press “+” and “-“ to scroll through the information.
Press EXIT twice to return to normal operation.
vogue combination boiler - Installation and Servicing
Hot Water
Temperature:
On
60°C
Exit
Press “+” and “-“ to view the full list.
Press EXIT twice to return to normal operation.
37
INSTALLATION
INSTALLATION
INSTALLATION
39 Menu Operation
State of Outputs
Service Mode Maximum Rate
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.
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
80oC. To activate the feature press ENTER and the following
screen will be displayed.
MENU
Vent System
MENU
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Enter
Vent System
Exit
Switch Pre-Heat
Maximum Flow Temperature
Press “-” until the following screen is displayed.
MENU
Outside Sensor Slope
Enter
Exit
Press “-“ until the following screen is displayed.
State of Inputs
MENU
State of Outputs
Service Mode Minimum Rate
Enter
Service Mode Maximum Rate
Exit
Service Mode Minimum Rate
Service Mode Maximum Rate
Show Efficiency Level
Press ENTER and a screen similar to the following will be
displayed.
System Frost Protection
Enter
Exit
Press ENTER and the following screen will be displayed.
State of Outputs
Service Mode
Diverter Valve:
CH
Pump:
On @
57%
Fan (Target 3000): 3000rpm
Spark Generator:
Off
Maximum Rate
Fan Target 5000rpm
Exit
Fan Actual 4950rpm
Exit
Press “+” and “-“ to view the full list.
Press EXIT twice to return to normal operation.
Press EXIT twice to return to normal operation.
Service Mode Minimum Rate
Efficiency Level
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.
To view the efficiency level of the boiler press ENTER and the
following screen will be displayed.
MENU
Vent System
MENU
Switch Pre-Heat
Maximum Flow Temperature
Vent System
Outside Sensor Slope
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Exit
Press “-“ until the following screen is displayed.
MENU
Service Mode Maximum Rate
MENU
Show Efficiency Level
System Frost Protection
State of Outputs
Reset Service Time
Service Mode Minimum Rate
Show Efficiency Level
Exit
Enter
Press “-” until the following screen is displayed.
Service Mode Maximum Rate
Enter
Enter
Exit
Enter
Exit
Press ENTER and a screen similar to following will be
displayed.
Press ENTER and the following screen will be displayed.
Efficiency Level
Service Mode
1346
Minimum Rate
Fan Target 2000rpm
Fan Actual 1950rpm
29260
Hours
Hours
High
Efficiency
Super
Efficiency
Exit
Exit
Press EXIT twice to return to normal operation.
Press EXIT twice to return to normal operation.
38
vogue combination boiler - Installation and Servicing
INSTALLATION
INSTALLATION
System Frost Protection
Plot Graphs
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 5oC.
To plot graphs of Water Pressure, Switched 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.
INSTALLATION
40 Menu Operation
MENU
MENU
Vent System
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Vent System
Enter
Exit
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Enter
Exit
Press “-” until the following screen is displayed.
Press “-“ until the following screen is displayed.
MENU
MENU
Show Efficiency Level
System Frost Protection
Reset Service Time
Plot Graphs
Reset Service Time
Enter
Plot Graphs
Exit
Bus Address
Maximum Flow Temperature
Press ENTER and a screen similar to the following will be
displayed.
System Frost Protection
Enter
Exit
Press ENTER and the following screen will be displayed.
Plot Graphs: Select
Data
ON press
Water Pressure
CH Switched Live
SAVE press
OFF
Pump may run during night
Enter
Exit
Hot Water Flow Rate
Enter
Exit
Hot Water
Temperature
Press “+” to activate or “-“ to de-activate.
Press EXIT twice to return to normal operation.
Press “+” & “-“ to highlight the desired input and then ENTER to
select. Press EXIT 3 times to return to normal operation.
Reset Service Time
Bus Address
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.
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
MENU
Vent System
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Vent System
Enter
Exit
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Enter
Exit
Press “-” until the following screen is displayed.
Press “-“ until the following screen is displayed.
MENU
MENU
System Frost Protection
Reset Service Time
Plot Graphs
Plot Graphs
Enter
Bus Address
Exit
Bus Address
Maximum Flow Temperature
Installer’s Details
Enter
Exit
Press ENTER and the following screen will be displayed.
Press ENTER and a screen similar to following will be displayed.
Reset Service Time
Bus Address
279
days
Service
due
Reset press
Enter
Exit
02
Only changed for
Multiple Boiler Installations
Enter
Exit
Press ENTER to reset.
Press EXIT to return to normal operation.
vogue combination boiler - Installation and Servicing
Press “+” or “-“ to change the address.
Press ENTER and then EXIT to return to normal operation.
39
INSTALLATION
INSTALLATION
INSTALLATION
41 Menu Operation
Installer’s Details
Set Zone 2 Flow Temperature
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.
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
MENU
Vent System
Vent System
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Switch Pre-Heat
Enter
Exit
Press “-” until the following screen is displayed.
MENU
Maximum Flow Temperature
Enter
Outside Sensor Slope
Exit
Press “-“ until the following screen is displayed.
MENU
Maximum Flow Temperature
Test Condensate Anti-Freeze
Installer’s Details
Set Zone 2 Flow Temperature
Test Condensate Anti-Freeze
Enter
Enter
Set Zone 2 Flow Temperature
Exit
Exit
Press ENTER and a screen similar to the following will be
displayed.
Press ENTER and the following screen will be displayed.
70°C
Installer’s Details
0
Enter
01482 498704
No. shown when service due
Enter
Exit
Set Zone 2 Flow Temperature
Exit
Press “+” and “-“ to change the number and ENTER to accept.
Press EXIT twice to return to normal operation.
Press “+” & “-“ to change the temperature to the require setting
and then ENTER. Press EXIT to return to normal operation.
Test Condensate Anti-Freeze
Pump Modulation
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.
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
MENU
Vent System
Switch Pre-Heat
Maximum Flow Temperature
Outside Sensor Slope
Vent System
Enter
Exit
Switch Pre-Heat
Maximum Flow Temperature
Enter
Outside Sensor Slope
Exit
Press “-” until the following screen is displayed.
Press “-” until the following screen is displayed.
MENU
MENU
Maximum Flow Temperature
Test Condensate Anti-Freeze
Set Zone 2 Flow Temperature
Enter
Set Zone 2 Flow Temperature
Pump Modulation
Exit
Enter
Exit
Press ENTER and the following screen will be displayed.
Press ENTER and the following screen will be displayed.
Condensate Anti-Freeze
Pump Modulation
Max
ON for 5mins press
OFF
Only active if optional kit purchased
Enter
Exit
Press ENTER to activate.
Press EXIT twice to return to normal operation.
40
For minimum press
to save press
Enter
to save press
Exit
Press “-” to change the setting and then ENTER. Press Exit to
return to normal operation.
vogue combination boiler - Installation and Servicing
INSTALLATION
Water circulation system
8. Finally, set the controls to the User’s requirements.
1. With the system COLD, check that the initial pressure
is correct to the system design requirements.
INSTALLATION
42 general checks
Notes.
1. If the pump has not operated in the last 24 hours it will run
briefly to prevent seizure
For pre-pressurised systems, this should be 1.0 bar.
2. With the system HOT, examine all water connections
for soundness. The system pressure will increase
with temperature rise but should not exceed 2.5 bar.
2. If the diverter valve has not operated in the last 24 hours
it will be operated briefly to prevent seizure. These two
operations will not occur at the same time.
3. With the system still hot, turn off the gas, water and
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).
4. Refill and vent the system, add inhibitor (see Frame
24), clear all air locks and again check for water
soundness.
5. Reset the system initial pressure to the design
requirement.
6. Balance the system. Refer to Frame 4.
7. Check the condensate drain for leaks and check that
it is discharging correctly.
vogue combination boiler - Installation and Servicing
Water temperatures
Temperatures can be selected using the CH and DHW thermostats.
Knob Setting
CH Flow Temp
o
C (oF)
DHW Outlet Temp
o
C (oF)
Max
80 (176)
65 (149)
Min
30 (86)
40 (104)
41
INSTALLATION
INSTALLATION
43HANDING OVER
After completing the installation and commissioning of the system the installer should hand over to the householder by
the following actions:
1. 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.
8. Loss of system water pressure
2. Explain and demonstrate the lighting and shutting down
procedures.
3. 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.
9. Explain boiler reset procedure (refer to Frame 32).
10.After installation and commissioning please complete
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.
Commissioning Checklist before
the
handover to the customer. For IE, its is necessary to complete
a “Declaration of Conformity” to indicate compliance to I.S.
813:2002.
4. 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 temperature can be controlled by
the user via the draw-off tap: the lower the rate the
higher the temperature, and vice versa”.
5. Explain the function of the boiler fault mode.
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.
Important
11.A comprehensive 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.
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).
6. Explain and demonstrate the function of time and
temperature controls, radiator valves etc., for the
economic use of the system.
7. If a timer is fitted draw attention to the timer Users
Instructions and hand them to the householder.
42
vogue combination boiler - Installation and Servicing
SERVICING
44 servicing schedule
For the very latest copy of literature for specification & 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 the boiler and carry out a pre-service check, noting any
operational faults.
Please Note: During routine servicing, and after any
maintenance or change of part of the combustion
circuit, the following must be checked:
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 integrity of the flue system and the flue seals,
- The integrity of the boiler combustion circuit and
the relevant seals
- 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
components the boiler front panel must be removed. Refer to
Frame 45.
- The combustion performance.
1. Clean the main burner. Refer to Frame 49.
Please Note:
BS 6798:2009 Specification for
installation and maintenance of gas-fired boilers of
rated input not exceeding 70kW net advises that:
2. Clean the heat exchanger & condensate trap/siphon. Refer to
Frames 50 & 51.
3. Check the main injector for blockage or damage. Refer to Frame
48.
4. Check that the flue terminal is unobstructed and that the flue
system is sealed correctly.
ALSO IF THE DHW FLOW RATE IS IN QUESTION :5. Check the DHW filter for blockage. Refer to Frame 76.
The cleaning procedures are covered more fully in Frames 45-51 and
must be carried out in sequence.
Important.
6. After completing the servicing or exchange of components always
test for gas tightness.
7. When work is complete the front panel MUST be correctly refitted,
ensuring that a good seal is made.
servicing
2. Check the flue terminal (and terminal guard if fitted) is undamaged
and clear of any obstruction.
Competence to carry out the check
of combustion performance
- The person carrying out a combustion
measurement should have been assessed as
competent in the use of a flue gas analyser and
the interpretation of the results.
- The flue gas analyser used should be one
meeting the requirements of BS7927 or BSEN50379-3 and be calibrated in accordance with
the analyser manufacturers requirements, and
- Competence can be demonstrated by satisfactory
completion of the CPA1 ACS assessment, which
covers the use of electronic portable combustion
gas analysers in accordance with BS7967, Parts
1 to 4.
Do not operate the boiler if the front panel is not
fitted.
8. If, for any reason, the condensate trap/siphon has been removed
ensure the trap is refilled with water before
reassembling.
9. Check the gas consumption.
10.Check combustion by connecting the flue gas analyser to the flue
gas sampling point as shown in the diagram and measure CO &
CO2.
Flue
Sampling Point
(ensure cap is
secured after
sampling)
If the CO/CO2 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 pressure (and gas rate) have been
verified, then contact Ideal.
11.Complete the service section in the Benchmark Commissioning
Checklist.
vogue combination boiler - Installation and Servicing
43
SERVICING
SERVICING
45boiler front panel removal / Replacement
REMOVAL
1,4
1. Loosen the 2 screws retaining the front panel at
the bottom.
2. Release catches at rear of door by pulling
downwards.
3. Pull the underside front panel forward then lift
upwards to remove.
2
REPLACEMENT
3. Engage the top of the front panel on the locating
lugs and push the panel back into position
engaging the securing screws
3
Servicing
4 Re-tighten the securing screws.
46 Lowering the Controls panel
1. Once the front panel has been removed
the controls panel can be hinged down
to access the wiring and electronics or
the internal components of the boiler.
1
Position 1
2. To lower the panel further (position 2)
squeeze the 2 clips inward and hinge
the panel into a lower position.
3. To gain access to the mains wiring
connection squeeze the 2 lugs together
and remove the cover.
2
Position 2
Clip
3
44
vogue combination boiler - Installation and Servicing
SERVICING
SERVICING
47 Fan and Venturi Assembly removal and cleaning
5
1. Refer to Frame 45 & 46.
2
2. Remove the ignition, detection and earth leads.
3. Remove the 2 clips securing the gas inlet pipe
and remove the pipe.
4. Remove the fan leads.
5. Remove the 4 securing nuts retaining the burner/
fan assembly.
6. Remove the assembly from the heat exchanger.
5
3
7. To remove the venturi release the 2 securing
screws to gain access for cleaning.
8. 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
4
3
servicing
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 c40 model only)
10.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.
7
Mounting Spacer
Fitted only to c40
9
Noise Damper
Fitted only to c40
& c32 models
48 Removal of Injector
1. Refer to Frames 45 & 46.
4
2. Refer to Frame 53.
3. Remove the 2 clips securing the gas inlet pipe and
remove the pipe (as point 3 above).
4. Carefully ease the injector out of the gas valve.
5. Examine or clean as necessary
6. Re-fit in reverse order ensuring the sealing o ring is in
good condition or replace if necessary.
7. Refit the gas pipe ensuring the seals are in good
condition and correctly located & secure with clips.
vogue combination boiler - Installation and Servicing
45
SERVICING
49 Burner Removal and Cleaning
7
1. Remove Fan and Venturi Assembly, Refer to Frame 46.
2. Remove the ignition, detection and earth leads.
3. Remove the 2 clips securing the gas inlet pipe and remove the
pipe.
4. Remove the fan leads.
5. Remove the 4 securing nuts from the heat exchanger.
6. Remove the assembly from the heat exchanger.
7. 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
Servicing
8b.Remove the silicon seal from around the burner door location
groove.
9. Re-new the seal and replace in reverse order.
8
50 Cleaning the Condensate Trap / Siphon
1. Remove the rubber condensate pipe from the
top of the trap.
2. Rotate the trap clockwise to disengage the trap
and lift clear of the outlet connection.
1
3. Flush out any debris under running water
4. Refit in reverse order making sure the trap is
engaged with the outlet connection.
5. Fill the trap with water before operating the
boiler.
46
vogue combination boiler - Installation and Servicing
SERVICING
51 Cleaning the Heat Exchanger
1. 1.Remove Fan and Venturi Assembly, Refer to
Frame 47.
2. 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.
2
52RE-assembly
1. Reassemble the boiler in the following order:
servicing
2. 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.
3. Refit the fan to the burner assembly. Refer to Frame 47.
4. Refit the venturi to the fan and burner assembly. Refer to Frame
57.
5. Refit the burner/fan/venturi assembly into the heat exchanger
and secure. Refer to Frame 51.
6. Refit the gas pipe and secure with the 2 clips. Refer to Frame
47.
7. Reconnect the ignition/detection/earth/fan leads
8. Swing the control panel back into its working position. Refer to
Frame 46.
9. Refit the front panel ensuring that a good seal is made. Refer to
Frame 45.
10.Turn on the gas supply at the gas service cock. Refer to Frame
33.
11.Reconnect the electrical supply.
12.Check the operation of the boiler.
vogue combination boiler - Installation and Servicing
47
SERVICING
53 Replacement of Components
IMPORTANT. when work is complete, the front
panel must be correctly refitted - ensuring that a
good seal is made.
When replacing ANY component
1. Isolate the electrical supply
THE BOILER MUST NOT BE OPERATED
WITHOUT THE FRONT PANEL FITTED.
2. Isolate the water connections
3. Turn off the gas supply
4. Remove the front panel
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
3
Servicing
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Remove the ignition, detection and earth leads.
4. Remove the 2 clips securing the gas inlet pipe and
remove the pipe.
6
5. Remove the fan leads.
6. Remove the 4 securing nuts retaining the burner/fan
assembly.
6
4
7. 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.
5
10.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
4
*Note a mounting spacer is fitted to the fan outlet on
c40.
11.Check the operation of the boiler. Refer to Frames
33-36.
Mounting Spacer
Fitted only to c40
8
9
Noise Damper
Fitted only to c40
& c32 models
48
vogue combination boiler - Installation and Servicing
SERVICING
55 Burner Injector Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
4
3. Remove the 2 clips securing the gas inlet pipe and remove the pipe.
4. Carefully ease the injector out of the gas valve.
5. Replace injector + ‘O’ ring.
6. Re-fit in reverse order ensuring the sealing o ring is in good condition or
replace if necessary.
7. Refit the gas pipe ensuring the seals are in good condition and correctly
located.
8. Secure with the clips.
9. Check the operation of the boiler. Refer to Frames 33-36.
1. Refer to Frames 45 & 46.
servicing
56 Burner/Door Assembly Replacement
9
2. Refer to Frame 53.
3. Remove the ignition, detection and earth leads.
4. Remove the 2 clips securing the gas inlet pipe and remove the pipe.
5. Remove the fan leads.
6. Remove the 4 securing nuts retaining the burner/door/fan assembly.
7. 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/door
assembly.
10.Remove the ignition and detection probes.
11.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
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Unclip the return thermistor.
4. Disconnect the electrical lead from the thermistor
5. 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.
6. Check the operation of the boiler. Refer to
Frames 33-36.
vogue combination boiler - Installation and Servicing
49
SERVICING
SERVICING
58 Ignition Electrode Replacement
4,7
1. Refer to Frames 45 & 46.
5
4.5±0.5
2. Refer to Frame 53.
3. Disconnect the ignition lead and the earth
connection
4. Release the 2 securing screws and carefully
withdraw the probe.
5. Check the gap on the replacement ignition
electrode is 4.5 ± 0.5mm.
6. Ensure the sealing gasket is fitted and in good
condition
7. Carefully feed the electrode into the burner/
door assembly and secure with the 2 screws
ensuring correct orientation.
Servicing
8. Reconnect the lead and earth.
9. Check the operation of the boiler. Refer to
Frames 33-36.
7
63 Flame Detection Electrode Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Disconnect the detection lead.
4. Release the 2 securing screws and withdraw
the probe.
4,6
5. Ensure the sealing gasket is fitted to the
replacement electrode and in good condition
6. Carefully feed the electrode into the burner/
door assembly and secure with the 2 screws
ensuring correct orientation.
7. Reconnect the lead
8. Check the operation of the boiler. Refer to
Frames 33-36.
50
6
vogue combination boiler - Installation and Servicing
SERVICING
SERVICING
60Spark Generator Replacement
3
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. 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.
5. Remove 2 securing screws.
6. 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.
4
7. Secure the spark generator assy using 2 screws in
the top of the case.
8. Check the operation of the boiler. Refer to Frames
33-36.
servicing
5
61Gas Control Valve Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Remove the gas inlet pipe. Refer to Frame 54.
8
4. Unplug the electrical connection.
5. Disconnect the earth lead at the rear of the gas valve.
6. Disconnect the gas service valve
7. Remove the 2 securing screws in the underside of the
boiler casing and remove the valve.
8. Remove brass injector from gas valve outlet and re-fit
into replacement valve.
9. 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
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Remove the condense trap. Refer to
Frame 50.
4. Disconnect the electrical cable
connection
5. Withdraw the securing clip
6. Lift the valve actuator clear of the valve
body.
5
7. Replace in reverse order.
8. Check the operation of the boiler. Refer to
Frames 33-36.
vogue combination boiler - Installation and Servicing
51
SERVICING
63 Condensate Trap Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Remove the rubber condensate pipe from
the top of the trap.
3
4. Rotate the trap clockwise to disengage
the trap and lift clear of the outlet
connection.
5. Refit in reverse order making sure the
trap is engaged with the outlet connection
6. Refill the condensate trap.
Servicing
7. Check the operation of the boiler. Refer to
Frames 33-36.
64 Main PCB Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Remove the electrical cover at the clips.
4. Carefully disconnect all electrical
connectors
5. Remove pcb from mounting posts.
6. 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.
3
3
7. Replace in reverse order.
8. Check the operation of the boiler. Refer to
Frames 33-36.
3
3
4
5
5
6
52
vogue combination boiler - Installation and Servicing
SERVICING
65 User PCB Replacement
6
5
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Set both the user temperature
selector knobs to the 12 o’clock
position.
3
4. Remove the electrical cover at the
clips indicated. Refer to Frame
64.
5. Disconnect all electrical
connectors carefully
6. Remove pcb from mounting posts.
7. Replace the pcb in reverse order.
8. Check the operation of the boiler.
Refer to Frames 33-36.
servicing
66 DHW FLow Turbine Sensor Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Lift off the flow turbine sensor plastic
retaining clip.
4. Unplug the electrical connection and
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
1. Close all the CH water isolating valves on the boiler inlet.
2. 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.
3. 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.
4. Disconnect filling loop. Refer to Frame 24.
5. Check operation of the boiler. Refer to Frames 33-36.
DOMESTIC HOT WATER CIRCUIT
1. Close the DHW water isolating valve on the DHW inlet.
CH
Flow
DHW
Outlet
Gas
CH
Drain
Circuit
DHW
CH
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.
3. 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 water flows from each tap.
4. Disconnect filling loop. Refer to Frame 24.
5. Check operation of the boiler. Refer to Frames 33-36.
vogue combination boiler - Installation and Servicing
53
SERVICING
68Pressure Gauge Renewal
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Close the isolating service valves
and drain the (CH) boiler
4
4. Remove the clip retaining the
pressure sensor
5. Remove the sensor.
6. Remove the electrical cover at the
clips indicated. Refer to Frame 64.
7. Remove the clip retaining the
pressure gauge and remove the
gauge, drawing the capillary carefully
out of the boiler.
Servicing
8. Refit in reverse sequence. Refill the
CH system. Refer to Frame 67.
9. Check the operation of the boiler.
Refer to Frames 33-36.
7
69Pressure Relief Valve Renewal
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Close the isolating service valves
and drain the (CH) boiler. Refer to
Frame 67.
5
4. Remove the burner & Fan assembly.
Refer to Frame 47.
5. Remove the CH Water Pressure
Sensor. Refer to Frame 75
6. Undo the PRV outlet retaining nut.
(retaining the washer)
7. Remove the securing clip at the rear
of the valve body.
8. Withdraw the valve vertically.
9. Renew the valve and refit in reverse
order.
10.Refill the CH system. Refer to
Frame 67.
11.Check the operation of the boiler.
Refer to Frames 33-36.
6
54
vogue combination boiler - Installation and Servicing
SERVICING
70Pump Auto Air Vent Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Close the isolating service valves and drain the (CH)
boiler. Refer to Frame 67.
4. Remove the burner & Fan assembly. Refer to Frame 47.
5. Remove return pipe connected at top of pump and heat
exchanger.
6. 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.
7. Reassemble in reverse order.
8. Ensure the air vent head o ring seal is in place when
refitting and the seal is in place at the pump outlet
connection.
9. 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.
servicing
5
71 DHW Flow Turbine Sensor Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Lift off the flow turbine sensor plastic retaining clip.
4. Unplug the electrical connection and transfer to new
turbine sensor.
3
5. Reassemble in reverse order.
6. Check operation of the boiler. Refer to
Frames 33-36.
4
72dIVERTER vALVE iNTERNAL cARTRIDGE rEPLACEMENT
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Close the isolating service valves and drain the
(CH) boiler. Refer to Frame 67.
4. Remove the Condense trap. Refer to Frame 50.
5. Disconnect the diverter valve head cable
7
6
6. Remove the diverter head retaining clip and
withdraw the diverter head.
7. 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.
10.Check the operation of the boiler. Refer to
Frames 33-36.
vogue combination boiler - Installation and Servicing
55
SERVICING
73dhw pLATE hEAT eXCHANGER rEPLACEMENT
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
5
3. Close the isolating service valves and drain the heating
and DHW systems. Refer to Frame 67.
4. Remove the burner & Fan assembly. Refer to Frame 47.
5. Remove the 2 Allen screws securing the plate heat
exchanger to the brass housings.
6. Ease the plate heat exchanger back to disengage and
lift out.
7. Fit the new heat exchanger using the new o rings
supplied.
8. Refit in reverse order.
9. Open the isolating service valves, refill the CH and DHW
systems and vent as necessary. Refer to Frame 67.
Servicing
10.Check the operation of the boiler. Refer to Frames
33-36.
74 pUMP hEAD rEPLACEMENT
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Close the isolating service valves and
drain the (CH) boiler. Refer to Frame
67.
4
5
4. Disconnect both electrical leads to the
pump
5. Remove the 4 Allen screws securing the
pump head and remove.
6. Refit in reverse order.
7. Open the isolating valves and refill the
CH system. Refer to Frame 67.
8. Check the operation of the boiler. Refer
to Frames 33-36.
75ch wATER pRESSURE sENSOR rEPLACEMENT
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
4
3. Close the isolating service valves and
drain the (CH) boiler. Refer to Frame 67.
4. Remove the retaining clip to the rear of the
housing.
5. 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.
8. Check the operation of the boiler. Refer to
Frames 33-36.
56
vogue combination boiler - Installation and Servicing
SERVICING
76 DHW Filter and Flow Regulator Cleaning/Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Isolate the DHW supply to the boiler.
4. Drain the DHW system. Refer to Frame 67.
5
5. Remove the DHW Flow Turbine Sensor. See Frame 71.
6. Using a spanner remove the DHW flow turbine cartridge.
7. Unscrew the flow regulator housing.
8. Remove the filter.
9. Clean or replace as necessary.
10.Refit in reverse order.
8
11.Open the isolating valves and refill DHW system. Refer
to Frame 67.
servicing
12.Check the operation of the boiler. Refer to Frames 33-36.
77 Flow Thermistor Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Unclip the flow thermistor.
4. Disconnect the electrical lead from the thermistor.
5. 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.
3
4
6. Check the operation of the boiler. Refer to Frames 33-36.
vogue combination boiler - Installation and Servicing
57
SERVICING
7
78Heat Exchanger Replacement
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Close the isolating service valves and drain the (CH) boiler. Refer to
Frame 67.
4. Remove the Burner & Fan assembly. Refer to Frame 47.
5. Remove the securing clips to disconnect the flow and return pipes
below the heat exchanger.
6
6. Disconnect the condensate pipe from the sump
7. Disconnect the DRYFIRE ONE TIME sensor lead.
5
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.Remove the heat exchanger forwards, lifting to clear the flow and
return pipes
12.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.
Servicing
10
9
79 Expansion Vessel Recharging and Replacement
Recharging:
3
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Remove the charge point cover.
10
4. Recharge the tank pressure to 0.75bar
5. Refit in reverse order
6. Check the operat ion of the boiler. Refer to Frames 33-36.
Replacement:
7. Refer to Frame 45 & 46.
8. Refer to Frame 53.
9. Close the isolating service valves and drain the (CH) boiler
10.Remove the clip securing the flexible connecting hose and
disconnect.
11.Remove the two securing screws from the top of the casing
at the same time holding the ignitor bracket to prevent
movement.
11
12.Hold the expansion vessel and move the ignition assembly
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
1. Refer to Frames 45 & 46.
2. Refer to Frame 53.
3. Remove the old seal from the casing.
4. Fit the new seal ensuring correct location
over the fixing pins and the material is fully
located within the casing.
5. Reassemble in reverse order.
6. Check the operation of the boiler. Refer to
Frames 33-36.
servicing
3
vogue combination boiler - Installation and Servicing
59
Fault finding
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
81fault finding chart MAIN MENU
Overheat Lockout
Fill System to 1 Bar
Bleed Radiators, Refill System
Check Radiator Valves are Open
Reset Boiler by pressing r
Low Mains Voltage
Go to Frame 82
Overheat Lockout
Ignition Lockout
Check other Gas Appliances work
If not, re-instate gas supply
Reset Boiler by pressing r
If fault persists contact installer
Low Water Pressure
Go to Frame 83
Ignition Lockout
Flame Loss
Check other gas appliances work. If
not, re-instate gas supply.
If fault persists, contact installer
Too Many Resets
Contact Installer
Flame on before Gas Valve on
Contact Installer
Go to Frame 84
Flame Loss
Contact Installer
Go to Frame 91
Low Water Pressure
Check if Flow
Thermistor correctly
clipped to pipe
Replace Flow
Thermistor
No Water Flow Fault
Go to Frame 85
Flame Loss
Fill System to 1 Bar
Bleed Radiators, Refill System
If Fault persists contact installer
Reset boiler by pressing r
Go to Frame 86
Flame On before Gas
Valve On
If fault persists contact installer
Reset boiler by
pressing r
Pump Rotor Blocked
No Connection to Primary PCB
Go to Frame 87
Flow Thermistor Fault
Go to Frame 92
No Water Flow Fault
PCB Replaced
5 Resets within 15
minutes
Turn power off and on
Flow Thermistor Fault
Contact Installer
Fill System to 1 Bar
Bleed Radiators
Refill System to 1 Bar
Flow/Return Reversed
Thermal Fuse Lockout
Reset Boiler
If fault persists contact installer
Less than 160V to boiler
Check voltage at boiler
mains in
Check if local generator 10V
Contact Electricity Provider
Turn power off and on
Contact Installer
Unblock Pump
Go to Frame 93
No Connection to
Primary PCB
Outside Sensor Fault
Contact Installer
Return Thermistor Fault
Contact Installer
Go to Frame 88
Outside Sensor Fault
No CH but DHW OK
Go to Frame 94
No CH but DHW OK
NO DHW but CH OK
Go to Frame 95
No DHW but CH OK
Blank Display
Go to Frame 96
Blank Display
Go to Frame 90
Fan Fault
Flow Temperature
Setpoint cannot be
increased to 80ºC
Ensure Flow Temperature
is not limited within Installer
Mode
(see Frame 37)
Ensure BCC fitted
correctly
Ensure correct BCC
fitted
Pump runs during
the nighT
Ensure System Frost
Protection Temperature
Setpoint is not set too high
(see Frame 40)
Go to Frame 89
Return Thermistor
Fault
Fan Fault
Contact Installer
PCB Replaced Incorrectly
Contact Installer
60
vogue combination boiler - Installation and Servicing
Fault finding
Has PCB just been replaced?
Yes
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
82oVERHEAT lOCKOUT
Reset Boiler
No
Are the Boiler and CH/DHW system filled with water
and are all Isolation Valves and Radiator Valves open?
No
Fill and vent the system and open all
Isolation Valves, then Reset the Boiler
Yes
Is the Flow/Return Differential across the boiler in
excess of 30°C?
No
Check the Flow and Return Thermistors
(refer to Frames 87 & 89)
Yes
Check that the Pump is rotating freely. Is the
Differential now below 20°C?
No
Replace the Pump, then Reset the Boiler
Yes
Reset boiler
83 Ignition Lockout
If the Boiler is Reset, does it Ignite for a short time
and then Extinguish
Yes
Check the Detection Electrode and associated Harness for
continuity, visual condition and position (refer to Frame 59).
Check if the Condensate Pipe is Blocked.
No
Is the Gas Pressure available at the boiler > 18mBar?
No
Check Gas Supply and rectify fault
Yes
Is 215Vdc available at the Gas Valve during
ignition? (* See note)
No
Check wiring from Gas Valve to PCB and replace if necessary,
otherwise replace the main PCB
Yes
Unplug the Gas Valve, is the resistance between the
pins between 1kW and 10kW?
No
Replace Gas Valve
Yes
Check Spark Generator and associated Harness
for continuity, visual condition and position (refer to
Frame 60). Are these functioning correctly?
No
Replace Spark Generator and Harness
as necessary
No
Replace Ignition Electrode and
associated Harness as necessary
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
for blockage and rectify if necessary. Boiler now
working OK?
vogue combination boiler - Installation and Servicing
No
Replace Gas Valve
61
Fault finding
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
84 Flame Loss
If the boiler is Reset, does the boiler Ignite for a
short time and then Extinguish
Yes
No
Check the Detection Electrode and associated Harness
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 > 18 mbar?
Check Gas Supply and rectify fault
Yes
Is 215Vdc available at the Gas Valve during
ignition? (* See note)
No
Check wiring from Gas Valve to PCB and replace if
necessary, otherwise replace the main PCB
Yes
Check Spark Generator and associated Harness
for continuity, visual condition and position (refer to
Frame 60). Are these functioning correctly?
No
Replace Spark Generator and Harness
as necessary
No
Replace Ignition Electrode and
associated Harness as necessary
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
for blockage and rectify if necessary. Boiler now
working OK?
No
Replace Gas Valve
* Note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure
the value. 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?
Yes
Disconnect the 6 way connector to the thermal fuse.
Is there continuity across the black and yellow wires
in pins 1 and 2?
Yes
Replace the primary PCB
Yes
Replace the wiring from the PCB to the
thermal fuse
No
Disconnect the electrical connection to the thermal
fuse. Is there continuity across the fuse?
No
Replace the heat exchanger
62
vogue combination boiler - Installation and Servicing
Fault finding
Reset the boiler, does boiler work OK?
Yes
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
86 Flame On Before Gas Valve 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
Disconnect the electrical connection to the Flame
Sense Electrode. Is there continuity between the
Electrode and earth?
Yes
Replace Flame Detection Electrode
No
Replace wiring from primary PCB to flame sense
electrode
87 Flow Thermistor Fault
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 Ω
At 60°C expect 2,400 - 2,600 Ω
At 85°C expect 1,000 - 1,100 Ω
Is the thermistor value correct?
No
Fit a new thermistor
Yes
Is there continuity in the wiring from the primary PCB to
the Thermistor? (6 way connector, connections 5 and
6, black and pink)
No
Replace wiring from flow thermistor to
primary PCB
No
Securely connect the wiring at both the
boiler and Outside Sensor
Yes
Replace primary PCB
88 Outside Sensor Fault
Is the wiring securely connected at both the 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 Ω
At 60°C expect 2,400 - 2,600 Ω
At 85°C expect 1,000 - 1,100 Ω
Is the thermistor value correct?
No
Fit a new outside sensor
Yes
Does the Outside Sensor wiring between the boiler
terminal strip and the PCB have continuity and is
securely connected (5 way low voltage connector,
connections 1 and 2, grey and black wires)?
No
Ensure the wiring has continuity and is
securely connected
Yes
Replace main PCB
vogue combination boiler - Installation and Servicing
63
Fault finding
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
89 Return Thermistor Fault
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 Ω
At 60°C expect 2,400 - 2,600 Ω
At 85°C expect 1,000 - 1,100 Ω
Is the thermistor value correct?
No
Fit a new thermistor
No
Replace wiring from flow thermistor to
primary PCB
Yes
Is there continuity in the wiring from the primary PCB to
the Thermistor? (6 way connector, connections 3 and
4, black and red)
Yes
Replace primary PCB
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?
No
Rectify wiring & connections
No
Replace main PCB
Yes
Is there 230Vac at the blue and brown connections to
the 3 way connection on the Fan?
Yes
Replace Fan
91 Low Water Pressure
Are the boiler and CH system filled with water and
all Isolation and Radiator Valves open?
No
Fill and vent the system and open
all Isolation Valves
Yes
No
Ensure wiring has continuity and is
securely connected
Does the wiring from the Water Pressure Sensor to the
PCB have continuity and is it securely connected?
Yes
Replace Water Pressure Sensor
92 No Water Flow
Are the boiler and CH system filled with water and
all Isolation and Radiator Valves open?
No
Fill and vent the system and open all
Isolation Valves
No
Ensure wiring has continuity and is
securely connected
No
Replace Main PCB
Yes
Does the mains wiring from the Pump to the main PCB
have continuity and is it securely connected (3 way
connector X1C)?
Yes
Is there 230V to the Pump
Yes
Replace Pump
64
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
Turn power Off and On, does the fault disappear
Yes
Replace the wiring from the Primary
PCB to the User Interface PCB
94 No CH but DHW OK
Press Enter
for MENU
OFF
Turn
NO
DEMAND
dial for Heating
Is the above screen shown?
No
Turn Central Heating Dial Clockwise
Yes
Are the Timer and Room Thermostat calling for Heat?
No
Ensure that the Timer and Room
Thermostat are calling for heat
Yes
Are the Radiator Valves open?
No
Open the Radiator Valves
Yes
Is an Ideal Electronic Programmable Room Stat
connected?
Yes
Consult Electronic Programmable Room
Stat Fault Finding Instructions
No
There is no voltage from the Timer/Room
Stat. This is not a boiler fault. Ensure
voltage is supplied to the boiler by
correcting external wiring
No
Is there 230Vac at (A)?
Yes
Is there 230V between pins 2 and 3 at the diverter
valve?
No
Replace Main PCB
Yes
Replace Diverter Valve
ROOM OPTIONA OPTIONA
L
L
STAT/ HEATING FROST
TIMER ZONE 2 STAT
IN
OUT
IN OUT
IN OUT
MAINS IN
L
N
A
vogue combination boiler - Installation and Servicing
65
Fault finding
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
95 No DHW but CH OK
Does the display show “ON” underneath the tap
symbol?
No
Is the red neon illuminated on the
DHW Turbine?
Yes
Ensure cold inlet and hot
water outlet are not reversed
No
Yes
Is the wiring connected between the
Main PCB and the DHW Turbine?
Are the flow rates correct as per Table 3
Yes
Re-connect wiring
No
Yes
Remove Turbine and clear any
debris, is DHW OK?
Does the wiring from the Main PCB to the Diverter
Valve have continuity and is fully connected
No
Fit new turbine
Yes
Check diverter valve head fully engaged and clip
secured onto waterset
No
Adjust flow rates to achieve 35oC
temperature rise and check filter fitted in
turbine is not blocked with debris
No
Replace or reconnect as appropriate
No
Re-engage diverter valve head and
secure clip to waterset
Yes
Is there 230V between pins 1 and 3?
Yes
Replace Diverter Valve head, is DHW OK?
Yes
No
Replace Diverter Valve body
Replace Main PCB
96 Blank Display
No
Is there 230Vac to the boiler at (A)?
Supply power to the boiler
Yes
Is the wiring from the boiler terminal block to the main
PCB connected securely?
No
Connect the wiring from the terminal
block to the main PCB securely
No
Replace the wiring from the boiler
terminal block to the Main PCB
No
Connect the cable from the main PCB to
the user interface PCB securely
Yes
Does the wiring from the boiler terminal block to the
Main PCB have continuity?
Yes
Is the cable from the main PCB to the user interface
PCB connected securely?
Yes
Does the cable from the main PCB to the user
interface PCB have continuity and is un-damaged?
No
Replace cable from main PCB to user
interface PCB
No
Replace Main PCB
Yes
Is the Fuse on the main PCB OK?
Yes
Replace the user interface PCB, still no display?
ROOM OPTIONAL OPTIONAL
STAT/ HEATING FROST
TIMER ZONE 2 STAT
IN
OUT
IN OUT
IN OUT
MAINS IN
L
N
No
Replace main PCB
A
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;
-
Boiler Model
-
Appliance GC Number
-
Boiler Serial Number
vogue combination boiler - Installation and Servicing
67
Short list of parts
68
vogue combination boiler - Installation and Servicing
Notes
vogue combination boiler - Installation and Servicing
69
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 he customer’s statutory rights.
Gas Safe Register Number
Telephone Number
If yes, and if required by the manufacturer, has a water scale reducer been fitted?
If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?
Gas Safe Register Number
Gas Safe Register Number
Gas Safe Register Number
Gas Safe Register Number
Gas Safe Register Number
Gas Safe Register Number
Gas Safe Register Number
Gas Safe Register Number
Gas Safe Register Number
Gas Safe Register Number
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.
For details of courses please ring:................ 01482 498 432
Manufactured under an ISO 9001
registered quality management system
The code of practice for the installation,
commissioning & servicing of central heating systems
FM 59915
Ideal, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN.
Telephone: 01482 492 251 Fax: 01482 448 858. Registration No.
London 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 Technical Helpline: 01482 498 663
www.idealboilers.com