Buderus 600-19R, 600-11R, 600-24R, 600 Series, 11R Installation And Servicing Instructions

...

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7212 2900 - 05/2004 GB(EN) For trade use

Installation and servicing instructions

Wall-mounted condensing gas boiler Buderus 600 - 11R / 19R / 24R

Please read thoroughly before installing or servicing

The boiler meets the basic requirements of the appropriate standards and directives.

Conformity has been substantiated by the proper documents which - together with the declaration of conformity - are filed with the manufacturer.

Buderus 600 Series

CE-0063BO3062

Subject to technical modifications!

Constant development efforts may result in minor deviations in illustrations, functional steps and technical data.

Updating the documentation

If you have suggestions for improvement or have found discrepancies, please do not hesitate to contact us.

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

2 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Contents

1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.1 Dimensions and connections . . . . . . . . . . . . . . . . . 9

1.2 Boiler assembly - exploded view . . . . . . . . . . . . . 10

1.3 Flue Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.4 Items supplied with unit . . . . . . . . . . . . . . . . . . . . 13

1.5 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.6 Pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.7 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.8 Electrical connections. . . . . . . . . . . . . . . . . . . . . . 17

1.9 Timing and temperature control . . . . . . . . . . . . . . 19

2 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.1 Preparing the boiler for operation. . . . . . . . . . . . . 20

3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.1 Preparing the heating boiler for inspection . . . . . . 26

4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.1 Clean the heat exchanger, burner and

condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 Operating codes . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.2 Fault codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.3 Checking and replacing parts. . . . . . . . . . . . . . . . 40

6 Conversion to another type of gas. . . . . . . . . . 48

7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7.1 Technical specifications . . . . . . . . . . . . . . . . . . . . 50

7.2 Short list of spare parts . . . . . . . . . . . . . . . . . . . . 52

8 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.1 Start-up report . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.2 Inspection and maintenance reports . . . . . . . . . . 54

Preface

These installation and servicing instructions apply to: Buderus wall-mounted condensing gas boilers 600 - 11R / 19R / 24R.

Model: C13, C33, C

Type: GB II

Fuse rating: 1.25 Ampere slow blow

Power rating: 230 VAC, 50 Hz, IPX4D

Important general instructions for use

Only use the boiler in accordance with its designated use and the installation and servicing instructions. Servicing and repair must be carried out by CORGI registered installer. Only use the boiler in combinations and with the accessories and spare parts indicated in the installation and servicing instructions. Other combinations, accessories and consumables may only be used if they are expressly provided for the designated use and if system performance and safety are not affected in any way.

The boiler is suitable for connection to fully pumped, open vented or sealed water systems. Adequate arrangements for completely draining the system by provision of draining valves must be provided in the installation pipework.

Subject to technical modifications.

As a result of our policy of constant development, there may be small differences between illustrations, functional steps and technical data.

20 mbar, 37 mbar

2H3P

G. C. Aplliance No. :

Buderus 600 - 11R 41-110-21 Buderus 600 - 19R 41-110-22 Buderus 600 - 24R 41-110-23

BENCHMARK' Log Book

All Boulter Buderus gas fired boilers now include an installation, commissioning and service record log book. The details of the log book will be required in the event of any warranty work being requested. Please complete the appropriate sections on completion of the installation and commissioning.

REMEMBER: Please hand the log book back to the user.

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Installation and maintenance instructions wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 3

Regulations and directives

It is law that all gas appliances are installed and serviced by a CORGI registered installer in accordance with the regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with.

The installation must also be in accordance with the latest I.E.E (BS.7671) Wiring Regulations, local building regulations, water regulations, the building regulations and the Building Standards (Scotland) and any relevant requirements of the local authority.

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).

BS. 5449 Forced circulation hot water systems. BS. 5546 Installation of gas hot water supplies for domestic

purposes (2nd. family Gases).

BS. 6798 Installation of gas fired hot water boilers of rated

input not exceeding 60 kW.

BS. 6891 Low pressure installation pipes.

IGE/UP/1b Tightness testing and purging domestic sized gas

installations.

Health and & Safety Document No. 635.

The Electricity at Work Regulations, 1989.

The manufacturer's notes must not be taken, in any way, as overriding statutory obligations.

The design and construction of the Buderus wall-mounted condensing gas boiler 600 - 11R/19R/24R conforms to the basic specifications listed in the European directive governing gas-fired appliances 90/396/EEC, and with respect to EN 625, EN 483 and EN 677.

NOTE

Observe the corresponding technical rules and the building supervisory and statutory regulations when installing and operating the system.

WARNING!

Keep the burner-control unit housing CLOSED when working on water-bearing components.

NOTE

It is mandatory to clean and service the system once a year. This includes an inspection of the entire system to see if it is in full working order. Defects and faults must be eliminated immediately.

NOTE

When instructions aren’t followed, warranty expires.

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/7:1998.

Bathroom Installations

This appliance is rated IPX4D.

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, in Scotland, 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.

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 can be installed in Zone 3, as detailed in BS.7671.

Compartment Installations

A compartment used to enclose the boiler should be designed and constructed especially for this purpose.

An existing cupboard or compartment may be used, provided that it is modified for the purpose.

In both cases, details of essential features of cupboard/ compartment design, including airing cupboard installation, are to conform to the following: BS 6798 (No cupboard ventilation is required - see 'Air Supply' for details).

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.

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. In addition, sufficient space may be required to allow lifting access to the wall mounting plate.

Wall-mounted condensing gas boilers must only be operated with the combustion air/flue gas systems especially devised and authorised for this type of boiler.

Observe the relevant standards, regulations and legislation of the country of final use.

CAUTION

Use this device for its intended purpose only.

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

4 Installation and maintenance instructions wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

DANGER! Notes relating to the heating system water.

Thoroughly flush the system before it is filled with water. Use only untreated water or water treatment product such as Sentinal X100 to fill and top up the system.

When using water treatment, only products suitable for use with Boulter Buderus heat exchangers are permitted (e.g. Sentinel X100). Your warranty is at risk if an incorrect water treatment product is used in conjunction with this appliance. For more information, contact Boulter Buderus Product Support Department.

It is most important that the correct concentration of the water treatment product is maintained in accordance with the manufacturer's instructions.

If the boiler is used in an existing system any unsuitable additives MUST be removed by thorough cleaning. BS.7593:1992 details the steps necessary to clean a domestic central heating system.

In hard water areas, treatment to prevent lime scale may be necessary - however, the use of artificially softened water is NOT permitted.

Under no circumstances should the boiler be fired before the system has been thoroughly flushed.

Do not use water softened in a salt bedding exchanger.

Do not use anti-freeze or other additives.

The expansion vessel must be of sufficient size.

When oxygen-permeable pipes are used (e. g. for floor heating systems) the system must be separated by means of heat exchangers. Unsuitable heating water promotes sludge formation and corrosion. This may cause malfunctions and damage in the heat exchanger.

This appliance is not suitable for gravity central heating nor are they suitable for the provision of gravity domestic hot water.

The boiler must be vented.

Drain cocks must be located in accessible positions, which permits the draining of the entire system. They should be at least ½" BSP nominal size and be in accordance with BS. 2879.

The hydraulic resistance of the boilers is shown in the graph below.

graph 1

350

300

250

200

150

resistance (mbar)

100

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3

flow (m /h)

resistance heat exchanger

NOTE: Notes relating to domestic hot water.

The boiler must not be used for direct hot water supply.

The hot water storage cylinder must be of the indirect type.

Single feed, indirect cylinders are not recommended and must not be used on sealed systems.

The hotwater cylinder and ancillary pipework, not forming part of the useful heating surface, should be lagged to prevent heat loss and any possible freezing - particularly wher pipes run throughroof spaces and ventilated underfloor spaces.

The domestic hot water service must be in accordance with BS 5546 and BS 6700.

Safe handling of substances

Care should be taken when handling the boiler's insulation, which can cause irritation to the skin.

No asbestos, mercury or CFCs are included in any part of the boiler and its manufacture.

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 5

Open vent system requirements

The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150 mm (6") away from the vent connection.

NOTE

Combined feed and vent pipes may also be fitted.

Feed / expansion cistern

Wate r

level

(cold)

22 mm

open vent

15 mm

cold feed

450 (18") minimum

1000 (40")

minimum

150 (6")

max.

There should be a minimum height, 450 mm (18"), of open vent above the cistern water level. The vertical distance between the highest point of the system and the feed/expansion cistern water level MUST not be less than 1000 mm (40"). The pump must be fitted on the flow side of the boiler.

A suitable pump is a domestic circulator capable of providing a maximum 11 °C (20 °F) temperature differential across the boiler with the whole of the heating circuit open. With the minimum flow circuit allowed by the controls the differential must not exceed 25 °C (see also the graph on page 5).

The vertical distance between the pump and feed/expansion cistern MUST comply with the pump manufacturer’s minimum requirements, to avoid cavitation. Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirements specified by Boulter Buderus. The isolation valves should be fitted as close to the pump as possible.

Schematic pipework and system balancing

The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load 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 footnote re. thermostatic radiator valves).

Balancing

1. Set the programmer to ON for both CH and HW. Turn the cylinder thermostat down. 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 these lockshield valves to give boiler flow and return temperatures not more than 20 °C apart. These valves should now be left as set.

2. Open all manual or thermostatic radiator valves and adjust the lockshield valves on remaining radiators to give around 11 °C temperature drop at each radiator.

3. Turn up the cylinder thermostat and adjust the cylinder balancing valve so that the cylinder achieves a maximum flow consistent with adequate flow to the radiators. Check that with only the domestic hot water loop in circuit a differential temperature of 20 °C across the boiler is not exceeded.

4. Adjust room and cylinder thermostats and programmer to NORMAL settings.

System flow to pump

Connection to boilers

fig. 1 Open vent system

22 mm open vent

15 mm

cold

feed

Elbow then tee

Flow

Return

BOILER

fig. 2 Schematic pipework and system

System return

Air vent

Alternative 2x2 port valves

Radiators

Inverted cold feed entry

3 port valve

Cylinder balancing valve

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

6 Installation and maintenance instructions wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Thermostatic radiator valves

Boulter Buderus support the recommendations made in BS. 5449, and by leading manufacturers of domestic heating controls, that heating systems utilising the thermostatic radiator valve control of temperature in individual rooms shall also be fitted with a room thermostat, controlling the temperature in a space served by radiators not fitted with such a valve.

Such an arrangement will provide for potentially more efficient control of the environment and will also avoid the continuous running of the circulation pump during programmed heating ON periods - thus saving electrical energy.

It is, therefore, strongly recommended that, when thermostatic radiator valves are used, space heating temperature control over a living/dining area or a hallway having a heating requirement of at least 10% of the minimum boiler heat output, is achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves.

Sealed system requirements

NOTE

The method of filling, refilling, topping up or flushing sealed hot water circuit from the mains via a temporary hose connection is only allowed if acceptable to the local water authority.

1. General

The installation must comply with the requirements of BS. 6798 and BS. 5449.

The installation should be designed to work with flow temperatures of up to 80 °C.

All components of the system, including the heat exchanger of the indirect cylinder, must be suitable for a working pressure of 3 bar (45 lb/in

) and temperature of 110 °C. Care should be taken in making all connections so that the risk of leakage is minimised.\

2. Safety valve

A spring loaded safety valve complying with the relevant requirements of BS. 6759 must be fitted in the flow pipe as close to the boiler as possible and with no intervening valve or restriction. The valve should have the following features:

– A non-adjustable preset lift pressure not exceeding 3 bar

(45 lb/in

);

– A manual testing device;

– Provision for connection of a discharge pipe. The valve or

discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or cause damage to electrical components and wiring.

Make-up vessel

(max. capacity 3 litres)

Hose union bib tap

Water supply

Hose connector

Nonreturn valve

Automatic air vent

Hosepipe (disconnect after refilling)

BS. 1010:2 stop tap

HEATING CIRCUIT

Test cock

Air vent

Pump

Double check valve

Pressure gauge

Expansion vessel

Safety valve

BOILER

Drain coc

fig. 3 Sealed system

3. Pressure gauge

A pressure gauge covering at least the range of 0-4 bar (0-60 lb/in

) must be fitted to the system. The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel.

4. Expansion vessel

A diaphragm type expansion vessel must be connected to a point close to the inlet side of the pump, the connecting pipe being not less than 15 mm (½" nominal) size and not incorporating valves of any sort.

The vessel capacity must be adequate to accept the expansion of the system water when heated to 110 °C (230° F).

The charge pressure must not be less than the static water head above the vessel. The pressure attained in the system when heated to 110 °C (230° F) should be at least 0.35 bar

(5 lb/in

) less than the lift pressure of the safety valve.

For guidance on vessel sizing refer to table 1.

For further details refer to BS. 5449 and BS. 7074:1 and the British Gas Corporation publication: "Material and Installation Specifications for Domestic Central Heating and Hot Water".

5. Cylinder

The cylinder must be either of the indirect coil type or a direct cylinder fitted with an immersion calorifier which is suitable for operating on a gauge of 0.35 bar (5 lb/in

) in excess of the safety valve setting. Single feed indirect cylinders are not suitable for sealed systems.

6. Make-up water

provision must be made for replacing water loss from the system, either:

– from a manually filled make-up vessel with a readily visible

water level. The vessel should be mounted at least 150 mm (6") above the highest point of the system, and be connected through a non-return valve to the system, filled at least 300 mm (12") below the make-up vessel on the return side of the domestic hot water cylinder or radiators.

– where access to a make-up vessel would be difficult by

pre-pressurisation of the system. Refer to "Filling", below.

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 7

7. Mains Connection

There must be no direct connection to the mains water supply or to the water storage tank supplying domestic water, even through a non-return valve, without the approval of the local water authority.

8. Filling

The system may be filled by one of the following methods:

a. Through a cistern, used for no other purpose, via a ball

valve permanently connected directly to a service pipe and/or a cold water distributing pipe. The static head available from the cistern should be adequate to provide the desired initial system design pressure. The cold feed pipe from the cistern should include a non-return valve and a stop valve with an automatic air vent connected between them, the stop valve being located between the system and the automatic air vent. The stop valve may remain open during normal operation of the system if automatic water make-up is required.

b. Through a self-contained unit comprising a cistern,

pressure booster pump (if required) and, if necessary, an automatic pressure reducing valve and flow restrictor. The cistern should be supplied through a temporary connection from a service pipe or cold water distributing pipe. This unit may remain permanently connected to the heating system to provide limited automatic water makeup. Where the temporary connection is supplied from a service pipe or distributing pipe which also supplies other draw-off points at a lower level then a double check valve shall be installed upstream of the draw-off point.

c. Through a temporary hose connection from a draw-off tap

supplied from a servicing pipe under mains pressure. Where the mains pressure is excessive a pressure reducing valve shall be used to facilitate filling.

The following fittings shall form a permanent part of the system and shall be fitted in the order stated:

– A stop valve complying with the requirements of

BS. 1010, Part 2 (the hose from the draw-off tap shall be connected to this fitting);

– A test cock;

– A double check valve of an approved type.

z Thoroughly flush out the whole of the system with cold

water, without the pump in position.

z With the pump filled, fill and vent the system until the

pressure gauge registers 1.5 bar (21.5 lb/in

). Examine

for leaks.

z Check the operation of the safety valve by manually

raising the water pressure until the valve lifts. This should occur within ± 0.3 bar (4.3 lb/in

) of the preset lift

pressure.

z Release water from the system until the initial system

design pressure is reached.

z Light the boiler and heat the system to the maximum

working temperature. Examine for leaks.

z Turn off the boiler and drain the system while still hot.

z Refill and vent the system.

z Adjust the initial pressure to the required valve.

Sizing procedure for expansion vessel

The volume of the expansion vessel (litres) fitted to a sealed system shall not be less than that given by the table below, multiplied by a factor of 0.8 (for flow temperatures of less than 80 °C).

Safety valve setting 3.0 bar 2.5 bar 2.0 bar

Vessel charge and initial system pressure

Total water content of system (litres) Expansion vessel volume litres

25 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0

50 4.2 5.4 7.8 4.7 6.7 11.8 5.6 10.0

75 6.3 8.2 11.7 7.0 10.0 17.7 8.4 15.0

100 8.3 10.9 15.6 9.4 13.4 23.7 11.3 20.0

125 10.4 13.6 19.5 11.7 16.7 29.6 14.1 25.0

150 12.5 16.3 23.4 14.1 20.1 35.5 16.9 30.0

175 14.6 19.1 27.3 16.4 23.4 41.4 19.7 35.0

200 16.7 21.8 31.2 18.8 26.8 47.4 22.6 40.0

225 18.7 24.5 35.1 21.1 30.1 53.3 25.4 45.0

250 20.8 27.2 39.0 23.5 33.5 59.2 28.2 50.0

275 22.9 30.0 42.9 25.8 36.8 65.1 31.0 55.0

300 25.0 32.7 46.8 28.2 40.2 71.1 33.9 60.0

Multiplying factors for other

system volumes

Table 1 Expansion vessel volumes

0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0

bar bar bar bar bar bar bar bar

0.0833 0.109 0.156 0.094 0.134 0.237 0.113 0.20

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8 Installation and maintenance instructions wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Installation 1

1 Installation

1.1 Dimensions and connections

CH FLOW

CH RETURN

460 mm (18")

290 mm (11,4")

105 mm (4")

230 mm (9")

50 (2")

70 (2.8")

130 (5")

145 (5,7")

619 mm (24")

604 mm (23,7")

Ø100 (4")

Ø60 (2 ")

328 mm (13")

376 mm (15")

25 mm (1")

20 (0.8")

700 mm (27½")

119 mm (4,7")

82 mm (3")

CWDO

GAS

CH Flow = Ø22 mm Compression (0.87") CH return = Ø22 mm Compression (0.87") GAS = Gas connection G½" INSIDE CWDO = Condensate water drainage outlet Ø21.5 mm (0.8") OUTSIDE

NOTE

See the wall-mounting template for the necessary clearances.

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 9

Installation1

1.2 Boiler assembly - exploded view

Single unit (11R / 19R / 24R)

350

380

310

340

420

440

360

320

290

330

250

370

280

260

270

120

520

510

400

390

410

430

450

460

470

480

Legend

10. Casing

230

110

130

230

250

240

300

200

100

500

170

530

180

560

540

160

190

210

220

490

140

150

240

290

20. Door complete

30. Ventilation cover

40. Bracket

50. Concentric adaptor

60. Clip adaptor

70. Lipring 100mm

80. Fan

90. Sealing Fan / Venturi

100. Lipring 60mm

110. Flue gas pipe

120. Condensate collector

130. Seal flue gas pipe

140. Flue gas sensor

150. Condensate trap

160. Suction pipe

170. Lipring 50mm

180. Gas valve

190. Rectifier

200. Venturi

210. Gas pipe

220. Gas service valve

550

230. Pipe return/flow top

240. Pipe connection

250. Clip

260. Return pipe

270. Drain cock

280. Connection return

290. Sensor

300. Flow pipe

310. Connection supply

320. Hairpin heat exchanger

330. Automatic air vent

340. O-ring

350. Lipring

360. Safety sensor

370. Sealing ring

380. Backpart heat exchanger

390. Seal heat exchanger

400. Insulation backpart heat exchanger

410. Burner 11 kW Burner 19 kW Burner 24 kW

420. Sealing burner

430. Heat exchanger helix

440. Combustion divider

450. Insulation front heat exchanger

460. Frontpart heat exchanger

470. Sight glass

480. Fasteners

490. UBA

500. Main switch

510. Hot surface ignitor

520. Ionisation electrode

530. Cable fan

540. Cable harness

550. Frame

560. RTH converter 230V

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

10 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Installation 1

1.3 Flue Installation

1.3.1 Siting the flue terminal

The flue must be installed in accordance with the recommendations of BS. 5440-1:2000.

Pluming will occur at the terminal so terminal positions where this could cause a nuisance should be avoided.

The air supply and the flue gas exhaust must meet the applicable general regulations. Please consult the instructions provided with the flue terminal kits prior to installation.

The boiler MUST be installed so that the terminal is exposed to external air.

It is important that the position of the terminal allows the free passage of air at all times.

Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in table 1.

If the terminal is fitted within 1000 mm of a plastic or painted gutter or within 500 mm of painted eaves, an aluminium shield of at least 1000 mm long should be fitted to the underside of the gutter or painted surface.

If the lowest part of the terminal is less than 2 metres above the level of the ground, balcony, flat roof or place to which any person has access, the terminal must be protected by a guard. Protective guards are available from Quinnell Barrett and Quinnell, Old Kent Road, London.

Ensure that the guard is fitted centrally.

The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of the building.

The air inlet/products outlet duct and the terminal of the boiler MUST NOT be closer than 25 mm (1'') to combustible material. Detailed recommendations on the protection of combustible material are given in BS. 5440 - 1:2000.

NOTE

It is absolutely essential to ensure, in practice, that products of combustion discharging from the terminal cannot re-enter the building or any other adjacent building through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation/airconditioning.

If this could occur the appliance MUST be turned off (with the owners permission), and labelled as unsafe until corrective action can be taken.

B,C

under carport

H, I

B,C

Fig. 1 Flue terminal position

Terminal Position

A. Directly below or alongside an opening

window, air vent or other ventilation opening

B. Below guttering, drain pipes or soil pipes

C. Below eaves

D. Below balconies or a car port roof

E. From vertical drain pipes or soil pipes

F. From internal or external corners

G. Above adjacent ground, roof or balcony level

H. From a surface facing the terminal

I. From a terminal facing a terminal

J. From an opening in a car port (e.g. door or

window) into dwelling

K. Vertically from a terminal on the same wall

L. Horizontally from a terminal on the wall

M. Adjacent to opening

Minimum

Spacing

300 mm (12")

75 mm (3")

200 mm (8")

150 mm (6")

300 mm (12")

600 mm (24")

1200 mm (48")

1500 mm (60")

300 mm (12")

Table 1 Balanced flue terminal position

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 11

Installation1

1.3.2 Air supply and flue gas exhaust in a closed installation

A ventilation cover is integrated into the 600 Series condensing gas boilers. This cover houses a number of components, such as the burner and the heat exchanger. Since this ventilation cover is part of the air supply system, it is vital that it is always installed correctly.

To ensure optimal operation, the 600 Series appliances must be connected to a Buderus wall-mounted or roof-mounted flue terminal. These terminals have been developed specifically for the 600 Series condensing gas boilers and have been comprehensively tested. The Buderus wall and roof-mounted flue terminal kits ensure trouble-free operation.

The following items for the flue (see fig. 2) are included in the delivery of the boiler:

– pos. 1: 1 Concentric bend 60/100;

– pos. 2: 1 Horizontal flue terminal 60/100;

– pos. 3: 1 Flue finishing kit.

1.3.3 Maximum Flue length

The maximum pipe length of the air supply and flue gas exhaust pipes for the 600 Series condensing gas boilers (see table 2) is determined by the total pressure loss of all components in the flue gas exhaust / air supply system.

Fig. 2 Horizontal flue pack

550 mm

50 mm

Take the flue conduit clearances into account when planning the layout of the place of installation (see subsection 1.3.1: "Siting the flue terminal" on page 11).

Maximum wall thickness without extensions is 550 mm. Maintain a minimum side wall clearance of 50 mm (see fig. 3).

1.3.4 Additional flue parts

Additional flue parts (see table 3) can be ordered from your supplier.

Fig. 3 Side flue and rear flue installation

Boiler

600 Series L = 7.5 m 1.2 m

Table 2 Pipe length

Flue parts Order No.

Concentric pipe, 500 mm long, adjustable NE 83703

Concentric pipe, 1000 mm long, not adjustable NE 83704

Concentric bend 90° NE 83705

Concentric bend 45° NE 83706

Table 3 Additional flue parts

Maximum

pipe length

For every 90° bend the

maximum pipe length has

to be reduced by

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12 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Installation 1

1.4 Items supplied with unit

z Check the contents against the packing list to ensure that

nothing is missing.

Key to fig. 4:

1: Wall-mounted condensing gas boiler

2: Wall bracket

3: Technical documents

4: CH Flow connection pipe

5: CH Return connection pipe

6: Gas service valve

7: Plastic bag containing the following accessories:

2 x wall fixing-screws 2 x wall plugs 2 x washers Seals (2 x ¾“) Square wrench Initial start-up sticker Second identification plate

Requirements to be met by the place of installation

NOTE

Observe all statutory building regulations applying to the place of installation.

Fig. 4 Items supplied with unit

DANGER!

Inflammable materials or liquids must not be stored or used near wall-mounted condensing gas boilers. The site of installation must be frost-protected.

1.5 Transport

The boiler is transported in a horizontal position.

z Open the box and remove the four foam supports (fig. 5,

item 1). The casing is not attached to the boiler.

z Take out the casing (fig. 5, item 2) and put aside during

installation.

CAUTION!

Do not carry the boiler by the casing at any time.

z Take out the wall bracket (fig. 4, item 2) and attach to the

wall using the wall mounting template.

z Take out the condensing gas boiler (fig. 5, item 3) and

hang onto the wall bracket (fig. 6).

z Dispose of packaging.

Fig. 5 Unpacking the box

Fig. 6 Installation

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 13

Installation1

1.6 Pipe connections

CAUTION!

Ensure that all pipework is routed so as to minimise any strain on the boiler fittings.

1.6.1 Gas Supply

The gas installation must be installed in accordance with

BS.6891.

CAUTION!

Pipework from the meter to the boiler MUST be of adequate size.

The complete installation MUST be tested for gas tightness and purged as described in IGE/UP/1b.

1.6.2 Gas connection

z A gas service valve is supplied with the unit. Take it out of

the box and connect it to the boiler see fig. 7, item 3 with P.T.F.E.-tape. Connect to gas supply according to the relevant standards.

1.6.3 Heating system connections

The central heating system should be in accordance with BS.6798 and, in addition, for smallbore and microbore systems, BS.5449.

z Take the CH flow connection pipe and the CH return

connection pipe out of the box and connect to the condensing gas boiler see fig. 7, item 1 and 2.

z Connect the central heating system to these pipe

connections according to the relevant standards.

1.6.4 Condensate drain

A condensate drain is integrated in the boiler. The drain outlet is a standard (21.5 mm) overflow pipe. This drain needs to be connected to a drainage point. All pipework and fittings in the condensate drainage system MUST be made of plastic - no other materials may be used.

The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler, throughtout its length.

Fig. 7 Pipe connections

Key to fig. 7:

1: CH flow

2: CH return

3: Gas

4: Condensate water drainage outlet (CWDO)

Excessive external pipe runs should be avoided in order to prevent possible freezing.

Any external pipework should be a minimum of 32 mm internal diameter.

WARNING!

Any external run must be insulated.

Ensure that the condensate trap is filled with water.

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14 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Installation 1

1.7 Flue installation

The only flue systems that may be used are those supplied by Boulter Buderus. The flue system must be installed in accordance with the requirements of BS.5440:1. 2000.

Standard 100 mm flue systems

The standard concentric flue system provides for a max. horizontal straight length of upto 7.5 m (see subsection 1.3.3). Full instructions for fitting this flue are in subsection 1.7.2: "Installation of the horizontal flue" on page 15.

IMPORTANT

Any horizontal flue system fitted to a condensing boiler must be inclined towards the appliance at an angle of 3% (30 mm per metre length) to prevent condensate dripping from the flue terminal. This means that the clearance above the appliance must be increased to match the duct length. See figure on page 9.

1.7.1 Connecting the vertical flue gas duct

z Fit the vertical flue gas duct (fig. 8) onto the appliance flue

connector.

z For remaining installation of the vertical flue assembly,

refer to the relevant installation instructions.

1.7.2 Installation of the horizontal flue

The standard 100 mm diameter horizontal flue system is siutable for lengths upto 560 mm (see fig. 10). For longer flue runs upto 7.5 m, extension air/flue ducts are available (see page 12, table 3).

NOTE

Use the wall-mounting template to help you mark the position of the side flue opening

Flue gas testing point

Fig. 8 Vertical flue connection

Flue gas testing point

Fig. 9 Elbow with flue gas testing point

Flue Turret

Maximum 560 mm

No Clamp

Terminal assembly

Outer Wall

Fig. 10 Standard flue

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 15

Installation1

1.7.3 Flue duct preparation and assembly

z Measure the flue length L. Refer to figures 11 and 12.

NOTE

The flue must be inclined to the boiler.

z Mark of the lengths shown onto the ducts and cut the

length. The cuts must be square and free from burrs. Terminal assembly outer (air) duct - L-70 mm, inner (flue) duct - L-50 mm. The measurement is made from the ridge at the terminal indicating the outer face of the wall. Refer to figure 13. Extension air duct - L-70 mm, flue duct - L-50 mm. The measurement is from the formed end.

z Assemble flue system completely. Push the ducts fully

together. The slope of the terminal outlet must be face downwards. The assembly will be made easier if a solvent free grease is lightly applied to the male end of the ducts.

NOTE

An inner wall sealing plate is provided which should be fitted to the ducts before assembly.

105

Fig. 11 Flue length - rear

z Push the assembly through the wall and slide the turret

onto the flue connector. Refer to figure 9.

z Ensure that the turret is fully entered into the socket on the

boiler. From the outside fix the flue finishing kit to the terminal and, after ensuring the duct is properly inclined towards the boiler, fix the finishing kit to the wall. If the terminal is within 2 m of the ground where there is access then an approved terminal guard must be fitted. The guard must give a clearance of at least 50 mm around the terminal and be fixed with corrosion resistant screws.

Fig. 12 Flue length - side

Outer Wall Face

Fig. 13 Flue terminal position

Flue Terminal

Raised Ring locating the terminal relative to the outside wall face

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16 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Installation 1

1.8 Electrical connections

1.8.1 Mains connection

CAUTION

This appliance MUST be earthed.

A mains supply of 230 V - 50Hz is required.

External controls are suitable for volt free or 230 V installation.

Wiring to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations.

Wiring should be a 3 core PVC insulated cable, not less than

0.75 mm

Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having 3 mm (1/8'') contact seperation in both poles, or a plug and socket, serving only the boiler and system controls. This boiler is equipped with a double pole switch see fig. 14, item 1. The means of isolation must be accessible to the user after installation.

The electrical connection to the mains supply should be readily accessible and adjacent to the boiler.

If the supply cord is damaged, it must be replaced by a registered Corgi installer to avoid a hazard.

(24 x 0.2 mm), and to BS.6500 Table 16.

Fig. 14 UBA

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 17

Installation1

1.8.2 Wiring Diagram

12 3

18-pin connection strip

Burner-control unit (UBA)

Flame-monitoring electrode

ignitor

Hot surface

STB

Fuse, main switch, emergency OFF switches and

safety measures to comply with local regulations and standards

port

I/O

Communication

24Vac

12 34

1234

To Boiler

1234

RTH

321

Loop

ON/OFF-

potential free

room thermostat

20-pin connection strip

KIM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

12 1 2

Ventilator

50 Hz

230V

Mains power source

Max. permitted

10A

fuse rating

STB Flue gas monitor

230Vac

321

230 Vac ON/OFF-

room thermostat

device may be connected.

FR Return-temperature sensor (return)

FS Safety-temperature sensor (safety)

FK Supply-temperature sensor (supply)

KIM Boiler identification module

MV Solinoid valve

Note:

1) Only one room-temperature regulating

IMPORTANT

The wires inthis mains lead are coloured in accordance with the following code:

GREEN AND YELLOW - EARTH ; BLUE - NEUTRAL ; BROWN - LIVE

As the colours of the wires in the mains lead of of the appliance may not correspond with the coloured markings identifying the terminals in your plug proceed as follows:

The wire coloured green and yellow must be connected to the terminal on the plug marked with the letter E or by the earth symbol or coloured green or green-and-yellow. The wire coloured brown must be connected to the terminal marked with

the letter L or coloured red. The wire coloured blue must be connected to the terminal marked with the letter N or coloured black.

FOR LOCATION OF INDIVIDUAL COMPONENTS, SEE TROUBLESHOOTING GUIDE IN THE SERVICE SECTION OF THIS MANUAL.".

WARNING

THIS APPLIANCE MUST BE EARTHED

Ensure that your appliance is connected correctly - if you are in any doubt consult a qualified electrician.

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18 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Installation 1

1.9 Timing and temperature control

The wall-mounted condensing gas boiler can be fitted with the following control devices:

– ON/OFF temperature controller, volt free;

– A room-temperature control device at 230V connected to

the RTH converter see fig. 15, item 2.

1.9.1 230V Room-temperature control device connection

CAUTION

DO NOT activate the condensing gas boiler at this stage.

z Lead the 230V control device wire through the cable lead

(see fig. 15, item 1).

z Fix the 230V wire to position 1 and 2 of the 230V

connection (see fig. 15, item 2).

z Secure the 230V wire with the bracket and the two screws

onto the RTH converter.

1.9.2 Volt free room-temperature control device connection

z Remove the cover of the connextion box (fig. 16, item 1).

z Lead the control device wire through the cable lead

(see fig. 16, item 2).

z Fix the wire to position 1 and 2 of the volt free connection

(see fig. 16, item 3).

z Secure the wire with the bracket and the two screws onto

the RTH converter (see fig. 16, item 4).

Fig. 15 Connecting the control device

Fig. 16 RTH converter - Volt free connection

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 19

Initial start-up2

2 Initial start-up

2.1 Preparing the boiler for operation

CAUTION

DO NOT operate the condensing gas boiler if large amounts of dust are present, e.g. due to building work in and around the place of installation.

2.1.1 Checking for leaks

z Disconnect the system from the power supply.

z Check all sections of gas pipework and connections for

signs of leaks before starting up system for the first time. If a leak is detected during tightness testing, use an approved leak detector to check all connections for possible escapes. The product must be certified as a gas leak-testing agent. DO NOT allow the product to come into contact with electrical wiring.

Fig. 17 Unscrew ventilation cover

2.1.2 Purging air from the gas supply system

z Loosen the 4 crosshead screws on the ventilation cover

(fig. 17).

z Remove the ventilation cover.

z Close the gas service valve.

z Unscrew the sealing closure of the gas connection-

pressure testing nipple by two turns (fig. 18).

z Purge system and appliance as per relevent procedures,

IGE/UP/1b. Ensuring all safety requirments are met.

z Open gas service valve.

z Close the gas service valve once more.

z Shut the sealing closure of the test nipple once more.

z Open cover for 2nd operating level (fig. 19, item 1).

z Make sure that system pump is running.

z Start boiler up and move chimney sweep switch (fig. 19,

item 3) to position “1”.

The display shows (fig. 19, item 2) “

-.” or “ =.” to indicate that

the gas supply system is purged of air. Return chimney sweep switch to position “0”.

Fig. 18 Purging air from the gas supply system

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20 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Fig. 19 Display and chimney-sweep switch

Initial start-up 2

2.1.3 Check combustion air/flue gas connection

Check to ensure that the correct combustion air/flue gas system has been fitted.

Check that the instructions included in the appropriate flue gas system installation manual have been followed.

2.1.4 Checking the type of gas and supply

CAUTION

The burner must only be put into operation with the correct nozzles (table 5).

Type of gas Factory settings of gas burners

When delivered ready for operation and set to Wobbe index 14.1 kWh/m (referred to 15 °C, 1,013 mbar),

Natural gas H

applicable for Wobbe index range

11.3 to 15.2 kWh/m

Inscription on gas-type indicating label: Category setting: G 20 - 2E_20 mbar

After adaptation by a CORGI registered installer, the unit can be

Propane P

run on propane. Inscription on gas-type indicating label: 3P G 31_30-50 mbar

Table 4 Gas-supply types

Type of gas

supply

Natural gas H (G20)

Gas nozzles ∅ [mm]

11R 19R/24R

Venturi

tubes

5.55 6.5 Standard

NOTE

Observe stickers attached to Venturi tubes.

Propane P 3.40 4.15 Standard

Table 5 Gas-nozzle diameter

Controller setting Flow temperature [°C]

1 40

2 44

3 48

4 53

5 58

6 62

7 67

8 71

9 76

10 80

Table 6 Flow temperature

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 21

Initial start-up2

2.1.5 Adjusting the flow temperature

z Open the cover to the 2nd operating level (fig. 20, item 1).

z Adjust the knob (fig. 20, item 2) to the desired flow

temperature (table 6) for your particular installation.

NOTE

Factory setting of the controller is "10" (around 83 °C).

NOTE

If the flow temperature is set too low, there is the risc that an external hot water cylinder cannot achieve a comfortable enough temperature.

Fig. 20 Control box

Key to Fig. 20:

1: Cover for second operating level

2: Flow temperature knob

3: Heat-capacity jumper

4: Heating capacity knob

5: only used when boiler is in service mode

6: only used when boiler is in service mode

2.1.6 Setting the heating capacity

Set the heating capacity (table 7), according to the amount of heat required, at the controller (fig. 20, item 4).

NOTE The controller is factory-adjusted to position “6”

Controller

setting

Heating capacity [kW] (±5 %)

11 R 19 R 24 R

14.99.79.7

2 5.6 10.7 11.3

3 6.3 11.8 12.9

4 6.9 12.8 14.5

5 7.6 13.8 16.0

6 8.3 14.9 17.6

7 9.0 15.9 19.2

8 9.6 16.9 20.8

9 10.3 18.0 22.4

10 11.0 19.0 24.0

Table 7 Heating capacity

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22 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Initial start-up 2

2.1.7 Measure gas-supply pressure (flow pressure)

z Open at least one radiator thermostat valve.

CAUTION

The condensing gas boiler must not be activated at this stage.

z Make sure that the system pump is running.

z Turn the chimney-sweep switch (fig. 21, item 4) to

position “1”.

z Loosen the screw plug on the gas test nipple (fig. 22) by

two turns.

z Attach the pressure-gauge connection hose to the gas test

nipple (fig. 23).

z Slowly open the gas service valve.

z Turn the power switch (fig. 21, item 2) to position “I”.

The burner should ignite after about 30 seconds.

z Measure the gas connection pressure and note it down on

the report form.

The gas-connection pressure must be for natural gas H min. 17 mbar, max. 25 mbar, nominal connection pressure 20 mbar. for propane P min. 30 mbar, max. 50 mbar, nominal connection pressure 37 mbar.

z Detach the gauge-connection tube once more and close

the test nipple at the screw plug.

NOTE

If the required connection pressure is not available or too high, contact your gas supplier or TRANSCO.

Ensure all disturbed joints and connections are checked for gas tightness on completion of tasks.

Fig. 21 Mains switch, service button and chimney-sweep

switch

Fig. 22 Measure the gas connection pressure

2.1.8 Check the gas/air ratio and adjust as required

z Turn mains power switch (fig. 21, item 2) and chimney-

sweep switch (fig. 21, item 4) to “0”.

z Unscrew the sealing closure of the burner-pressure testing

nipple by one turn (fig. 22).

z Connect the positive port of the pressure gauge with a

hose to the burner pressure measuring nipple (fig. 23).

z Make sure that the system pump is running.

z Turn mains power switch to “I” and chimney-sweep switch

to “1”.

z If the burner has fired after approx. 30 seconds, keep the

service button (fig. 21, item 3) pressed until “Y” appears on the display.

z Turn the hot-water temperature controller (fig. 21, item 1)

Fig. 23 Check the gas/air ratio

to “1”.

z Read the differential pressure.

The differential pressure (p (±5 Pa = 0,05 bar) (display on measuring gauge: -10 Pa to

GAS–pAIR

) should total -5 Pa

0Pa).

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 23

Initial start-up2

z If the gas/air ratio does not conform to specifications,

readjust at the setscrew (fig. 23, item 1).

z Turn mains power switch and chimney-sweep switch to “0”.

z Remove the measuring equipment and retighten the screw

in the burner-pressure measuring nipple.

z Readjust the hot-water temperature controller to its original

setting.

z Turn the mains power switch to “I”.

2.1.9 Record readings

z Unscrew the corresponding sealing closure (fig. 24) on the

connection adapter for the combustion-air/flue-gas system and replace it once the measuring operation in question has been carried out.

Carbon monoxide content

CAUTION

The carbon monoxide values under vacuum must be smaller than 400 ppm or 0.04 Vol%. Values around or exceeding 400 ppm indicate a faulty burner adjustment, a dirty gas burner or heat exchanger, or a defective burner. Ensure that the cause of the fault is remedied immediately.

2.1.10 Function testing

NOTE

During initial start-up and annual servicing, make sure that all control, regulating and safety devices are in full working order and, if applicable, check for correct adjustment.

Measuring the ionisation current (fig. 25)

z Disconnect the system from the power supply.

z Loosen the plug-and-socket connector of the ionisation

electrode and connect the multimeter in series. On the measuring device, select the µ-direct current range. The measuring device must have a resolution of at least 1 µA.

z Make sure that the system pump is running.

z Reconnect the system to the power supply and turn the

chimney-sweep switch to “1”.

z Measuring the ionisation current. The ionisation current

being checked must measure >2 µA direct current.

z Enter the reading on the report form.

z Disconnect the system from the power supply.

z Remove multimeter and restore the plug-and-socket

connection to its original state.

z Turn the chimney sweep switch to position “0”.

z Reconnect the system to the power supply.

When the display shows “7” and the service button is pressed, the display turns to “c”. Press the Reset button. The display shows “r”.

Fig. 24 Measuring points on exhaust conduit

Key to Fig. 24:

1: Exhaust-fume temperature, CO

2: Combustion-air temperature

, CO, NO

Fig. 25 Measuring the ionisation current

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24 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Initial start-up 2

z Place the casing (see fig. 26, item 1).

z Tighten the fixing screw (see fig. 26, item 2).

2.1.11 Handing over

After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions:

z Hand the User Manual to the householder and explain

his/her responsibilities under the relevant national regulations.

z Explain and demonstrate the lighting and shutting down

procedures.

z 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 heating. 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.

z Explain the function and the use of the boiler heating

controls.

z Explain the function of the boiler fault mode. Emphasise

that if a fault is indicated, the boiler should be turned off and a registered local heating installer consulted.

z Explain and demonstrate the function of time and

temperature controls, radiator valves etc., for the economic use of the system.

Fig. 26 Place casing

Loss of system water pressure

z Explain that when there is a significant loss of pressure the

user should contact a Corgi registered installer.

WARNING

Do not fire the boiler if the pressure has reduced to zero from the original setting.

z After installation, commissioning and customer handover

instructions please complete the BENCHMARK appliance log book and leave this with the customer.

z IMPORTANT

A comprehensive service should be carried out annually. Stress the importance of regular servicing by a Corgi registered installer.

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 25

Inspection3

3 Inspection

3.1 Preparing the heating boiler for inspection

z Disconnect the system.

DANGER OF FATAL INJURY

due to electric shock when system is opened.

z Before opening the system:

disconnect the heating unit at the emergency OFF switch or the corresponding circuit breaker of the house power supply.

z Ensure that the heating system cannot be

reconnected by accident.

z Remove the burner housing or cover from the heating

boiler.

NOTE

If the gas supply pipes are to be disconnected from the burner, the housing MUST ONLY be removed by a qualified service technician and checked for tightness on reassembly.

For further information, please refer to subsection 8.2 "Inspection and maintenance reports" on page 54 and fill out the Benchmark.

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26 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Maintenance 4

4 Maintenance

For further information, please refer to subsection 8.2 "Inspection and maintenance reports" on page 54 and fill out the Benchmark.

4.1 Clean the heat exchanger, burner and condensate trap

NOTE

The cleaning of the burner and heat exchanger described here should be carried out whenever there are signs of heavy soiling on the wallmounted condensing gas boiler. It is sufficient, during annual servicing, to clean the burner and heat exchanger with the help of an appropriate cleaning product and a soft brush and compressed-air hose (see following section). The heat exchanger can be dismantled completely for thorough cleaning if required (see “Cleaning the heat exchanger after dismantling” on page 28).

Fig. 27 Loosen the union nut and remove the cable

4.1.1 Cleaning the heat exchanger without dismantling

z Disconnect the system from the power supply.

z Close the gas service valve.

z Loosen the fixing screws, remove casing and ventilation

cover.

z Release plug-in connection of fan power lead (fig. 27,

item 1), burner-control unit fan control lead (fig. 27, item 2) and gas-burner assembly (fig. 27, item 3).

z Loosen union nut on gas valve assembly (fig. 27, item 4).

z Push safety plate out of way.

z Turn air suction tube and pull off from below.

z Swivel the air combination unit forward (fig. 28, item 1).

z Pull the air combination unit up and out of bayonet

connector (fig. 28, item 2) and remove via front of unit.

z Remove burner gasket (fig. 29, item 1).

z Remove rubber seal in heat exchanger by pushing

upwards from inside (fig. 29, item 2).

Fig. 28 Remove the air combination unit

Fig. 29 Remove burner gasket and rubber seal

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 27

Maintenance4

z Remove heat exchanger by pulling upwards through the

opening (fig. 30).

NOTE

Maintain the specified clearance of approx. 25 cm between the ceiling and the ventilation cover.

z Remove the front of the heat exchanger. This is done by

releasing the four snap catches at the sides.

z Remove the hot surface ignitor (fig. 31, item 1) and

ionisation electrode (fig. 31, item 2). In the case of the hot surface ignitor: loosen the fixing screw of the hot surface ignitor, detach both earth (ground) leads and remove the retaining plate of the hot surface ignitor by pulling it upwards, withdraw the hot surface ignitor by pulling it upwards. In the case of the ionisation electrode: Swivel the retaining plate to one side and carefully remove the ionisation electrode by pulling it upwards.

z Clean the burner and both parts of the heat exchanger with

compressed-air or brush.

z Refit the heat exchanger by following the above procedure

in reverse order.

CAUTION

The gasket between the two halves of the casing shell should normally be replaced. Fit the new gasket by pressing in from the top on both sides, and without stretching. DO NOT attempt to cut the gasket to size.

Fig. 30 Remove burner

CAUTION

The burner gasket must match the shape of the groove in the housing.

CAUTION

Check the heat-exchanger for leaks BEFORE reassembling the casing shells.

4.1.2 Cleaning the heat exchanger after dismantling

z Disconnect the system from the power supply.

z Close the gas service valve.

z Loosen the retaining screw and remove the casing.

z Close the heating shutoff valves and drain the system.

CAUTION

Cut hot water on supply side by closing the heating shutoff valve.

Fig. 31 Remove the hot surface ignitor and ionisation

electrode

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

28 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Maintenance 4

To drain the boiler take the following steps:

z First drain the system.

z In case of frost, drain the boiler.

z Loosen the draining nipple with a screwdriver see fig. 32.

z Attach temporary hose to the nipple. Connect the other

side of the temporary hose to a draining pipe.

z When the boiler is drained then tighten the draining nipple

screw.

z Release plug-in connection of fan power lead (fig. 27,

item 1, page 27), burner-control unit fan control lead (fig. 27, item 2, page 27) and gas-burner assembly (fig. 27, item 3, page 27).

z Loosen union nut on gas valve assembly (fig. 27, item 4,

page 27).

z Push safety plate out of way.

z Turn air suction tube and pull off from below.

z Swivel the air combination unit forward (fig. 28, item 1,

page 27).

z Pull the air combination unit up and out of bayonet

connector (fig. 28, item 2, page 27) and remove via front of unit.

z Remove rubber seal in combustion chamber from top

(fig. 29, item 2, page 27).

Fig. 32 Draining the boiler

z Remove burner and burner gasket (fig. 29, item 1,

page 27) by pulling upwards through the opening (fig. 33, item 1).

z Remove the front of the heat exchanger by releasing the

four retaining clips (fig. 33, item 2).

z Remove the hot surface ignitor (fig. 31, item 1) and

ionisation electrode (fig. 31, item 2). In the case of the hot surface ignitor: Loosen the fixing screw of the hot surface ignitor, detach both earth (ground) leads and remove the retaining plate of the hot surface ignitor by pulling it upwards, withdraw the hot surface ignitor by pulling it upwards. In the case of the ionisation electrode: Swivel the retaining plate to one side and carefully remove the ionisation electrode by pulling it upwards.

z Remove securing pin on flow and return connection

conduit (fig. 34) of heat exchanger.

z Remove spiral heat exchanger by pulling towards front

(fig. 34). Drain any water remaining in the heat exchanger into the condensate trap.

Fig. 33 Remove burner and release retaining clips

Fig. 34 Securing pin on spiral heat exchanger

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 29

Maintenance4

z Remove the diffusion head (fig. 35, item 2) on the

underside of the heat exchanger by withdrawing the securing pin (fig. 35, item 1) and unscrewing the diffusion head.

z Clean the front and back cover of the heat exchanger and

the heat exchanger with water or compressed air.

z Clean the burner with compressed air only.

Take care not to damage the fins of the heat exchanger.

Refitting (fig. 36) :

NOTE

Excessive flue gas temperatures may be an indication of an incorrectly-fitted diffusion head.

z Screw the diffusion head in as far as it will go on the

underside of the heat exchanger (the final turn of the heat exchanger increases the clearance between the pipes) and insert securing pin.

CAUTION

Take care not to damage the insulation on the diffusion head.

z Check to ensure that the heat exchanger has been fitted

the right way round. The upper securing-pin groove must be horizontal (fig. 36, item 1).

z Refit the heat exchanger by following the above procedure

in reverse. Note the following:

z The gasket between the front and back cover of the heat

exchanger should normally be replaced. Fit the new gasket by pressing in from the top on both sides, and without stretching. DO NOT attempt to cut the gasket to size.

z Check the heat exchanger for leaks BEFORE

reassembling the front and back cover of the heat exchanger.

z Check O-ring seals (spiral), and replace as required.

z Smear the O-ring seal with a thin layer of silicone grease.

Fig. 35 Removing the diffusion head

Fig. 36 Refitting the heat exchanger

4.1.3 Cleaning the condensate trap

z Remove the trap and withdraw it from the outlet see fig. 37.

z Clean the condensate trap.

z Fill the condensate trap with water and then reassemble in

reverse order.

z Measuring the gas input pressure (flow pressure).

z Check the gas/air ratio.

z Leak test in operational condition.

z Measuring the carbon monoxide content.

z Carry out function testing.

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

30 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Fig. 37 Removing the condensate trap

Servicing 5

5 Servicing

5.1 Operating codes

NOTE

If the code displayed on the burner-control unit is not listed under the operating codes or fault warnings, the burner-control unit itself is malfunctioning.

Display Display after

pressing the service button

0 Buderus 600 - 11R / 19R / 24R is ready for operation

A Burner interval circuit, 10 min. from burner start-up

H Standby activated, Buderus 600 - 11R / 19R / 24R ready to provide heat

L Initial safety period: self-testing of burner-control unit during burner start-up

U Post- or pre-purging period of fan unit

Y Flow temperature over setpoint

-. Buderus 600 - 11R / 19R / 24R running in heating mode

Meaning

“Chimney-sweep” mode, flow-temperature controller bypassed, Buderus 600 - 11R / 19R / 24R heating to previously-entered flow temperature.

H Normal heating mode

Y Service mode

r Reset

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 31

Servicing5

5.2 Fault codes

Code Meaning

2C Safety sensor exceeds 95 °C

Possible cause

1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are clogged

2 Heating capacity is too large for the installation Adjust the heating capacity (see subsection 2.1.6)

3 Safety sensor is faulty Measure if resistance over the sensor is correct.

4 Problem with the pump or pump cabling (no circulation) Check if the pump cabling is faulty or if the pump is stuck

5 Water pressure is too low in the installation Top up the system

Code Meaning

2F Temperature difference between the safety sensor and flow sensor is greater than or equal to 15 °K

Possible cause

1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or

2 Safety sensor is dirty or faulty Check the safety sensor for dirt. Measure if resistance over

3 Flow sensor is dirty or faulty Check the sensor, replace if necessary (see subsection

4 Problem with the pump or pump cabling (no circulation) Check if the pump cabling is faulty or if the pump is stuck.

5 Water pressure is too low in the installation Top up the system

Action

with dirt.

If not replace safety sensor (see subsection 5.3.8, subsection 5.3.9, subsection 5.3.10)

Action

clogged with dirt

the sensor is correct. If not replace safety sensor (see subsection 5.3.8, subsection 5.3.9, subsection 5.3.10)

5.3.11, subsection 5.3.12, subsection 5.3.13)

Replace pump if necessary.

Code Meaning

2P Safety sensor rises faster than 5 °C/sec.

Possible cause

1 Heating capacity is too large for the installation Adjust the heating capacity (see subsection 2.1.6)

2 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or

3 Safety sensor is dirty or faulty Check the safety sensor for dirt. Measure if resistance over

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Action

clogged with dirt

the sensor is correct. If not replace safety sensor (see subsection 5.3.8, subsection 5.3.9, subsection 5.3.10)

32 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Servicing 5

Code Meaning

2U Temperature difference between flow and return more than 55 °C

Possible cause

1 Flow sensor is dirty or faulty Check the sensor, replace if necessary (see subsection

2 Problem with the pump or pump cabling (no circulation) Check if the pump cabling is faulty or if the pump is stuck.

3 Water pressure is too low in the installation Top up the system

4 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or

5 Safety sensor is dirty or faulty Check the safety sensor for dirt. Measure if resistance over

Code Meaning

3C Bad plug-in connection at cable harness, or damaged wiring

Possible cause

1 Cable harness is faulty Check cable harness for faults and bad connections

2 Connectors at the back of the UBA are loose or faulty Check the connectors at the back of the UBA

3 UBA might be faulty Check the UBA by temporarily connecting an other UBA

Action

5.3.11, subsection 5.3.12, subsection 5.3.13)

Replace pump if necessary.

clogged with dirt

the sensor is correct. If not replace safety sensor (see subsection 5.3.8, subsection 5.3.9, subsection 5.3.10)

Action

(see subsection 5.3.3)

Code Meaning

4A Flow sensor exceeds 100 °C

Possible cause

1 Flow sensor is dirty or faulty Check the sensor, replace if necessary (see subsection

2 There is a problem with the pump or pump cabling

(no circulation)

3 Water pressure is too low in the installation Top up the system

Code Meaning

4C F2 fuse malfunction, or flue gas thermostat active

Possible cause

1 Water pressure is too low in the installation Top up the system

2 Heat exchanger is dirty Check for a dirty heat exchanger and clean if necessary.

3 Flue gas retarder faulty or missing Check if the flue gas retarder is installed in the heat

4 Heat exchanger has a problem Purge heat exchanger

Action

5.3.11, subsection 5.3.12, subsection 5.3.13)

Check if the pump cabling is faulty or if the pump is stuck. Replace pump if necessary.

Action

(see subsection 4.1)

exchanger

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 33

Servicing5

Code Meaning

4F Safety sensor exceeds 95 °C

Possible cause

1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are clogged

2 Heating capacity is too large for the installation Adjust the heating capacity

3 Safety sensor is faulty Check the sensor and measure if resistance over the

4 Problem with the pump or pump cabling (no circulation) Check if the pump cabling is faulty or if the pump is stuck

5 Water pressure is too low in the installation Top up the system

Code Meaning

4L Short circuit in safety sensor

Possible cause

1 Safety sensor is faulty Check the sensor and measure if resistance over the

2 A short or bad connection in the cable harness Check the cable harness and/or connector of the sensor

3 UBA might be faulty Check the UBA by temporarily connecting a different UBA

Action

with dirt

sensor is correct. If not replace safety sensor (see subsection 5.3.8, subsection 5.3.9, subsection 5.3.10)

Action

sensor is correct. If not replace safety sensor (see subsection 5.3.8, subsection 5.3.9, subsection 5.3.10)

(see subsection 5.3.3)

Code Meaning

4P Safety sensor has a loose connection or is defective

Possible cause

1 Safety sensor faulty or disconnected Check the sensor and measure if resistance over the

2 A short or bad connection in the cable harness Check the cable harness and/or connector of the sensor

3 UBA might be faulty Check the UBA by temporarily connecting a different UBA

Code Meaning

4U Short circuit in flow sensor

Possible cause

1 Flow sensor is dirty or faulty Check the sensor, replace if necessary (see subsection

2 A short or bad connection in the cable harness Check the cable harness and/or connector of the sensor

3 UBA might be faulty Check the UBA by temporarily connecting a different UBA

Action

sensor is correct. If not replace safety sensor (see subsection 5.3.8, subsection 5.3.9, subsection 5.3.10)

(see subsection 5.3.3)

Action

5.3.11, subsection 5.3.12, subsection 5.3.13)

(see subsection 5.3.3)

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

34 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Servicing 5

Code Meaning

4Y Flow sensor interrupted

Possible cause

1 Flow sensor faulty or disconnected Check the sensor and measure if resistance over the

2 A short or bad connection in the cable harness Check the cable harness and/or connector of the sensor

3 UBA might be faulty Check the UBA by temporarily connecting a different UBA

Code Meaning

6A F1 fuse defective, or no ionisation message after ignition

Possible cause

1 There is no flame, ionisation electrode doesn’t

glow, fan is turning

2 There is no flame, ionisation electrode does

glow, fan isn’t turning

3 There is no flame, ionisation electrode and fan

are working

4 There is a flame, but the flame disappears

when the fan starts up

Action

sensor is correct. If not replace safety sensor (see subsection 5.3.11, subsection 5.3.12, subsection 5.3.13)

(see subsection 5.3.3)

Action

– Check wiring of the hot surface ignitor, measure the resistance

of the hot surface ignitor (should be between 50 and 300 Ohm). Replace hot surface ignitor if necessary (see subsection 5.3.14 and subsection 5.3.15)

– Check the UBA’s F1 fuse, replace if necessary

– Check the fan and KIM connectors and the UBA fuses

– Check and adjust the gas/air ratio (see subsection 2.1.8)

– Check for 24 V~ on the gas valve during start up

– Check the gas-supply pressure (see subsection 2.1.7), this

should be higher than 20 mbar for natural gas.

– Check the earthing cable connections

(yellow/green wire).

– Check the cabling on the ionisation electrode

– Check the gas-supply pressure (see subsection 2.1.7), this

should be higher than 20 mbar for natural gas.

– Check and adjust the gas/air ratio (see subsection 2.1.8)

– Check the earthing cable connections (yellow/green wire)

– Check the cabling on the ionisation electrode

– Press reset. If fault code remains than try to temporarily connect

a different UBA (see subsection 5.3.3)

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 35

Servicing5

Code Meaning

6C Ionisation message, but no flame

Possible cause

1 There is no flame, ionisation electrode doesn’t

glow, fan is turning

2 There is no flame, ionisation electrode does

glow, fan isn’t turning

3 There is no flame, ionisation electrode and fan

are working

4 There is a flame, but the flame disappears

when the fan starts up

Action

– Check wiring of the hot surface ignitor, measure the resistance

of the hot surface ignitor (should be between 50 and 300 Ohm). Replace hot surface ignitor if necessary (see subsection 5.3.14 and subsection 5.3.15)

– Check the UBA’s F1 fuse, replace if necessary

– Check the fan and KIM connectors and the UBA fuses

– Check and adjust the gas/air ratio (see subsection 2.1.8)

– Check for 24V – on the gas valve during start up

– Check the gas-supply pressure (see subsection 2.1.7), this

should be higher than 20 mbar for natural gas.

– Check the earthing cable connections (yellow/green wire).

– Check the cabling on the ionisation electrode

– The gas valve doesn’t close properly. If there is still more than

20 V~ on the gas valve when there is no heat demand then check the UBA by temporarily connecting a different UBA.

– Check ionisation electrode/circuit (see subsection 2.1.10 and

subsection 5.3.17)

– When both the UBA and the ionisation electrode/circuit are OK,

then replace the gas valve

– Press reset. If fault code remains than try to temporarily connect

a different UBA (see subsection 5.3.3)

Code Meaning

6H Flame dies out after gas valve is opened

Possible cause

1 Gas/air ratio not in order Check and adjust the gas/air ratio (see subsection 2.1.8)

2 Gas supply pressure may need adjusting Check the gas-supply pressure (see subsection 2.1.7),

3 Earthing cable may be faulty Check the earthing cable connections (yellow/green wire)

4 Ionisation electrode may be faulty Check the cabling on the ionisation electrode

Code Meaning

6L Flame goes out during warm-up phase

Possible cause

1 Gas/air ratio not in order Check and adjust the gas/air ratio (see subsection 2.1.8)

3 Earthing cable may be faulty Check the earthing cable connections (yellow/green wire)

4 Ionisation electrode may be faulty Check the cabling on the ionisation electrode

Gas supply pressure may need adjusting

Action

this should be higher than 20 mbar for natural gas

Action

Check the gas-supply pressure (see subsection 2.1.7), this should be higher than 20 mbar for natural gas

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36 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Servicing 5

Code Meaning

7A Voltage in burner-control unit too low (lower than 187 V~) or too high (higher than 246 V~)

Possible cause

1 Regulating device may have to cope with interference – Check if for example induction fields interfere with the

Code Meaning

7C Mains supply interrupted

Possible cause

1 A problem with the mains supply Check the mains supply during operation (230V~)

2 Reset button pressed too briefly Press the Reset button until "r" appears in the display

Action

regulating device

– Check if the are any peaks in the electrical network

caused by maybe windmills or a power generator

Action

Code Meaning

7F F3 fuse defect, or burner control unit error

Possible cause

1 Short circuit in the 24V circuit (three-way-valve or

connector)

2 Regulating device may have to cope with interference – Check if for example induction fields interfere with the

Code Meaning

7H Voltage peaks in the UBA

Possible cause

1 Regulating device may have to cope with interference – Check if for example induction fields interfere with the

Action

Check for a short circuit and replace the F3 fuse

regulating device

– Check if the are any peaks in the electrical network

caused by maybe windmills or a power generator

Action

regulating device

– Check if the are any peaks in the electrical network

caused by maybe windmills or a power generator

Code Meaning

7L Internal UBA error

Possible cause

1 Regulating device may have to cope with interference – Check if for example induction fields interfere with the

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 37

Action

regulating device

– Check if the are any peaks in the electrical network

caused by maybe windmills or a power generator

Servicing5

Code Meaning

8Y Gas fault

Possible cause

1 External switching contact (e.g. temperature-

monitoring device for underfloor heating has been tripped or gas pressure too low

Code Meaning

9A System error

Possible cause

1 Regulating device may have to cope with interference – Check if for example induction fields interfere with the

2 UBA may be defective Press reset. If fault code remains then try to temporarily

Action

Check gas pressure detector is defective or the wires have not been properly connected to the back of the UBA (see subsection 5.3.6)

Action

regulating device

– Check if the are any peaks in the electrical network

caused by maybe windmills or a power generator

connect a different UBA

Code Meaning

9C KIM error

Possible cause

1 Kim connected incorrectly or KIM defective Check the KIM connector and fan connector.

Code Meaning

9F/H System error

Possible cause

1 Regulating device may have to cope with interference – Check if for example induction fields interfere with the

2 UBA may be defective Press reset. If fault code remains then try to temporarily

Code Meaning

9L Gas valve assembly error

Possible cause

1 Wiring to the gas valve incorrect, or loose wiring

connections in UBA

2 UBA may be defective – Press reset. If fault code remains then try to temporarily

3 Peaks in the electrical network – Check if the are any peaks in the electrical network

Action

If the connectors are fine then contact Boulter Buderus

Action

regulating device

– Check if the are any peaks in the electrical network

caused by maybe windmills or a power generator

connect a different UBA (see subsection 5.3.3)

Action

– Check the electrical connections of the gas valve.

– Measure the resistance of the gas valve (18-55 Ohm)

– Check if for example induction fields interfere with the

regulating device

connect a different UBA (see subsection 5.3.3)

caused by maybe windmills or a power generator

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38 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Servicing 5

Code Meaning

9U KIM defective

Possible cause

1 Kim connected incorrectly or KIM defective Check the KIM connector and fan connector.

Code Meaning

E with any character but P

Possible cause

1 Regulating device may have to cope with interference – Check if for example induction fields interfere with the

2 UBA may be defective – Press reset. If fault code remains then try to temporarily

UBA defective

Action

If the connectors are fine then contact Boulter Buderus

Action

regulating device

– Check if the are any peaks in the electrical network

caused by maybe windmills or a power generator

connect a different UBA (see subsection 5.3.3)

Code Meaning

EP Non compatible UBA fitted

Possible cause

1 Regulating device may have to cope with interference – Check if for example induction fields interfere with the

2 Kim connected incorrectly or KIM defective – Check the KIM connector and fan connector. If the

Problem: No heating, despite that there is a demand for heat and the boiler is operational

– Check regulating device configuration and/ or the wiring

– Check the wiring between the regulating device and the UBA (see subsection 5.3.6)

– Check all the wiring

– Check the UBA and replace if necessary (see subsection 5.3.3)

Action

regulating device

– Check if the are any peaks in the electrical network

caused by maybe windmills or a power generator

connectors are fine then contact Boulter Buderus

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 39

Servicing5

5.3 Checking and replacing parts

5.3.1 Checking the flue gas sensor

z Detach plug-and-socket connection on cable to flue gas

sensor. Ensure that no cable is earthed (grounded) at any point.

z Allow the flue gas sensor to cool down. Activation

temperature: Buderus 600 - 11R / 19R / 24R: 105 °C

z Check flue gas sensor for continuity. If continuity is not

present, the flue gas sensor is defective.

z Replace any flue gas sensor found to be defective.

Ensure you use only genuine Boulter Buderus spare parts.

z If the flue gas sensor is working correctly, plug it in once

more.

5.3.2 Replacing the flue gas sensor

z Unscrew the flow-backup mounting.

z Detach the cable plug at the flue gas sensor.

z Loosen both retaining screws on the flue gas sensor.

z Remove the flue gas sensor and replace with a new unit

(fig. 38).

z Retighten the retaining screws.

z Reconnect the cable plug.

z Screw the mounting into place.

5.3.3 Replacing the UBA

z Disconnect the system from the power supply.

z Loosen the two screws on the UBA (fig. 39, item 1).

z Carefully turn the UBA around with the backside facing up

(fig. 40).

z Note the position of the cable plugs, disconnect all cable

plugs.

z Fit a new UBA.

z Reconnect all plug-in cables to their correct sockets.

z Turn the UBA around and place back onto the bracket.

z Tighten the two screws.

z Connect system to mains power supply.

Fig. 38 Buderus 600 - 11R / 19R / 24R :

replacing the flue gas sensor

Fig. 39 Replacing the UBA

Fig. 40 Backside of the UBA

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40 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Servicing 5

5.3.4 Checking the fan

z Set the mains switch to “0”.

z Disconnect the fan's plug and socket connection.

z Connect a multimeter (230 V AC).

z Turn the mains power switch to “I”.

z Take voltage reading at measuring device.

If the voltage reading is 230 V, the power supply is in order.

z Set the mains switch to “0”.

z If the power supply is in order, plug the unit in once more.

z Turn the mains power switch to “I”.

z If the fan now fails to run, it must be replaced.

z If the fan runs at only partial load (i.e. effective operation of

the boiler is not possible), troubleshooting should start at the connection cable to the UBA or UBA.

5.3.5 Replacing the fan

Fig. 41 Checking the fan

z Shut the gas valve.

z Disconnect the system from the power supply.

z Disconnect the fan, using the plug and socket from the

power supply (fig. 42, item 1), loosen the UBA control line at the fan (fig. 42, item 2) and the gas burner fitting (fig. 42, item 3).

z Loosen the union nut (fig. 42, item 4) on the gas burner

fitting.

z Push the safety plate out of the way (fig. 43, item 1).

z Turn air suction tube and pull off from below.

Fig. 42 Replacing the fan on the 600 Series:

loosen plug and union nut

Fig. 43 Replacing the fan on the 600 Series:

remove the air suction tube

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 41

Servicing5

z Swivel the gas combination unit forward (fig. 44, item 1)

z Remove the gas combination unit from its bayonet

connector and pull upwards to detach (fig. 44, item 2).

z Detach the fan by loosening the 2 x 2 screws on the

connection unit.

z Replace the fan.

z Refit by following the above procedure in reverse.

Fig. 44 Replacing the fan on the 600 Series:

remove the gas connection unit

NOTE

Once installation has been completed successfully, carry out leak testing as per subsection 2.1.1.

5.3.6 Checking the wiring connections of the UBA

z Disconnect the system from the power supply.

z Loosen the two fixing screws and carefully turn the UBA

around (fig. 39, item 1, page 40).

z Check all cable terminals for tightness and

resecure/retighten as required.

z Turn the UBA around and place back onto the bracket.

z Tighten the two screws.

z Connect system to mains power supply.

Fig. 45 Replacing the fan on the 600 Series:

replace the fan

Fig. 46 Checking the wiring connections of the UBA

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42 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Servicing 5

5.3.7 Checking the miniature fuses

z Disconnect the system from the power supply.

z Loosen the two fixing screws and carefully turn the UBA

around.

z Check miniature fuses (fig. 47) for correct functioning,

or carry out visual inspection. If defective, fit new fuse (1.25 AT).

Fuse Function

1 Hot surface ingitor

2 UBA, sensors, thermostat valve

3UBA

z Turn the UBA around and place back onto the bracket.

z Tighten the two screws.

z Connect system to mains power supply.

5.3.8 Checking the safety sensor

z Unplug cable connection from sensor.

z Measure resistance of sensor (fig. 48, item 1).

z Use a second-reading thermometer to measure the

temperature around the sensor.

z Compare readings with values shown in table 8 on

page 44. If there is any mismatch (i.e. > 5%), the sensor is defective.

z If the sensor is working correctly, plug it in once more.

Fig. 47 Checking the miniature fuse

Fig. 48 Buderus 600 - 11R / 19R / 24R:

checking the safety sensor

5.3.9 Replacing the safety sensor

z Shut the servicing valve.

z Drain the Buderus 600 - 11R / 19R / 24R as per the

"Installation and Servicing Instructions".

z Loosen the plug-in connection (fig. 49, item 1).

z Unscrew the sensor (fig. 49, item 2) and replace with a new

unit.

z Plug in cable connection.

z Open servicing valves.

NOTE

Fill the Buderus 600 - 11R / 19R / 24R and purge the system of air.

Fig. 49 Buderus 600 - 11R / 19R / 24R:

replacing the safety sensor

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 43

Servicing5

5.3.10 Checking the safety sensor connection lead

Check to ensure that all plug-in connections on the sensor and UBA are in order. Note that an incorrectly-inserted plug can lead to the generation of error messages. Start up the boiler by pressing the “reset” button.

z Set the mains switch to “0”.

z Disconnect the system from the power supply.

z Unplug cable connection from flow sensor.

z Disconnect 18-pin plug from UBA.

z Use a continuity tester to check the cable between the

plug-in connection and the 18-pin plug in the UBA. The test should be carried out on connections 06-18 and 08-18 (fig. 50).

z If the cables are in order, plug them in.

z Connect system to mains power supply.

z Turn the mains power switch to “I”.

Fig. 50 Buderus 600 - 11R / 19R / 24R:

checking the safety sensor connection lead

5.3.11 Checking the flow sensor

z Unplug cable connection from sensor.

z Measure resistance of sensor (fig. 51, item 1).

z Use a second-reading thermometer to measure the

temperature around the sensor.

z Compare readings with values shown in table 8. If there is

any mismatch (i.e. > 5%), the sensor is defective.

z If the sensor is working correctly, plug it in once more.

Fig. 51 Buderus 600 - 11R / 19R / 24R:

checking the flow sensor

Temp.

[°C]

029,490

5 23,462 55 3,271.0

10 18,787 60 2,760.0

15 15,136 65 2,339.0

20 12,268 70 1,990.0

25 10,000 75 1,700.0

30 8,197 80 1,458.0

35 6,754 85 1,255.0

40 5,594 90 1,084.0

45 4,656 95 1,939.6

50 3,893 100 1,817.2

Table 8 Resistance values for hot water / boiler sensor

Resistance

[Ω]

(approximate values)

Temp.

[°C]

Resistance

[Ω]

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

44 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Servicing 5

5.3.12 Replacing the flow sensor

z Shut the servicing valve.

z Drain the Buderus 600 - 11R / 19R / 24R as per the

"Installation and Servicing Instructions".

z Loosen the plug-in connection (fig. 52, item 1).

z Unscrew the sensor (fig. 52, item 2) and replace with a new

unit.

z Plug in cable connection.

z Open servicing valves.

NOTE

Fill the Buderus 600 - 11R / 19R / 24R and purge the system of air.

5.3.13 Checking the flow sensor connection lead

z Set the mains switch to “0”.

z Disconnect the system from the power supply.

z Unplug cable connection from flow sensor.

z Disconnect 20-pin plug from UBA.

z Use a continuity tester to check the cable between the

plug-in connection and the 20-pin plug in the UBA. The test should be carried out on connections 05-20 and 18-20 (fig. 53).

z If the cables are in order, plug them in.

z Connect system to mains power supply.

z Turn the mains power switch to “I”.

Fig. 52 Buderus 600 - 11R / 19R / 24R:

replacing the flow sensor

UBA

Fig. 53 Buderus 600 - 11R / 19R / 24R:

checking the flow sensor connection lead

5.3.14 Checking the hot surface ingitor

z Disconnect the system from the power supply.

z Loosen the two fixing screws and carefully turn the UBA

around.

z Unplug and remove hot surface ingitor from UBA housing

(fig. 54).

z Check hot surface ingitor for free throughput.

If throughput is free, the hot surface ingitor is in order.

z If the hot surface ingitor is in order, plug the cable into the

UBA housing.

z Turn the UBA around and place back onto the bracket.

z Tighten the two screws.

z Connect system to mains power supply.

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 45

Fig. 54 Checking the hot surface ingitor

Servicing5

5.3.15 Replacing the hot surface ingitor

z Disconnect the system from the power supply.

z Remove burner cover.

z Remove the earth (ground) lead from the hot surface

ingitor (fig. 55, item 1).

z Loosen the two screws on the UBA and carefully turn the

UBA around with the backside facing up.

z Unplug hot surface ingitor connection cable from UBA

(fig. 56).

z Loosen nut on clamp used to secure earth (ground) lead

(fig. 55, item 2).

z Detach retaining plate of hot surface ingitor (fig. 55, item 3)

and remove hot surface ingitor.

Fig. 55 Replacing the hot surface ingitor

5.3.16 Measuring the ionisation current

z Disconnect the system from the power supply.

z Loosen the plug-and-socket connector of the monitoring

cable and connect the measuring device in series. Select the µA direct current range on the multimeter. The multimeter must have a resolution of at least 1 µA.

z Reconnect the system to the power supply, make sure that

the system pump is running and turn the chimney-sweep switch to “1”.

z Measure the ionisation current.

The ionisation current must be > 2 µA DC.

z Enter the reading on the report form.

z Disconnect the system from the power supply.

z Remove the measuring device and restore the

plug-and-socket connection to its original state.

z Turn the chimney-sweep switch to position “0”.

z Refit the cover for 2nd operating level.

z Reconnect the system to the power supply. When the

display shows “7”, press the service button to display “c”. Press the "reset" button. The display shows “r”.

Fig. 56 Disconnect the plug-in cable from the UBA housing

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

46 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Servicing 5

5.3.17 Replacing the ionisation electrode

z Remove the air combination unit.

z Loosen the plug-and-socket connection of the ionization

electrode.

z Loosen screw (fig. 57, item 1) by a half-turn and slide bar

to remove.

z Pull electrode to remove, and fit new unit.

z Reassemble by following the above procedure in reverse.

Fig. 57 Replacing the ionisation electrode

5.3.18 Checking KIM connections

z Locate Kim on the side of the UBA bracket.

z Check if 4 pin connector (fig. 58, item 1) is fitted and

secure.

NOTE

This is not a servicable part and any fault identified with this component, contact Boulter Buderus.

Fig. 58 KIM connections

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 47

Conversion to another type of gas6

6 Conversion to another type of gas

WARNING!

Work on components in contact with gas must only be carried out by a registered CORGI engineer.

Switch off the heating boiler

z Disconnect the system from the power supply.

z Close the gas service valve.

z Loosen the 4 crosshead screws on the ventilation cover

(fig. 59).

z Remove the ventilation cover.

Fig. 59 Unscrew ventilation cover

z Loosen union nut on gas valve assembly (fig. 60, item 4).

z Release plug-in connection of fan power lead (fig. 60,

item 1), burner-control unit fan control lead (fig. 60, item 2) and gas-burner assembly (fig. 60, item 3).

z Push safety plate out of way (fig. 61, item 1).

z Turn air suction tube and pull off from below.

Fig. 60 Loosen the union nut and remove the cable

Fig. 61 Remove safety plate

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48 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Conversion to another type of gas 6

sz Swivel the air combination unit forwards (fig. 62, item 1).

z Pull the air combination unit up and out of the bayonet

connector (fig. 62, item 2) and remove via the front of the unit.

Type of gas

supply

Natural gas H (G20)

Propane P 3.40 4.15 Standard

Table 9 Gas-nozzle diameter

Replacing a gas nozzle

WARNING!

Conversion to another gas type is implemented by installing/removing a gas nozzle (fig. 63, item 3) of the appropriate gas nozzle diameter (table 9).

z Undo the three screws (fig. 63, item 2) on the long side of

the gas fitting.

z Remove the gas nozzle and insert the correct gas nozzle

for the new gas type.

z Insert new seal (fig. 63, item 4).

z Remount all components in the reverse sequence.

z Cover stickers (fig. 64, item 1) with the new stickers

(2 pieces, included in conversion kit).

Gas nozzles ∅ [mm]

11R 19R/24R

5.55 6.5 Standard

Venturi

tubes

Fig. 62 Remove the air combination unit

Starting up

z Start up the appliance following the procedure described in

the mounting and maintenance instructions.

z Include all seal areas concerned during mounting in the

gas-tightness check when in operation.

z Refit all covers.

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Fig. 63 Replacing a gaz nozzle

Fig. 64 Place new stickers

Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 49

Appendix7

7 Appendix

7.1 Technical specifications

Dimensions Unit

Type of gas supply as established in EN 437 (GB)

Rated heating capacity for system temperature (modulating from 30° to 100°) Heating curve 75/60 °C Heating curve 40/30 °C

Seasonal efficiency (SEDBUK) % 90.3 90.3 90.2

Central heating installation

Heating water temperature °C 40 - 80

∆T at residual head of 200 mbar K <20

Max. operating overpressure of boiler bar 3.0

Volume heat exchanger heating circuit l 1.0

Pipe connections

Gas G½" (outside) / R½" (inside)

Heating water G¾" (device) / Ø 22 mm (accessory)

kW kW

600 Series Buderus wall-mounted condensing gas boiler

11R 19R 24R

GB II

(natural gas H, propane P)

4.3 - 10.0

4.9 - 11.0

20 mbar, 37 mbar

2H3P

8.6 - 17.4

9.7 - 19.0

8.6 - 22.0

9.7 - 24.0

Condensate-water outlet mm Ø 21.5

Flue gas values

Condensate water quantity, natural gas, 40/30 °C

pH value of condensate water approx. 4.1

Flue gas mass-flow rate Full load Part-load

Flue gas temperature, full load Heating curve 75/60 °C Heating curve 40/30 °C

Flue gas temperature, part-load Heating curve 75/60 °C Heating curve 40/30 °C

full load, natural gas

standard test gas G20 % 9.2

full load, natural gas

standard test gas G31 propane % 10.3

Standard emission factor CO mg/kWh <22

Standard emission factor NO

Max. pressure drop permitted Pa 35 60 100

l/h 0.7 1.3 1.6

g/s g/s

°C °C

mg/kWh <30

4.9

2.2

75 50

65 40

8.4

4.3

85 55

70 45

10.6

4.3

95 55

70 45

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50 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Appendix 7

Dimensions Unit

Flue-gas system

Type of flue gas connection C

Diameter of flue gas system mm 60/100

Electrical data

Mains connection voltage V 230

Electrical power consumption Full/Part load W 40/25 40/25 40/25

Electrical protection rating IPX4D

Boiler dimensions and weight

Height x Width x Depth mm 700 x 460 x 290

Weight (without casing) kg 23.5 23.5 23.5

Casing kg 5.5 5.5 5.5

600 Series Buderus wall-mounted condensing gas boiler

11R 19R 24R

, C33, C

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 51

Appendix7

7.2 Short list of spare parts

The following are parts commonly required due to damage or expendability. Their failure or absence is likely to affect safety or performance of this appliance. For a pictorial representation of the part see the respective position number on the exploded view pictures on page 10.

Pos. Art. no. Description

10 75131 Casing complete 20 75130 Door 30 38470 Ventilation cover 40 38092 Bracket 50 77465 Concentric adaptor 60 38496 Clip adaptor 70 77464 Lipring 100 mm 80 73366 Fan 90 73565s Sealing fan / venturi (set of 5 pieces)

73566s Sealing ventilator (set of 5 pieces) 100 73563 Lipring 60 mm 110 73743 Flue gas pipe 120 73630 Condensate collector 130 73579 Seal flue gas pipe 140 73376 Flue gas sensor 150 75969 Condensate trap 160 73573 Suction pipe 170 73574 Lipring 50 mm 180 73278 Gas valve 190 38355 Rectifier 200 73567 Venturi 11 kW 200 73568 Venturi 19-24 kW 210 76680 Gas pipe 220 76681 Gas service valve 230 75968s Pipe return-flow top (set of 2 pieces) 240 75970 Pipe connection

75971 Drain pipe condensate trap 250 38602s Clip sanitary pipe (set of 5 pieces) 260 75966 Return pipe 270 75967 Drain cock 280 73583 Connection return 290 38352 Sensor 300 75965 Flow pipe 310 73581 Connection supply

320 73582s

330 38618 Automatic air vent 340 73580s O-ring (set of 10 pieces) 350 73584s Lipring (set of 2 pieces) 360 38323 Safety sensor 370 38478s Sealing ring (set of 10 pieces) 380 73611 Backpart heat exchanger 390 73578 Seal heat exchanger 400 73514 Insulation backpart heat exchanger 410 73593 Burner 11 kW 410 Burner 19 kW 410 73594 Burner 24 kW 420 73571s Sealing burner (set of 5 pieces)

Hairpin heat exchanger (set of 2 pieces)

Pos. Art. no. Description

430 73612 Heat exchanger helix 440 73587 Combustion divider 450 73513 Insulation front heat exchanger 460 73610 Frontpart heat exchanger 470 38009 Sight glass 470 73576 Sight glass 480 75132s Fasteners (set of 2 pieces) 490 38324 UBA 500 38340 Mains switch 510 78105 Hot surface ignitor 520 38320 Ionisation electrode 530 73367 Cable fan 540 78109 Cable harness 560 78079 RTH converter 230V 550 - Frame

78110 Kim 163 (11 kw) 78111 Kim 164 (19 kw)

78112 Kim 165 (24 kw) 36404s Plate screw (set of 10 pieces) 36406s Screw 6x5/8" (set of 5 pieces)

38456 Seal ventilation cover 38458s Assembly casing block (set of 2 pieces) 38460s Casing clamp (set of 5 pieces) 38462s Air seal bush (set of 5 pieces) 38463s Air seal bush (set of 4 pieces)

38474s

38475s Clip (set of 5 pieces)

73591s

79058s Pull relief (set of 5 pieces) 79084s Sealing ring (set of 2 pieces)

75300 Thermomanometer 73572s Screw M5 ( set of 10 pieces)

73054

73515 Insulation divider

73560 Cap 73586s Seal

73053 Clip suction pipe

73570 Gas air supply 73056s Clip (set of 5 pieces) 73368s Sealing ignitor (set of 10 pieces) 73488s Gasket (set of 5 pieces) 73569s Sealing venturi / gasket

75301 230V cable

75882 Swivel dreg with pinchring

73561 Sealing

Clip CH tank (2) / clip sensorhousing (2)

O-ring condensate trap (set of 5 pieces)

Bracket ionisation electr. and glow ignitor

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52 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Reports 8

8Reports

8.1 Start-up report

z Please check off the start-up tasks carried out and enter

the corresponding readings.

Initial start-up tasks Remarks or measurement readings

1. Note down gas characteristics:

Wobbe index Operating heat value

2. Inspect to check for leaks (See section 2.1.1 on page 20)

3. Check combustion air/flue gas connection (See section 2.1.3 on page 21)

4. Checking the boiler equipment (change to another type of gas if necessary) (See section 2.1.4 on page 21)

5. Carry out adjustment settings (See section 2.1.5 on page 22)

6. Measure the gas connection pressure (flow pressure) (See section 2.1.7 on page 23)

7. Checking and adjusting the gas/air -ratio

-content: at full load

(See section 2.1.8 on page 23)

8. Leak test in operational condition

9. Measure carbon monoxide content (CO), vacuum (See section 2.1.9 on page 24)

at part load

_____________________ kWh/m _____________________ kWh/m

_____________________ mbar

_____________________ Pa

_____________________ % _____________________ %

_____________________ ppm

10. Function testing

Measuring the ionisation current (See section 2.1.10 on page 24)

11. Fit the boiler casing

12. Instruct the user. Fill in Benchmark log book. Hand over documentation. (See section 2.1.11 on page 25)

13. Confirm initial start-up

Confirmation of initial start-up by qualified service technician

(Company stamp, signature)

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 53

_____________________ µA

Reports8

8.2 Inspection and maintenance reports

The inspection and maintenance reports provide an overview of all the tasks and operations carried out.

See also Section 3: "Inspection“ on page 26 or Section 4: "Maintenance“ on page 27.

Inspection tasks Date: _____________ Date: _____________

1. Check general state of system

2. Visual inspection and function check of system

3. Check gas- and water-bearing components for:

- leaks;

- signs of corrosion;

- signs of ageing.

4. Take system out of service and check the burner, heat exchanger and siphon for signs of dirt and soiling. (See section 4.1.1 on page 27)

5. Check the burner, hot surface ignitor and ionisation electrode, after disconnecting the system. (See section 4.1.1 on page 27)

Please check off the inspection and/or requirement-related maintenance tasks carried out and enter the corresponding readings.

z Sign details of inspection and maintenance tasks,

indicating date carried out.

Use only original replacement parts.

6. Measuring the ionisation current (See section 2.1.10 on page 24) _________________ µA _________________ µA

7. Measure the gas connection pressure (flow pressure) (See section 2.1.7 on page 23) ________________ mbar ________________ mbar

8. Check the gas-air ratio (See section 2.1.8 on page 23) _________________ Pa _________________ Pa

9. Gas leak test in operational condition (See section 2.1.1 on page 20)

10. Measure the carbon monoxide content (CO), vacuum (See section 2.1.9 on page 24) ________________ ppm ________________ ppm

11. Pressure-testing of heating system:

- admission pressure of expansion tank

(see installation instructions supplied with expansion tank)

- Filling pressure

12. Check ventilation and flue gas conduits for correct functioning and safety

13. Check requirement-related adjustment settings of control device (see documentation supplied with control device)

14. Final check of inspection tasks, with record kept of measurement readings and test results

________________ mbar

15. Confirm inspection carried out by qualified service engineer and fill out the Benchmark

Company stamp / Date / Signature)

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54 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Reports 8

Date: _________ Date: ___________ Date: ___________ Date: ___________ Date: ___________

_______________ µA _______________ µA _______________ µA _______________ µA _______________ µA

_____________ mbar _____________ mbar _____________ mbar _____________ mbar _____________ mbar

_______________ Pa _______________ Pa _______________ Pa _______________ Pa _______________ Pa

______________ ppm ______________ ppm ______________ ppm ______________ ppm ______________ ppm

_____________ mbar

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 55

Reports8

Requirement-related maintenance tasks Date: _____________ Date: _____________

1. Clean heat exchanger, burner and condensate trap (See section 4.1 on page 27)

2. Check and adjust the gas-air ratio

-content: at full load

at part load

(See section 2.1.8 on page 23)

3. Confirm servicing work Confirmation of servicing carried out by qualified technician

Company stamp, signature)

______________________

% %

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56 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Reports 8

Date: ___________ Date: ___________ Date: ___________ Date: ___________ Date: ___________

___________________

____________________

___________________

____________________

___________________

____________________

___________________

____________________

___________________

____________________

% %

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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 57

Notes

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58 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004

Notes

Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk

Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 59

Heating system specialist:

Boulter Buderus Ltd.

Magnet House

30 Whitehouse Road

Ipswich

Suffolk, IP1 5JA

Telephone: 01473 241555

Fax: 01473 241321/463411

http://www.boulter-buderus.co.uk

e-mail: info@boulter-buderus.co.uk

721.229A - 4066 - 05/2004

Buderus 600-19R, 600-11R, 600-24R, 600 Series, 11R Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Installation

1.1 Dimensions and connections

1.2 Boiler assembly - exploded view

1.3 Flue Installation

1.3.1 Siting the flue terminal

1.3.2 Air supply and flue gas exhaust in a closed installation

1.3.3 Maximum Flue length

1.3.4 Additional flue parts

1.4 Items supplied with unit

1.5 Transport

1.6 Pipe connections

1.6.1 Gas Supply

1.6.2 Gas connection

1.6.3 Heating system connections

1.6.4 Condensate drain

1.7 Flue installation

1.7.1 Connecting the vertical flue gas duct

1.7.2 Installation of the horizontal flue

1.7.3 Flue duct preparation and assembly

1.8 Electrical connections

1.8.1 Mains connection

1.8.2 Wiring Diagram

1.9 Timing and temperature control

1.9.1 230V Room-temperature control device connection

1.9.2 Volt free room-temperature control device connection

2 Initial start-up

2.1 Preparing the boiler for operation

2.1.1 Checking for leaks

2.1.2 Purging air from the gas supply system

2.1.3 Check combustion air/flue gas connection

2.1.4 Checking the type of gas and supply

2.1.5 Adjusting the flow temperature

2.1.6 Setting the heating capacity

2.1.7 Measure gas-supply pressure (flow pressure)

2.1.8 Check the gas/air ratio and adjust as required

2.1.9 Record readings

2.1.10 Function testing

2.1.11 Handing over

3 Inspection

3.1 Preparing the heating boiler for inspection

4 Maintenance

4.1 Clean the heat exchanger, burner and condensate trap

4.1.1 Cleaning the heat exchanger without dismantling

4.1.2 Cleaning the heat exchanger after dismantling

4.1.3 Cleaning the condensate trap

5 Servicing

5.1 Operating codes

5.2 Fault codes

5.3 Checking and replacing parts

5.3.1 Checking the flue gas sensor

5.3.2 Replacing the flue gas sensor

5.3.3 Replacing the UBA

5.3.4 Checking the fan

5.3.5 Replacing the fan

5.3.6 Checking the wiring connections of the UBA

5.3.7 Checking the miniature fuses

5.3.8 Checking the safety sensor

5.3.9 Replacing the safety sensor

5.3.10 Checking the safety sensor connection lead

5.3.11 Checking the flow sensor

5.3.12 Replacing the flow sensor

5.3.13 Checking the flow sensor connection lead

5.3.14 Checking the hot surface ingitor

5.3.15 Replacing the hot surface ingitor

5.3.16 Measuring the ionisation current

5.3.17 Replacing the ionisation electrode

5.3.18 Checking KIM connections

6 Conversion to another type of gas

7 Appendix

7.1 Technical specifications

7.2 Short list of spare parts

8Reports

8.1 Start-up report

8.2 Inspection and maintenance reports