Buderus Buderus 600 - 28C INSTALLATION AND SERVICING INSTRUCTIONS (7212 7900 - 07/2009 GB/IE (en))
7212 7900 - 07/2009 GB/IE (en) For the installer
Installation and servicing
instructions
Gas wall hung Boiler condensing
Buderus 600 - 28C
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.
CE Declaration of Conformity
The design and operation of this product conform to European Directives and the supplementary national requirements.
Conformity is demonstrated by the CE designation.
You can view the Declaration of Conformity regarding this product on the internet at www.buderus.de/konfo or www.buderus.com or
request a copy from your local Buderus sales office.
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.
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
2 Installation and servicing instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Contents
1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Dimensions, connections and assembly . . . . . . . . 6
1.2 Boiler assembly - exploded view . . . . . . . . . . . . . . 7
1.3 Flue Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Items supplied with unit . . . . . . . . . . . . . . . . . . . . 10
1.5 Hanging the boiler . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Water circulation system . . . . . . . . . . . . . . . . . . . 11
1.7 Pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.9 Electrical connections. . . . . . . . . . . . . . . . . . . . . . 16
1.10 Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Preparing the boiler for operation. . . . . . . . . . . . . 21
3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 General directions . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Preparing the boiler for inspection . . . . . . . . . . . . 31
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1 Cleaning the heat exchanger and burner . . . . . . . 32
4.2 Cleaning the condensate trap . . . . . . . . . . . . . . . 35
4.3 Flushing the hot water tank . . . . . . . . . . . . . . . . . 36
5 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3 Short list of spare parts . . . . . . . . . . . . . . . . . . . . 66
Preface
These installation and servicing instructions apply to:
Buderus gas wall hung boiler condensing 600 - 28C.
Model C13, C33, C
Type GB/IE II
In this document: NG = 2H-G20-20 mbar
Power rating 230 VAC, 50 Hz, IPX4D
Fuse rating: 5 AF sand filled
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, sealed
water systems ONLY. Adequate arrangements for completely
draining the system by provision of draining valves must be
provided in the installation pipework.
Pipework from the boiler is routed downwards as standard, but
may be routed upwards behind the boiler using the distance
frame (supplied in a separate kit).
53
20 mbar, 37 mbar
2H3P
LPG = 3P-G31-37 mbar
G. C. Aplliance No. :
Buderus 600 - 28C 47-110-02
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.
BENCHMARK' Log Book
All 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 for gas wall hung boiler condensing Buderus 600-28C • 07/2009 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, water regulations, the
building regulations and the Building Standards (Scotland) and
any relevant requirements of the local authority.
It is a requirement and in your own interest, and that of safety
that this boiler must be installed by a CORGI registered
installer, in accordance with the relevant requirements of the
current Gas Safety (Installation and Use) Regulations, The
Building Regulations, current I.E.E. Wiring Regulations and
the relevant British Standard Codes of Practise.
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.
NOTE
For optimum, long-term reliable functioning of
the heating boiler, and in order to be able to
claim under the terms of the manufacturer's
warranty, the heating boiler must be inspected
and maintained at least once a year (under
normal operating conditions) by an officially
recognized installation and service engineer.
The term "normal operating conditions" means
that the heating boiler is used to provide
central heating and/or hot water to no more
than one single-family dwelling.
In all other cases, the heating boiler must be
inspected and maintained by an officially
recognised installation service engineer every
2,500 burner operating hours.
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.
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 gas wall hung
boiler condensing 600 - 28C 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.
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.
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
4 Installation and maintenance instructions gas wall hung boiler condensing Buderus 600-28C • 07/2009
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.
Gas wall hung boilers condensing 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.
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 Sentinel X100 to fill
and top up the system.
When using water treatment, only products
suitable for use with 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
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 inhibitors, 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.
NOTE:
Notes relating to domestic hot water.
z The domestic hot water service must be in
accordance with BS 5546 and BS 6700.
z The boilers are suitable for connection to
most types of washing machine and
dishwasher appliances.
z When connecting to suitable showers,
ensure that:
a. The cold inlet to the boiler is fitted with
an approved anti-vacuum or
condensate trap non-return valve.
b. Hot and cold water supplies to the
shower are of equal pressure.
z Where the water hardness exceeds
150 mg/litre, it is recommended that a
proprietary scale reducing device is fitted
into the boiler cold supply with the
requirements of the local water company.
CAUTION
Provision must be made to accommodate the
expansion of DHW contained within the
appliance, if a non-return valve is fitted to the
DHW inlet, as detailed in BS. 67989: §5.4.3.
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.
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 5
Installation1
1 Installation
1.1 Dimensions, connections and assembly
>100 mm (4")
240 (9½")
850 mm (33½")
(excentrical connections)
480 mm (19")
6
¯
(Ø80mm / 125mm)
(Ø3" / 5")
120-130
5" - 5½"
8
>100 mm (4")
370 mm (14½")
186 mm (7¼")
6
(Ø80mm / 125mm)
(Ø3" / 5")
>500 (20") for expansion
vessel disassembly
>200 (8") for burner
disassembly
7
65
(2½")65(2½")65(2½")
13
1. CH flow Ø 22 mm (compression fitting)
2. CH return Ø 22 mm (compression fitting)
3. DHW hot Ø 15 mm (compression fitting)
4. DHW cold Ø 15 mm (compression fitting)
5. Gas connection Ø 22 mm (compression fitting)
6. Air supply Ø 80 or Ø 125 mm socket
7. Condensate drain G1 "
8. Safety valve R¾" (¾"-½" adaptor supplied with boiler)
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
6 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
65
(2½")
542
100 (4")
7
8
1-2-5
3-4
95 (3.7")
50 (2")
35 (1½")
NOTE
See wall-mounting template for
the necessary clearances.
1.2 Boiler assembly - exploded view
Combi unit (Buderus 600 - 28C)
Installation 1
32
25
28
27
26
24
30
31
29
40
33
35
36
37
47
89
50
46
12
48
49
17
51
84
88
13
14
8
15
7
19
16
18
Legend
1. Casing (incl. insulation)
2. Door control panel
3. Ventilation cover
4. Seal ventilation cover
5. Latches
6. Assembly casing block
7. Insulation frame
8. Bracket
9. Seal top
10. Seal bottom
11. Seal
12. Cover flue gas adaptor
13. Flue gas adaptor
14. Seal 60 mm
15. Exhaust pipe
9
16. Seal 60 mm
41
44
42
43
6
45
52
4
3
20
5
21
23
85
22
11
17. Condensate collector
18. Flue gas sensor
19. Seal exhaust pipe
20. Condensate trap
10
21. Drain pipe condensate trap
22. Syphon
23. Flex. drain pipe condensate trap
24. Flow connection piece
25. Automated air vent
26. Bi-sensor
27. Sealing
79
1
2
61
53
87
59
57
76
55
54
56
86
63
64
62
65
60
58
80
81
78
62
75
73
72
67
66
74
71
69
68
67
83
28. O-ring
29. Supply pipe
30. Clip
31. Service set GLE complete
32. Ignition unit
33. Ionisation electrode
34. Seal
35. Seal
36. Gas/air supply valve
82
37. Seal fan
38. Seal burner
70
39. –
40. Heat exchanger
41. Front panel heat exchanger
42. Latches
43. Divider combustion gas
44. Sight glass
45. Seal heat exchanger
46. Back panel heat exchanger
47. Seal heat exchanger /
gas/air supply
48. Fan
49. Gas valve
50. Venturi 24 KW
51. Gas pipe
52. Suction pipe
53. UBA 3
54. Room control converter
55. Cable harness 24V
56. Cable harness 230V
57. BC10 mount
58. Backpanel mounting plate
59. Backpanel KIM
60. Sensor flow detection
61. Transformer
62. Sensor CH and outflow
63. Hot water tank
64. DHW pipe (hot)
65. DHW pipe (cold)
66. Hot water flow regulator
67. Connection assembly
68. Pump Uper 15-50-130
69. Pressure sensor
70. Return pump connection
71. Return connection
72. Actuator 3-way valve
73. Cartridge 3-way valve
74. 3-way valve without actuator
75. Clip actuator
76. Power switch
77. Return pipe
78. Pressure relief valve
79. Sanitary supply pipe
80. Supply manifold
81. By-pass
82. Expansion vessel pipe
83. Expansion vessel
84. Seal 125 mm
85. Seal frame/condensate trap
86. Insulation casing
87. RCC connection box
88. Manifold assembly
89. Burner thermostat (if present)
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 7
Installation1
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.
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/air-conditioning.
If this could occur the appliance MUST be turned off (with the
owners permission), and labelled as unsafe until corrective
action can be taken.
A
B,C
M
A
F
M
G
under carport
H, I
B,C
K
F
F
G
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
L
D
FJ
K
G
C
K
L
K
G
Minimum
Spacing
300 mm (12")
75 mm (3")
200 mm (8")
200 mm (8")
150 mm (6")
300 mm (12")
300 mm (12")
600 mm (24")
1200 mm (48")
1200 mm (48")
1500 mm (60")
300 mm (12")
300 mm (12")
table 1 Balanced flue terminal position
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
8 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
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 horizontal or vertical flue terminal.
These terminals have been developed specifically for the 600
Series condensing gas boilers and have been comprehensively tested. The Buderus horizontal or vertical flue terminal
kits ensure trouble-free operation.
Horizontal flue pack:
– item 1: 1 Flue turret 80/125 to 60/100 (NE 87603);
60/100
80/125
1
fig. 2 Horizontal flue pack
Installation 1
2
3
– item 2: 1 Horizontal flue terminal 60/100;
– item 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
(Æ table 2) is determined by the total pressure loss of all
components in the flue gas exhaust / air supply system.
Flow pressure available for use [Pa]
Buderus 600 - 28C 75
Take the flue pipe clearances into account when planning the
layout of the place of installation (Æ subsection 1.3.1: "Siting
the flue terminal" on page 8).
Maximum wall thickness without extensions is 550 mm.
Maintain a minimum side of 100 mm (Æ fig. 3).
1.3.4 Additional flue parts
Additional flue parts (Æ table 3) can be ordered from your
supplier.
L
50 mm
fig. 3 Side flue and rear flue installation
Boiler
Buderus 600 - 28C
for 60/100 L = 12.0 m 1.4 m
for 80/125 L = 20.0 m 1.4 m
Maximum
pipe length
For every 90° bend the
maximum pipe length has
to be reduced by
table 2 Pipe length
Flue parts Order No.
Concentric pipe, 500 mm long,
adjustable, 60/100
Concentric pipe, 1000 mm long,
not adjustable, 60/100
Concentric bend 90°, 60/100 NE 83705
Concentric bend 45°, 60/100 NE 83706
Vertical flue turret adaptor 80/125 to 60/100
NE 83703
NE 83704
550 mm
table 3 Additional flue parts
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 9
Installation1
1.4 Items supplied with unit
z Check the contents against the packing list to ensure that
nothing is missing.
Requirements to be met by the place of installation
NOTE
Observe all statutory building regulations
applying to the place of installation.
DANGER!
Inflammable materials or liquids must not be
stored or used near gas wall hung boilers
condensing. The site of installation must be
frost-protected.
2
3
1
4
7
fig. 4 Items supplied with unit
Key to fig. 4:
1: Gas wall hung boiler condensing
2: Wall bracket
3: Manifold assembly (located at top of boiler)
4: Filling loop
5: Condensate drain
6: Plastic bag containing the following accessories:
2 x wall fixing screws
2 x wall plugs
2 x washers
Seals (1 x G½“ - 1“, 2 x ¾“ - 22 mm, 2 x ½“ - 15 mm)
Initial start-up sticker
Second identification plate
Safety valve nipple (from ¾“ to ½“)
Pressure meter
7: Technical documents
5
6
1.5 Hanging the boiler
CAUTION
DO NOT remove the polystyrene foam bottom
slab protecting the connection nozzles.
During installation work, cover the gas wall
hung boiler condensing and the flue gas
adapter to prevent site dirt from entering, e. g.
using aluminium foil.
z Attach the manifold assembly (located at top of boiler) to
the wall (Æ fig. 5, item 1).
z Attach the pipes.
2
1
fig. 5 Installation
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10 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
z Attach the wall bracket (Æ fig. 5, item 2).
z When using a stand-off frame, refer to the manual of the
stand-off frame for the correct mounting instructions.
z Loosen the retaining screw on the bottom of the
condensing gas boiler (Æ fig. 6, item 1).
z Detach the outer casing of the condensing gas boiler.
z Hang the condensing gas boiler onto the wall bracket
(Æ fig. 5).
NOTE
If the boiler isn't connected to the pipework
immediately, place caps on the pipe connections.
Installation 1
1
1.6 Water circulation system
The central heating system should be in accordance with
BS.6798 and, in addition, for smallbore and microbore
systems, BS.5449.
1.7 Pipe connections
Pipework from the boiler is routed downwards as standard, but
may be routed upwards behind the boiler using the stand-off
frame (supplied in a separate kit).
z Connect pipes as shown in fig. 7. Ensure that all pipework
is routed so as to minimise any strain on the boiler fittings.
1.7.1 Gas Supply
The gas installation must be installed in accordance with
BS6891.
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.
1.7.2 Gas connection
fig. 6 Remove outer casing
1 2 3 4 65
fig. 7 Pipe connections
Key to fig. 7:
1: CH flow
2: DHW warm out
3: Gas
4: DHW cold in
5: CH return
6: Condensate trap
z Connect to gas supply according to relevant standards,
installing a screw-threaded gas shutoff valve (accessory)
to the gas supply system.
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 11
Installation1
1.7.3 Hot water temperature
CAUTION
DO NOT use galvanised pipes or fittings.
The hot water heat exchanger is made of
copper and is liable to suffer the effects of electrolytic corrosion.
NOTE
When using plastic pipes, observe the
supplier’s instructions - especially those referring to recommended jointing techniques and
the notes relating to the heating system water
on page 5.
z Connect pipes free of tension (Æ fig. 7).
1.7.4 Condensate drain
A condensate drain is integrated in the boiler.
The drain outlet is a standard (21.5 mm) overflow pipe.
z Assemble hose as shown in fig. 8.
z Screw the hose to the condensate trap as shown in fig. 9.
z Insert the end of the flexible hose 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, throughout its length.
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.
fig. 8 Hose assembly
WARNING!
Any external run must be insulated.
Ensure that the condensate trap is filled with water.
1.7.5 Condensate removal
Positioning and termination of the condensate drain pipe
The condensate pipe should be run and terminate internally to
the house soil and vent stack or waste pipe. Alternatively, the
condensate can be discharged into the rainwater system, or
into a purpose-made soak away (condensate absorption
point).
All connecting drainage pipework should have a fall of at least
2.5° to the horizontal, or approximately 50 mm per metre of
pipe run.
If the drainage pipe has to be run externally, it is recommended
that the pipe be insulated to protect against frost.
It should be noted that the connection of a condensate pipe to
a drain may be subject to local building controls.
fig. 9 Hose connection
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
12 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Material for condensate
The condensate drainage pipe should be run in a standard
drain pipe material, e.g. PVC (polyvinyl chloride), PVC-U
(unplasticized polyvinyl chloride), BS (acrylonitrile-butadienestyrene), PP (polypropylene polyprolene) or PVC-C (crosslinked polyvinyl chloride).
Any internal pipework should be of a diameter to match the
requirements of the condensate exit pipe on the appliance.
A 32 mm (1¼") waste pipe solvent weld fitting can be used,
fitted externally over the condensate exit pipe on the appliance.
All external pipework should be kept to a minimum to avoid
freezing and should have a diameter of not less than 22 mm.
Internal termination to internal stack
The condensate drainage pipe should have a minimum
diameter of G1" outside connection with no length restriction.
It should incorporate a trap with a 75 mm condensate seal and
be connected to the stack at a point at least 450 mm above the
invert of the stack. The trap built into the boiler will provide this
75 mm condensate seal. For all internal and external stack
connections a second trap is required to prevent any odours
emanating from the condensate air break at the boiler
(Æ fig. 10).
Installation 1
Boiler
Ø22 mm min.
No length restriction
75 mm min. trap
invert
fig. 10 Internal termination of condensate drainage pipe to
internal stack
internal soil
and vent stack
450 mm min.
External termination via internal branch (e.g. sink waste)
The condensate drainage pipe should have a minimum diameter of G1" outside connection with no length restriction and
should incorporate a trap with a 75 mm seal. The connection
should preferably be made downstream of the sink waste trap.
If the connection is only possible upstream, then the air break
is needed between the two traps. This is normally provided by
the sink waste pipe (Æ fig. 11 and fig. 12).
Boiler
No length restriction
Sink
Ø22 mm min.
75 mm min. trap
Open end of pipe
direct into gully,
below ground but
above water level
fig. 11 External termination of condensate drainage pipe via
internal discharge branch (e.g. sink waste) and
condensate trap
Boiler
Ø22 mm min.
No length
restriction
Sink
75 mm min. trap
Open end of pipe
direct into gully,
below ground but
above water level
fig. 12 External termination of condensate drainage pipe via
internal discharge branch (e.g. sink waste – proprietary
fitting) and condensate trap
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 13
Installation1
Condensate absorption point
The condensate drainage pipe should have a minimum
diameter of G1" outside connection and the external pipe
length should not be more than 3 m. The condensate absorption point should be sited in a convenient position as close as
possible to the boiler but not in the vicinity of other services
(Æ fig. 13 for information).
NOTE
When discharging condensate to an outside
drain caution must be taken to ensure
blockage cannot occur during freezing conditions. If this is likely to occur, the use of a
condensate trap is recommended.
1.8 Flue installation
The only flue systems that may be used are those supplied by
Buderus. The flue system must be installed in accordance with
the requirements of BS5440:1. 2000.
External length of
pipe 3m max.
Ø22 mm min.
1000 mm min.
Ø100 mm min.
plastic tube
bottom of
tube sealed
limestone
cladding
Two rows of three
12 mm holes at 25 mm centres
50 mm from bottom of tube and
facing away from house
fig. 13 External termination of condensate drainage pipe to
absorption point
Ground
(either/or)
25 mm min.
300 mm min.
hole depth
400 mm min.
Standard 100 mm flue systems
The standard concentric flue system provides for a max. horizontal straight length of upto 12.0 m for 60/100 flue connection
(Æ subsection 1.3.3).
Full instructions for fitting this flue are in subsection 1.8.2:
"Installation of the horizontal flue" on page 15.
IMPORTANT
Any horizontal flue system fitted to a
condensing boiler must be incline 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 (Æ figure on page 6).
NOTE
When using a stand-off frame, don’t forget to
take its measurements into account when
designing a flue system.
1.8.1 Connecting the vertical flue gas duct
z Fit the vertical flue gas duct or flue gas adaptor (80/125 to
60/100) (Æ fig. 14) onto the appliance flue connector.
z For remaining installation of the vertical flue assembly,
refer to the relevant installation instructions.
Flue gas
testing point
fig. 14 Vertical flue connection
Flue gas
testing point
fig. 15 Elbow with flue gas testing point
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14 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Installation 1
1.8.2 Installation of the horizontal flue
The flue gas adaptor (80/125 to 60/100) is suitable for lengths
upto 560 mm (Æ fig. 16).
For longer flue runs upto 12.0 m, extension air/flue ducts are
available (Æ page 9, table 3).
NOTE
Use the wall-mounting template to help you
mark the position of the side flue opening
1.8.3 Flue duct preparation and assembly
z Measure the flue length L. Refer to figures 17 and 18.
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 19.
Extension air duct - L-70 mm, flue duct - L-50 mm.
The measurement is from the formed end.
Flue
turret
adaptor
fig. 16 Installation with flue gas adaptor 80/125 to 60/100
Maximum length
Terminal
assembly
Outer
Wall
L
105
fig. 17 Flue length - rear
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.
z Push the assembly through the wall and slide the turret
onto the flue connector. Refer to figure 15.
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. 18 Flue length - side
L
Flue Finishing Kit
Outer
Wall
Face
Flue Terminal
Raised Ring
locating the
terminal relative
to the outside
wall face
fig. 19 Flue terminal position
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 15
Installation1
1.9 Electrical connections
1.9.1 Mains connection
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 separation in both poles, or a plug
and socket, serving only the boiler and system controls. This
boiler is equipped with a double pole switch Æ fig. 20, 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.
The electrical supply for both the boiler and the system must
be taken from the same fused spur outlet.
2
(24 x 0.2 mm), and to BS.6500 Table 16.
8 8 8
1
fig. 20 UBA
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16 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
1.10 Wiring Diagram
Installation 1
81 pin Low Voltage
Connection box UBA 3
120 VAC
120 VAC
230 VAC
230 VAC
230 VAC
L
13
N
12
PE
14
N
9
PE
11
10
L
4
N
7
120 VAC
L
3
6
120 VAC
5
16 pin High voltage
5 AF sand filled
1
81 pin Low voltage
Pump
2
3
1
2
3
Fan
4
5
1
2
Gas
3
1
2
3WV
3
1
2
Transformator
3
4
5
6
7
Ignition unit
Pin 12855
Pin 81
1
L
M
2
N
3
PE
1
N
2
M
PE
3
L
1
N
120
2
VAC
3
L
1
2
Pin 16
KIM
16 pin High voltage
Pin 1
67
68
45
17
44
16
10 VAC
10 VAC
230 VAC
230 VAC
Flue gas monitor
24 VRAC
24 VAC
0 VAC
switch contact
24 VAC
0 VAC
24 VAC
1
2
3
Return sensor
Safety sensor
Supply sensor
Hot water sensor
Boiler sensor
Burner thermostat
Ionisation
Pressure
sensor
Earth
P
Supply/
Safety
sensor
49
76
53
79
23
27
52
25
81
80
28
1
55
2
70
61
62
11
12
38
39
13
14
9
10
63
64
50
78
3
Mains
switch
815161
1
2
Earth
8
34 354360
33
6 7 851 2 3 4
BC10 connector
Volt free
external control
device
RTH converter
external
2
230V controls
1
Volt free room
thermostat
1
when used with
2
230V timer *)
*) remove wirebridge
when used
IMPORTANT
The wires in this 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 connector proceed as follows:
The wire coloured green and yellow must be connected to the terminal on the connector 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.
WARNING
THIS APPLIANCE MUST BE EARTHED
Ensure that your appliance is connected correctly - if you are in any doubt consult a qualified electrician.
21
12
587726373664635379 23
747557
12 34 56 78 9 10 11 12 13
Connection made by a Corgi registered installer
3 4
1 2
5 6
7 8 9 10 11
24Vac
12
green orange red blue grey light blue
1 - 2 1 - 2 1 - 2 1 - 2 1 - 2 1 - 2 - 3
RCC
1 2
ModuLine roomtemp.
controller
External temperature sensor
External switch contact
for underfloor heating system
0Vac
13
power source
230 VAC 50 Hz
4
Mains
For location of individual components, see service section and the exploded views in this manual.
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 17
Installation1
1.10.1 External controls
The gas wall hung boiler condensing can be fitted with the
following external controls:
– a Buderus RC,
temperature controller (Æ subsection 1.10.2);
– a room-temperature control device at 230V connected to
the room control converter (Æ subsection 1.10.3);
– ON/OFF temperature controller, volt free
(Æ subsection 1.10.4).
1.10.2 Buderus modulating room thermostat connection
z Open the connection box (Æ fig. 21).
z Connect a Buderus modulating room thermostat (Buderus
iRT or RC) to the RCC connection box (Æ fig. 22, item 1).
z Replace the cover of the connection box and secure with
the screw.
iRT or ModuLink 250 RF modulating room-
fig. 21 Connection box cover
0Va c
24Vac
ModuLine RCC
1
1.10.3 External 230V controls
WARNING!
This appliance must be earthed.
z Connect the black pre-wired lead to a permanent live
supply (from the same fused isolator as all other controls
on the heating system), L N E.
z Remove the cover of the room control converter (Æ fig. 23,
item 1).
z Feed the 230V switch live and neutral (from external
controls) through the cable gland (Æ fig. 23).
z Identify the 230V terminal block by the shaded area and
230V label.
z Connect the switch live to terminal "1" and a neutral to
terminal "2" (Æ fig. 23, item 2).
NOTE
Terminal 3 (Æ fig. 23, item 2) is not used.
fig. 22 RCC connection box
1
fig. 23 Connection box - 230 Volt connection
2
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18 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Installation 1
1.10.4 Volt free room-temperature control device connection
z Connect the black pre-wired lead to a permanent live
supply (from the same fused isolator as all other controls
on the heating system), L N E.
z Remove the cover of the room control converter
(Æ fig. 24, item 1).
z Lead the control device wire through the cable lead
(Æ fig. 24).
z Fix the wire to terminal 1 and 2 of the volt free connection
(Æ fig. 24, item 2).
1.10.5 Other connections
Room control converter
The room control converter is connected to this
position.
1-2 green
Do not use this connection.
3-4 orange
1
fig. 24 Connection box - Volt free connection
5-61-2 9-10
11-12-13
7-83-4
14-15
ModuLine RCC
2
Connection of an external switch contact for underfloor
heating system
When this connection is in use for the safety of
for example an underfloor heating system, then
an "8Y" code is generated when the switch
5-6 red
connection is open, the boiler will shut down.
External temperature sensor
When a Buderus modulating room temperature
controller is installed which is used as an
external temperature controller, then the
7-8 blue
external temperature sensor may be connected
to this position.
Do not use this connection.
Do not use this connection.
24 Vac
0 Vac
fig. 25 Connection box
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 19
Installation1
1.10.6 System example
Buderus 600-28C with ModuLink 250 RF control
Condensing gas boiler
600 – 28C
CB
PL
RV
CHF CHR
DHW
MCW
JB
LSV
LSV
reference room / main living area
fig. 26
Buderus 600-28C with external 230V controls
Condensing gas boiler
600 – 28C
PL
DHW
MCW
CB JB
CHF CHR
JB
T
RT
LSV
LSV
reference room / main living area
fig. 27
RT/Programmer
ModuLink 250 RF
TRV
radiator radiator
LSV
TRV
radiator radiator
LSV
other rooms
other rooms
Key to abbreviations:
CB = Connection Block
CHF = Central Heating Flow
CHR = Central Heating Return
DHW = Domestic Hot Water
JB = Junction Block /
RTH Converter
LSV = Lockshield Valve
MCW = Mains Cold Water
PL = Permanent Live
RT = ModuLink 250 RF
RV = ModuLink 250 RF
Receiver
TRV = Thermostatic Radiator
Valve
Key to abbreviations:
CB = Connection Block
CHF = Central Heating Flow
CHR = Central Heating Return
DHW = Domestic Hot Water
JB = Junction Block /
Connection box (RTH
Converter)
LSV = Lockshield Valve
MCW = Mains Cold Water
PL = Permanent Live
RT = Room Thermostat
T=Timer
TRV = Thermostatic Radiator
Valve
Buderus 600-28C with external Volt Programable Room thermostat
Condensing gas boiler
600 – 28C
PRT
Key to abbreviations:
CB = Connection Block
CHF = Central Heating Flow
CHR = Central Heating Return
DHW = Domestic Hot Water
JB
PL
CB
JB = Junction Block /
Connection box
(RTH Converter)
LSV = Lockshield Valve
CHF CHR
DHW
MCW
LSV
radiator radiator
LSV
reference room / main living area
TRV
LSV
other rooms
MCW = Mains Cold Water
PL = Permanent Live
PRT = Programmable Room
Thermostat (Volt Free
Contacts)
TRV = Thermostatic Radiator
Valve
fig. 28
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
20 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
2 Initial start-up
Fill out the protocol during the 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 Fill the heating system
Initial start-up 2
WARNING
The gas wall hung boiler condensing must not
be activated at this stage.
NOTE
The boiler will not start up until the system
pressure is greater than 0.2 bar.
z Remove the ventilation cover (Æ fig. 29).
z Adjust the knobs for central heating (Æ fig. 30, item 1) and
domestic hot water (Æ fig. 30, item 2) to '0'.
1
1
fig. 29 Remove ventilation cover
2
1
1
1
3
fig. 30 Control panel
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 21
4
Initial start-up2
z Loosen the automated air vent one turn (Æ fig. 31).
z Connect the system to the mains power supply.
z Set the switch on the BC10 to "1" (Æ fig. 30, item 3)
z Press the service button (Æ fig. 30, item 4) several times
until the system pressure (for example P1.1) appears in the
display.
z If necessary open the CH flow and CH return maintenance
valves (Æ fig. 32, item 1 and 2).
1
fig. 31 Automatic air vent
z Connect temporary hose (Æ fig. 33).
z Open both stop valves.
1
CH Flow
DHW Hot
(combi only)
Gas
fig. 32 Maintenance shutoff valves
stop
valve
double
check
valve
DHW
cold
fig. 33 Connecting temporary hose
temporary
hose
DHW Cold
(combi only)
stop
valve
CH
return
2
CH Return
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22 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Initial start-up 2
z Fill the system to a pressure of approx. 1.5 bar (Æ fig. 34,
item 1).
z Shut both stop valves and disconnect the filling loop.
z Purge all radiators from air starting downstairs and working
your way up.
z Check the pressure after purging. If the pressure has
dropped under 1.0 bar then top up the system as described
previously.
1
fig. 34 Pressure display
To drain the system take the following steps:
z Close the DHW cold and the CH return valve.
z Connect temporary hose (Æ fig. 36).
z Open the CH return stop valve to drain the system.
1
fig. 35 Purge the hot water heat exchanger of air
Stop
valve
Drain
Drain
CH Flow
fig. 36 Draining the system
CH Return
DHW Cold
temporary
hose
Stop
valve
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 23
Initial start-up2
2.1.2 BC10 adjustments
The boiler is equipped with an 3.0 UBA. This is the brain of the
boiler. The BC10 is located behind the access panel cover.
The BC10 allows you to operate the boiler and to make adjustments in its settings such as the temperature for the DHW.
BC10 overview:
Mains switch (Æ fig. 37, item 1)
Use this switch to turn the boiler on or off.
Reset button (Æ fig. 37, item 2)
When a blinking code is in the display, it is possible to try and
restart the boiler by pressing this button.
Chimney sweep button (Æ fig. 37, item 3)
When this button is pressed for 2 to 5 seconds, the boiler will
operate at full power for central heating. A dot is visible in the
lower right hand corner of the display when the chimney sweep
mode (service mode) is active (Æ fig. 38). When the set flow
temperature is reached within 30 minutes then the boiler
returns to normal operation. Otherwise the boiler will return to
normal operation after 30 minutes. Once the boiler is in service
mode you can terminate the service mode by pressing the
chimney sweep button for 2 to 5 seconds again.
10
89
8 8 8
1
fig. 37 BC10
item 1: Mains switch
item 2: "reset" button
item 3: "chimney sweep" button
item 4: "service" button
item 5: LED "burner on"
item 6: LED "central heating staus"
item 7: central heating water temperature knob
item 8: display
item 9: DHW temperature knob
item 10: LED "DHW status"
3
2
4
7
5
6
Emergency operation
By pressing the chimney sweep button for longer than
5 seconds, the emergency operation is activated. The boiler
will burn continuously for 24 hours according to the set flow
temperature. Warm water is available during emergency operation.
The dot in the lower right hand corner of the display will blink
(Æ fig. 39).
z Press the chimney sweep button until the blinking dot
disappears from the display to end the emergency operation.
Service Button (Æ fig. 37, item 4)
Pressing the 'service button' repeatedly allows you to scroll
through this menu. The menu shows the flow temperature,
system pressure and the current operating status.
LED "burner on" (Æ fig. 37, item 5)
This LED indicates that the burner is on.
8 8 8
fig. 38 Boiler is in chimney sweep (service) mode
8 8 8
fig. 39 Emergency operation is active.
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
24 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Initial start-up 2
Setting the flow temperature (Æ fig. 37, item 7)
The knob with the radiator symbol (Æ fig. 37, item 7) allows
the installer to set the maximum flow temperature (Æ table 4).
When the boiler is in operation for central heating then the LED
"CH operation" (Æ fig. 37, item 6) is lit.
Setting the domestic hot water temperature
(Æ fig. 37, item 9)
Turn the knob with the tap symbol (Æ fig. 37, item 9) to the
desired temperature for your domestic hot water (Æ table 5).
Set the knob to "Eco" when the boiler is situated in an area with
calcareous water to prevent calcification as much as possible.
When the boiler is in operation for domestic hot water, the LED
"DHW operation is on (Æ fig. 37, item 10).
Setting Function Description
0 off Central heating
30 - 90 Flow temperature in °C.
However the boiler is capped off
at 80 °C. This means that position 80 is 80 °C, but also position
90 is 80 °C.
Aut. Do not use this setting
table 4 Flow temperature
Setting Function Description
0 off DHW is turned off
Eco Energy saving setting
The heat retaining
temperature of the hot
water tank is 26 °C and
the outlet temperature
of the hot water tank is
60 °C.
30 - 60 Desired temperature of
the heat retaining
temperature of the hot
water tank and the
outlet temperature of
the hot water tank.
Aut. Do not use this setting
table 5 Domestic hot water temperature
function is switched
off.
minimal comfort, minimal
energy consumption,
minimal calcification.
Maximum comfort when set
at 60° C
Setting the pump run over time
ATTENTION
When there is a freezing hazard set the pump
run over time to 24 hours (F1d) (Æ fig. 40,
item 3).
z Press the chimney sweep button and the service button
(Æ fig. 40, item 2 and 1) simultaneously until "L--"
appears in the display.
z Press the service button repeatedly until “F5” appears in
the display. “F5” means that the pump run over time is
currently set at 5 minutes. This is the factory setting.
z Adjust the pump run over time by pressing the chimney
sweep button to reduce the run over time of the pump and
the reset button to increase the pump run over time. The
range is 0 min to 60 min. (F 0..F60) and 24 hours (F1d).
z Confirm the selection by pressing the service button
(Æ fig. 40, item 1).
23
1
fig. 40 Pump run over time to 24 hours
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 25
Initial start-up2
2.1.3 Setting the heating capacity
The heating capacity can be adjusted on the BC 10.
z Press the chimney sweep button and the service button at
the same time until "L--" (Æ fig. 41) appears in the
display.
z Adjust the capacity with the reset button and chimney
sweep button. The range is from "L01..L99" (Æ table 6).
To run the boiler at 100% set to "L--"
z Confirm the setting by pressing the service button two
times (Æ fig. 41, item 1).
2
fig. 41 Maximum heating capacity
1
2.1.4 Checking for leaks
Use a suitable pressure gauge for the different pressure readings. It should be able to handle pressures a minimum of
50 mbar with an accuracy of 0.01 mbar minimum.
z Disconnect the system from the power supply.
z Check all sections of gas pipework and connections for
signs of leaks before starting up the 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.
The test pressure of the gas pipe when the gas shutoff valve is
open may not exceed 150 mbar.
ATTENTION
Check the used measuring nipples for gas
tightness.
2.1.5 Checking the gas type
It is very important that the gas type to which the boiler will be
connected corresponds to the gas type the boiler is equipped
with. If this is not the case, then the boiler may not be put into
operation.
z Check the gas type with your gas supplier and compare
this to the boiler's gas type as registered on the identfication tag (Æ table 8).
It is possible to change the boiler to another gas type
(Æ table 7). This accessory can be ordered from your supplier.
Display [%] Heating capacity at 40/30 °C [kW]
Buderus 600 - 28C
L25 6.0
L30 7.2
L35 8.4
L40 9.6
L45 10.8
L50 12.0
L55 13.2
L60 14.4
L65 15.6
L70 16.8
L75 18.0
L80 19.2
L85 20.4
L90 21.6
L95 22.8
L-- 24.0
table 6 Heating capacity in percentages
Type of gas Factory settings of gas burners
Natural gas H When delivered ready for operation and set to
Wobbe index 14.1 kWh/m
1013 mbar), applicable for Wobbe index range
11.3 to 15.2 kWh/m
Inscription on gas-type indicating label:
Category setting: 2H G 20_20 mbar
LPG After adaptation by a CORGI registered installer,
the unit can be run on LPG. Inscription on gastype indicating label: 3P G 31_37 mbar
table 7 Gas-supply types
3
(referred to 15 °C,
3
.
Type of gas Gas nozzles
∅ [mm]
Buderus 600 - 28C
Natural gas H (G20) 4.45 Standard
LPG 3.45 Standard
table 8 Gas-nozzle diameter
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
Venturi
tubes
Venturi tubes
Venturi tubes
26 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
2.1.6 Adjusting the hot water flow regulator
CAUTION
It is important to adjust the flow of hot water,
due to the resistance of the pipes in the installation and the differences in water pressure.
Adjust the hot water flow regulator (Æ fig. 42) to the desired
setting:
– To increase the flow of hot water:
turn valve towards “+”.
– To reduce the flow of hot water:
turn valve towards “-”.
Factory setting:
8 l/min of 60 °C, assuming that the DHW cold is 10 °C.
2.1.7 Measuring the gas-supply pressure (flow pressure)
Initial start-up 2
fig. 42 Hot water flow regulator
There are two ways to measure the gas-supply pressure:
– measuring the standing gas-supply pressure (boiler not in
operation);
– measuring the working gas-supply pressure (boiler
operating at full power).
NOTE
The difference between the standing and
working pressure may never be greater than
5mbar.
If the difference between the two is greater
than 5 mbar then the pressure in the gas pipe
is too great.
Measuring the standing gas-supply pressure
z Take the boiler out of service by pressing the mains switch
(Æ fig. 43, item 1) to "0".
z Close the gas shutoff valve (Æ fig. 44, item 1).
z Set the pressure gauge to "0".
z Attach a tube from the pressure gauge to the gas test
nipple (the lower one, Æ fig. 45, item 2).
z Slowly open the gas shutoff valve.
z Measure the standing gas-supply pressure.
8 8 8
1
fig. 43 Press the chimney sweep button
2
3
Measuring the working pressure
z Take the boiler out of service by pressing the mains switch
(Æ fig. 43, item 1) to "0".
z Close the gas shutoff valve (Æ fig. 44, item 1).
z Set the pressure gauge to "0".
z Attach a tube from the pressure gauge to the gas test
nipple (the lower one, Æ fig. 45, item 2).
z Slowly open the gas shutoff valve.
z Open at least two radiators.
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 27
fig. 44 Gas valve
item 1: Gas valve closed
item 2: Gas valve open
1
2
Initial start-up2
z Set the mains switch (Æ fig. 43, item 1) to "1".
z Create a heat demand by pressing the chimney sweep
button (Æ fig. 43, item 2), until a LED is visible in the lower
right hand corner (chimney sweep mode).
z Measure the working gas-supply pressure.
z The working gas-supply pressure should be between:
a minimum of 17 mbar and a maximum of 25 mbar (nominal connection pressure of 20 mbar) for natural gas H.
a minimum of 30 mbar and a maximum 50 mbar
(nominal connection pressure 37 mbar for LPG.
z Pull off the tube from the gas testing nipple.
z Tighten the screw of the gas testing nipple.
ATTENTION
If the required connection pressure is not
available or too high, contact your gas supplier
or TRANSCO.
Ensure that all disturbed joints and connections are checked
for gas tightness on completion of tasks.
fig. 45 Measuring the gas-supply pressure
2.1.8 Checking the gas/air ratio and adjust as required
z Turn mains power switch to "0" and make sure that the
boiler is not in chimney sweep mode.
z Remove the casing of the boiler.
z Shut the gas shutoff valve underneath the boiler (Æ fig. 44,
item 1).
z Open at least two radiators.
z Open the top measuring nipple (Æ fig. 46, item 1) with two
turns.
z Set the pressure gauge to "0".
z Connect a tube from the "+" side of the pressure gauge to
burner-pressure testing nipple (Æ fig. 46, item 2)
z Open the gas shutoff valve (Æ fig. 44, item 2).
z Set the mains switch to "1".
z Set the boiler in service mode by pressing the chimney
sweep button until a non-blinking LED appears in the lower
right hand corner of the display.
z Press the chimney sweep button and the service button at
the same time, until "L--" appears in the display.
z Adjust the capacity to "L25" by pressing the reset button.
z The optimum gas/air ratio is - 5 Pa (-0.05 mbar).
The pressure difference should be between -10 and 0 Pa
(Æ fig. 47).
If this is not the case then adjustment is needed:
z Remove the safety screw with a flat head screwdriver
(Æ fig. 48, item 1).
z Adjust the adjustment screw of the burner pressure to the
correct gas/air ratio using a (4 mm) socket head wrench
and by referring to fig. 47.
z Replace the safety screw.
Set mains power switch to "0".
z
fig. 46 Check the gas/air ratio
wrong wrongcorrect
-15 -10 -5 0 5 (Pa)
-0.15 -0.10 -0.05 0.00 0.05 (mbar)
left turn right turn
fig. 47 Pressure difference at gas/air at "L25"
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28 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
z Shut the gas shutoff valve (Æ fig. 44, item 1).
z Remove the tube from from the burner-pressure testing
nipple.
z Tighten the screw on the burner-pressure testing nipple.
z Open the gas shutoff valve (Æ fig. 44, item 2).
z Turn the mains power switch to "1".
z Set the boiler in service mode by pressing the chimney
sweep button, until a non-blinking LED appears in the
lower right hand corner of the display.
z Check the testing nipples for gas tightness.
z Turn off the boiler again by pressing the mains power
switch to "0".
z Turn the boiler on by setting the mains power switch to "1".
CAUTION
Check the test nipples for gas tightness.
Initial start-up 2
fig. 48 Adjust gas/air ratio
z Check if the boiler is still set at the desired heating capacity
("L--" for example) and adjust when necessary
(Æ subsection 2.1.3: "Setting the heating capacity").
2.1.9 Gas rating test
z Isolate all other appliances.
z Set the boiler to maximum firing rate.
z Ensure that there is no modulating of the fan gas valve.
z Carry out the Gas Rating procedure as described in
"Essential Gas Safety' 3rd edition on pages 169-176.
2.1.10 Checking for leaks while boiler is in operation
z Use an approved leak detector to check all connections for
possible leaks. The product must be certified as a gasleaktesting agent.
z Do not allow the product to come into contact with the
electrical wiring.
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 29
Initial start-up2
2.1.11 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 (Æ fig. 49)
z Turn the mains power switch to "0" (Æ fig. 43, item 1).
z Remove the casing.
z Remove the ventilation cover.
z Loosen the plug-and-socket connector of the ionisation
electrode and connect the multimeter in series.
z On the measuring device, select the µ-direct current range.
The measuring device must have a resolution of at
least 1 µA.
z Set mains power switch to "1" (Æ fig. 43, item 1).
z Set the boiler in service mode by pressing the chimney
sweep button until a non-blinking LED appears in the lower
right hand corner of the display.
z Press the chimney sweep button and the service button at
the same time, until "L--." appears in the display.
Write down the set heating capacity.
z Adjust the heating capacity to "L25." by pressing the reset
button.
z Confirm by pressing the service button.
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 Set the mains power switch to "0" (Æ fig. 43, item 1).
z Remove multimeter and restore the plug-and-socket
connection to its original state.
z Refit the ventilation cover.
z Refit the casing and the safety screw (Æ fig. 50, item 1).
z Set the mains power switch to "1" (Æ fig. 43, item 1).
z Reset the heating capacity to the desired capacity
(Æ subsection 2.1.3: "Setting the heating capacity").
fig. 49 Measuring the ionisation current
2
1
fig. 50 Refit casing and safety screw
2.1.12 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.
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30 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
3Inspection
3.1 General directions
z Do a visual and functional test of the installation.
3.2 Preparing the boiler for inspection
z Disconnect the boiler from the mains power supply.
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.
Inspection 3
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.
z Replace the following seals two-yearly:
– Flat seal between the gas pipe and gas air unit
(Æ fig. 53),
– Seal ignition unit (Æ fig. 55),
– Seal ionisation electrode (Æ fig. 55),
– Seal heat exchanger (Æ fig. 58),
– Burner seal (Æ fig. 59).
z Fill out the Benchmark.
3.2.1 Internal leak test
z Disconnect the boiler from the mains power supply.
Do not allow the product to come into contact with the electrical
wiring.
3.2.2 Check the combustion chamber and heat exchanger for pollution
3.2.3 Check the burner
3.2.4 Check the functioning and safety of the flue gas exhaust
3.2.5 Check the pre-pressure of the expansion vessel
3.2.6 Check the hot water tank for leakage
3.2.7 Check the programming of the room thermostat
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 31
Maintenance4
4 Maintenance
NOTE
The described cleaning of the burner and heat
exchanger is only necessary when the boiler is
heavily soiled. Otherwise it is sufficient to clean
the burner and heat exchanger with a soft
brush or compressed air without
disassembling them.
1
1
4.1 Cleaning the heat exchanger and burner
z Switch the boiler off by setting the mains switch to "0"
(Æ fig. 43, item 1).
z Close the gas shutoff valve (Æ fig. 44, item 1).
z Loosen the retaining screw (Æ fig. 6, item 1) and remove
the outer casing .
z Open the latches (Æ fig. 51, item 1) and remove the venti-
lation cover.
z Loosen the gas connection between the gas supply and
the gas air unit (Æ fig. 52, item 1).
1
fig. 51 Remove the ventilation cover
1
1
fig. 52 Loosen gas connection
z Replace the flat seal between the gas pipe and the gas air
unit (Æ fig. 53).
fig. 53 Replace the flat seal of the gas pipe
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32 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Maintenance 4
z Remove the plugs (Æ fig. 54, item 1, 2 and 3) from the gas
air unit.
z Remove the air suction tube from the gas air unit
(Æ fig. 54, item 4).
z Then remove the plugs of the ionisation electrode
(Æ fig. 54, item 6) and the ignition unit (Æ fig. 54, item 5).
z Remove the ignition unit (Æ fig. 55, item 1) and ionisation
electrode (Æ fig. 55, item 2).
z Mount a new ignition unit with mounting plate and nut.
z Mount the old ionisation electrode with a new seal,
mounting plate and nut.
6
1
5
2
3
4
fig. 54 Remove plugs of the gas air unit
z By turning the unit a quarter turn (Æ fig. 56, item 2), the unit
can be removed by lifting it out of the boiler.
z Clean the burner when necessary. The burner may only be
cleaned with a soft brush or compressed air.
CAUTION
Replace the ceramic burner seal after
removing the burner from the gas air unit.
z Now the front cover of the heat exchanger can be removed
by opening the latches (Æ fig. 56, item 1).
12
fig. 55 Remove the ignition unit and ionisation electrode
2
1
fig. 56 Remove gas air unit
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 33
Maintenance4
z Remove the flue gas retarder from the heat exchanger
(Æ fig. 57, item 1).
z Inspect the heat exchanger. When needed clean the heat
exchanger with a soft brush or compressed air.
NOTE
Only when a heat exchanger is heavily soiled
is it recommended to drain the system, to
remove the heat exchanger for cleaning.
z Replace the seal of the heat exchanger (Æ fig. 59, item 1).
The seal must be placed without tension and cut at the
proper length at the end of it.
z Replace the 4 o-rings (Æ fig. 59, item 2), 2 pieces at each
side.
1
fig. 57 Remove flue gas retarder
1
fig. 58 Replace the seal of the heat exchanger
2
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34 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
z Remove the old burner seal (Æ fig. 59).
z Place a new burner seal.
Maintenance 4
fig. 59 Replace burner seal
z Place a new flat seal between the gas pipe and the gas
valve (Æ fig. 60).
z Reassemble in reverse order.
4.2 Cleaning the condensate trap
z Remove the condensate trap (Æ fig. 61).
z Clean the condensate trap with tapwater and a brush.
z If required, place a new lip seal.
z Fill the condensate trap with water and reassemble.
fig. 60 Place a new flat seal
fig. 61 Cleaning the condensate trap
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 35
Maintenance4
4.3 Flushing the hot water tank
z Switch the boiler off by setting the mains switch to "0"
(Æ fig. 43, item 1).
z Close the DHW (cold).
z Open the DHW (hot) to relieve the pressure from the water
pipe.
z Pull out the safety clips (Æ fig. 62, item 1).
CAUTION
Hot water will come out.
z Pull out the standby- and hot water sensor and place the
flushing connections in their place (Æ fig. 63).
z Connect the descaling device and flush the hot water tank.
After flushing reconnect everything in reverse order.
z Open the DHW (cold) cock.
z Close the DHW (hot) cock after it has been purged and
flushed.
z Take the boiler back in service by setting the mains switch
to "1" (Æ fig. 43, item 1).
1
fig. 62 Remove safety clips of sensors DHW cold and hot
1
ATTENTION
Check all couplings for leakage.
fig. 63 Flushing the hot water tank
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36 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
5 Servicing
The display of the BC10 in the boiler always shows a code
when the boiler is operational. It may be necessary to press the
service button (Æ fig. 43, item 2) once or twice to see the
code.
The display will show normal operating codes (Æ subsection
5.1), non-flashing fault codes and flashing fault codes
(Æ subsection 5.2).
The normal operating codes let the installer know what the
current operational status is of the boiler.
A non-flashing fault code is mostly not too serious. Often the
code disappears after a while, there is no need to reset the
boiler.
A blinking fault code however is a blocking code. This means
that the boiler will not operate until the problem is solved and/or
the boiler is reset.
UBA 3
The LED on the UBA 3 (Æ fig. 64, item 1) can also give useful
information.
– When the indicator LED is off, then the boiler is operating
normally.
– The LED flashes when there is a blocking fault code.
– The LED flashes quickly for 10 sec. when the boiler is fired
for the first time.
– The LED is on when there is a problem with the UBA 3 or
when it doesn't recognise the KIM.
– The LED comes on shortly after the electricity is switched
on.
Servicing 5
1
fig. 64 UBA 3
item 1: red indicator LED
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 37
Servicing5
5.1 Operating codes
NOTE
If the code displayed on the burner-control unit
is not listed under the operating codes or fault
codes, the burner-control unit itself is malfunctioning.
Display after
pressing the
service button
0 Buderus 600 - 28C is ready for operation
0A Burner interval circuit, 10 min. from burner start-up
0C Waiting for activation of the three-way valve (if fitted) or pump
0H Stand-by activated, Buderus 600 - 28C ready to provide heat or hot water
0L Initial safety period: self-testing of burner-control unit during burner start-up
0U Post- or pre-purging period of fan unit
0Y Flow temperature at adjustment setting
- Buderus 600 - 28C running in heating mode
-A
-H Normal heating mode
-Y Service mode
= Buderus 600 - 28C running in hot water mode
Meaning
“Chimney-sweep” mode, flow-temperature controller bypassed, Buderus 600 - 28C heating to previouslyentered flow temperature.
=H Normal hot water mode
r Reset
rE Reset (when the reset button is pressed on the BC10, the boiler will attempt to fire up)
table 9 BC10 operating codes (after pressing the service button)
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38 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Servicing 5
5.2 Fault codes
Code Meaning
1C Blinking fault code: Flue gas thermostat or the burner thermostat (if present) measured a too high temperature.
Possible
cause
1 Flue gas temperature too high – Check the flue gas system
2 Burner temperature too high – Check the heat exchanger
3 Flue gas sensor faulty Check the wiring and connections of the flue gas sensor
4 Burner thermostat faulty Check the wiring and connections of the burner thermostat
Code Meaning
2E Non blinking fault code: Water pressure in the system lower than 0.2 bar
Possible
cause
1 System pressure not checked in time Top up the system to at least 1.0 bar (Æ subsection 2.1.1)
2 Pressure sensor is defect Replace pressure sensor
Action
– Check the flue gas retarder
– Check the flue gas system (including condensate trap)
and replace when necessary (Æ subsection 5.3.1)
and replace when necessary (Æ subsection 5.3.20)
Action
Code Meaning
2F Non blinking fault code: The flow part of the bi-sensor did not detect a rise in the temperature of the central heating
water after a burner start
Possible
cause
1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or
2 Water pressure is too low in the installation Top up the system (Æ subsection 2.1.1)
3 Problem with the pump or pump cabling
(no circulation)
4 Bi-sensor is dirty or faulty Check the bi-sensor for dirt. Measure if resistance over the
Code Meaning
2P Non blinking fault code: Bi-sensor rises faster than 5 K/sec.
Possible
cause
1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or
2 Water pressure is too low in the installation Top up the system (Æ subsection 2.1.1)
3 Problem with the pump or pump cabling
(no circulation)
4 Bi-sensor is dirty or faulty Check the bi-sensor for dirt. Measure if resistance over the
Action
clogged with dirt
Check if the pump cabling is faulty or if the pump is stuck.
Replace pump when necessary (Æ subsection 5.3.6 and
subsection 5.3.7)
sensor is correct. If not replace bi-sensor (Æ subsection
5.3.8 and subsection 5.3.9)
Action
clogged with dirt
Check if the pump cabling is faulty or if the pump is stuck.
Replace pump when necessary (Æ subsection 5.3.6 and
subsection 5.3.7)
sensor is correct. If not replace bi-sensor (Æ subsection
5.3.8 and subsection 5.3.9)
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 39
Servicing5
Code Meaning
2U Non blinking fault code: Temp. difference between the bi-sensor and the return sensor is greater than 50 K
Possible
cause
1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or
2 Water pressure is too low in the installation Top up the system (Æ subsection 2.1.1)
3 Problem with the pump or pump cabling
(no circulation)
4 Bi-sensor is dirty or faulty Check the bi-sensor for dirt. Measure if resistance over the
5 Return sensor may be faulty Check return sensor and when necessary replace sensor
Code Meaning
3A Non blinking fault code: No communication between fan and UBA
Possible
cause
1 Faulty cable or connection Check the cabling and connections and replace when
2 Fan is defect Replace fan (Æ subsection 5.3.3)
Action
clogged with dirt
Check if the pump cabling is faulty or if the pump is stuck.
Replace pump when necessary (Æ subsection 5.3.6 and
subsection 5.3.7)
sensor is correct. If not replace bi-sensor (Æ subsection
5.3.8 and subsection 5.3.9)
(Æ subsection 5.3.8)
Action
necessary (Æ subsection 5.3.3)
Code Meaning
3L Blinking fault code: Fan signal not detected at power up stage
Possible
cause
1 Faulty cable or connection Check the cabling and connections and replace when
2 Fan is defect Replace fan (Æ subsection 5.3.3)
Code Meaning
3P Blinking fault code: Fan running too slow
Possible
cause
1 Fan may be dirty Check fan for dirt (Æ subsection 5.3.3)
2 Power supply may be faulty Check the power supply
3 Fan wiring or connections faulty Check the fan wiring and connections
Code Meaning
3Y Blinking fault code: Fan running too fast
Possible
cause
1 Fan wiring or connections faulty action Check the fan wiring and connections
2 Power supply may be faulty Check power supply
3 Flue gas system may be dirty Check the flue gas system (Æ subsection 5.3.1)
4 Problem with the fan, heat exchanger, burner Check the fan, heat exchanger and burner for dirt
Action
necessary (Æ subsection 5.3.3)
Action
(Æ subsection 5.3.3)
Action
(Æ subsection 5.3.3)
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40 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Servicing 5
Code Meaning
4A Blinking fault code: Flow sensor exceeds 105 °C
Possible
cause
1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or
2 Water pressure is too low in the installation Top up the system (Æ subsection 2.1.1)
3 Problem with the pump or pump cabling
(no circulation)
4 Bi-sensor is dirty or faulty Check the bi-sensor for dirt. Measure if resistance over the
Code Meaning
4E Blinking fault code: Bi-sensor not working
Possible
cause
1 Bi-sensor is faulty Replace bi-sensor (Æ subsection 5.3.9)
Action
clogged with dirt
Check if the pump cabling is faulty or if the pump is stuck.
Replace pump when necessary (Æ subsection 5.3.6 and
subsection 5.3.7)
sensor is correct. If not replace bi-sensor (Æ subsection
5.3.8 and subsection 5.3.9)
Action
Code Meaning
4F Blinking fault code: Flow sensor exceeds 100 °C
Possible
cause
1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or
2 Water pressure is too low in the installation Top up the system (Æ subsection 2.1.1)
3 Problem with the pump or pump cabling
(no circulation)
4 Bi-sensor is dirty or faulty Check the bi-sensor for dirt. Measure if resistance over the
Code Meaning
4L Blinking fault code: Wiring or connections or sensor exceeds 130 °C
Possible
cause
1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or
2 Water pressure is too low in the installation Top up the system (Æ subsection 2.1.1)
3 Problem with the pump or pump cabling
(no circulation)
4 Bi-sensor is dirty or faulty Check the bi-sensor for dirt. Measure if resistance over the
Action
clogged with dirt
Check if the pump cabling is faulty or if the pump is stuck.
Replace pump when necessary (Æ subsection 5.3.6 and
subsection 5.3.7)
sensor is correct. If not replace bi-sensor (Æ subsection
5.3.8 and subsection 5.3.9)
Action
clogged with dirt
Check if the pump cabling is faulty or if the pump is stuck.
Replace pump when necessary (Æ subsection 5.3.6 and
subsection 5.3.7)
sensor is correct. If not replace bi-sensor (Æ subsection
5.3.8 and subsection 5.3.9)
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 41
Servicing5
Code Meaning
4P Blinking fault code: Bi-sensor has a loose connection or is defective
Possible
cause
1 Bi-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 Blinking fault code: Short circuit in bi-sensor
Possible
cause
1 Bi-sensor is dirty or faulty Check the sensor, replace when necessary
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 bi-sensor (Æ subsection
5.3.8 and subsection 5.3.9)
(Æ subsection 5.3.2)
Action
(Æ subsection 5.3.8 and subsection 5.3.9)
(Æ subsection 5.3.2)
Code Meaning
4Y Blinking fault code: Bi-sensor interrupted
Possible
cause
1 Bi-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
Action
sensor is correct. If not replace bi-sensor (Æ subsection
5.3.8 and subsection 5.3.9)
(Æ subsection 5.3.2)
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42 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Code Meaning
6A Blinking fault code: No ionisation message after ignition
Possible
cause
1 There is no flame, ignition unit doesn’t glow, fan
is turning
2 There is no flame, ignition unit does glow, fan
isn’t turning
3 There is no flame, ignition unit and fan are
working
4 There is a flame, but the flame disappears
when the fan starts up
Action
– Check wiring of the ignition unit, measure the resistance of the
ignition unit (should be between 50 and 300 Ω). Replace
ignition unit when necessary (Æ subsection 5.3.11 and
subsection 5.3.12)
– Check the UBA’s F1 fuse, replace when necessary
– Check the fan and KIM connectors and the UBA fuses
– Check and adjust the gas/air ratio (Æ subsection 2.1.8)
– Check for 24 V~ on the gas valve during start up
– Check the gas-supply pressure (Æ 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 (Æ subsection 2.1.7), this
should be higher than 20 mbar for natural gas.
– Check and adjust the gas/air ratio (Æ subsection 2.1.8)
– Check the earthing cable connections (yellow/green wire)
– Check the cabling on the ignition unit
– Press reset. If fault code remains then try to temporarily connect
a different UBA (Æ subsection 5.3.2)
Servicing 5
Code Meaning
6C Blinking fault code: Ionisation message, but no flame
Possible
cause
1 There is no flame, ignition unit doesn’t glow, fan
is turning
2 There is no flame, ignition unit does glow, fan
isn’t turning
3 There is no flame, ignition unit and fan are
working
4 There is a flame, but the flame disappears
when the fan starts up
Action
– Check wiring of the ignition unit, measure the resistance of the
ignition unit (should be between 50 and 300 Ω). Replace
ignition unit when necessary (Æ subsection 5.3.11 and
subsection 5.3.12)
– Check the UBA’s F1 fuse, replace when necessary
– Check the fan and KIM connectors and the UBA fuses
– Check and adjust the gas/air ratio (Æ subsection 2.1.8)
– Check for 24V – on the gas valve during start up
– Check the gas-supply pressure (Æ 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 ignition unit
– 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 (Æ subsection 2.1.11 and
subsection 5.3.13)
– 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 (Æ subsection 5.3.2)
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 43
Servicing5
Code Meaning
6L Blinking fault code: Flame goes out during operation
Possible
cause
1 Gas/air ratio not in order Check and adjust the gas/air ratio (Æ subsection 2.1.8)
2 Wrong gas supply pressure Check the gas-supply pressure (Æ subsection 2.1.7)
3 Earthing cable may be faulty Check the earthing cable connections (yellow/green wire)
4
Ionisation electrode may be faulty
5 Recirculation of flue gas Check the flue gas system
6
Code Meaning
6P Blinking fault code: Ignition unit has been on too long
Possible
cause
1 Try to reset the boiler by pressing the reset button for
2
Gas valve shuts down during operation
KIM may be defect
Action
Check the cabling on the ionisation electrode, check the
ionisation electrode and replace when necessary
(Æ subsection 2.1.11 and subsection 5.3.13).
Check connections and wiring of the gas valve and replace
when necessary
Action
2 seconds
Check if UBA 3 is fitted tightly onto the boiler
(Æ subsection 5.3.2).
If this is the case then contact the Buderus service
department.
Code Meaning
7C Blinking fault code: Mains supply interrupted
Possible
cause
1 A problem with the mains supply Carry out a power test procedure for safe testing of the
2 Reset button pressed too briefly Press the Reset button for two seconds
Code Meaning
7L Blinking fault code: Internal UBA error
Possible
cause
1 Bad UBA connection Check UBA connector
UBA may be defective Replace UBA (Æ subsection 5.3.2)
KIM may be defective Call the service department of Buderus
Code Meaning
8Y Blinking fault code: External switch contact is open
Possible
cause
1 External switch contact (e.g. temperature-monitoring
device for underfloor heating has been tripped or gas
pressure too low
Action
mains electrical supply
Action
Action
– Check wiring and connections of the external switch
contact
– Check the external switch contact
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44 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Servicing 5
Code Meaning
9A; 9H;
9U; P
Possible
cause
1 UBA not placed correctly Check to see if UBA is securely mounted
2 UBA may be defective Press reset. If fault code remains then try to temporarily
3 KIM may be defective action Call the service department of Buderus
Code Meaning
9L Blinking fault code: Gas valve assembly error
Possible
cause
1 Wiring to the gas valve incorrect, or loose wiring
2 UBA may be defective Press reset. If fault code remains then try to temporarily
3 KIM may be defective Call the service department of Buderus
Blinking fault code: System error
connections in UBA
Action
(Æ subsection 5.3.2)
connect a different UBA (Æ subsection 5.3.2)
Action
– Check the electrical connections of the gas valve.
– Measure the resistance of the gas valve
– Check if for example induction fields interfere with the
regulating device
connect a different UBA (Æ subsection 5.3.2)
Code Meaning
CA Blinking fault code: Return sensor exceeds 105 °C
Possible
cause
1 Resistance in the installation is too high Check if not all (thermostatic) radiator valves are closed or
2 Water pressure is too low in the installation Top up the system (Æ subsection 2.1.1)
3 Problem with the pump or pump cabling
(no circulation)
4 Return sensor is dirty or faulty Check the return sensor for dirt.
Code Meaning
CO Blinking fault code: Pressure sensor fault
Possible
cause
1 Wiring and connections of the pressure sensor may be
faulty
2 Pressure sensor may be faulty Check the pressure sensor and replace when necessary
Action
clogged with dirt
Check if the pump cabling is faulty or if the pump is stuck.
Replace pump when necessary (Æ subsection 5.3.6 and
subsection 5.3.7)
Measure if resistance over the sensor is correct.
If not replace return sensor (Æ subsection 5.3.8)
Action
Check the wiring and connection of the pressure sensor
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 45
Servicing5
Code Meaning
CU; CY Blinking fault code: Short circuit in return sensor or interrupted
Possible
cause
1 Wiring and connections of the return sensor may be
faulty
2 Return sensor may be faulty Check return sensor and replace when necessary
Code Meaning
E1; A; C; F;
H; L; Y
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
Non blinking fault code: Internal UBA error
Action
Check wiring and connections of the return sensor
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 (Æ subsection 5.3.2)
– Check if UBA 3 is correctly mounted
(Æ subsection 5.3.2)
Code Meaning
H07 Non blinking fault code: System pressure too low
Possible
cause
1 System pressure too low Top up the system (Æ subsection 2.1.1)
2 Pressure sensor may be defect Check the pressure sensor
Problem: No DHW, despite the system being operational
– Check three-way valve replace when necessary
– Check DHW sensor and replace when necessary
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
– Check all the wiring
– Check the UBA and replace when necessary (Æ subsection 5.3.2)
Action
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46 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Servicing 5
5.3 Checking and replacing parts
5.3.1 Checking and replacing the flue gas sensor
z Shut the boiler down by setting the mains switch to "0".
z Remove the casing.
z Remove the ventilation cover.
z Remove both plugs from the flue gas thermostat
(Æ fig. 65).
z Measure the resistance of the flue gas thermostat
(Æ fig. 66).
z Measure the temperature of the flue gas. Compare the
outcome to the measured resistance using the table below.
Flue gas thermostat
Temperature Position Resistance in Ω
≤ 105 °C open 0
> 105 °C closed endless high
Type A
fig. 65 Remove plugs from flue gas thermostat
Type A
Type B
Type B
table 10 Flue gas thermostat
z Remove the UBA 3 (Æ fig. 67) to test the cable's
resistance (Æ fig. 68).
z Remove the flue gas sensor when necessary by pulling it
out.
z Install the new flue gas sensor in reverse order.
fig. 66 Measure flue gas thermostat resistance
fig. 67 Remove UBA 3
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 47
Servicing5
3
5.3.2 Remove or replace the UBA 3
z Disconnect the system from the mains power supply.
z Loosen the screw (Æ fig. 69, item 1) and remove the
UBA 3 (Æ fig. 69, item 2). When necessary install a new
UBA 3 and secure by tightening the screw.
z Connect system to mains power supply.
2
1
1
3
2
3
2
fig. 68 Measure cable resistance
1
fig. 69 Remove UBA 3
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48 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
5.3.3 Checking or replacing the fan
z Disconnect the system from the mains power supply.
z Remove casing and ventilation cover.
z Set multimeter to VAC.
z Remove the 230 VAC plug (Æ fig. 70) from the fan.
z Connect the multimeter to the blue and brown connections.
z Connect the system to the mains power supply.
z Check if there is 230 VAC on the connections when the
operating code "0C" appears in the display.
z If necessary remove the UBA (Æ fig. 69) and set the multi-
meter to measuring resistance. The resistance of each
pole should be 0 Ω.
z Reconnect the cable.
z If necessary measure the resistance over the tachoplug
(Æ fig. 71) in the same manner.
z If the problem is still not solved then replace the fan.
Servicing 5
fig. 70 Remove 230 VAC plug
fig. 71 Measure resistance of tachoplug
z Disconnect the plug from the gas valve (Æ fig. 72, item 1).
z Loosen the swivel nut (Æ fig. 72, item 2)
z Remove the suction tube (Æ fig. 72, item 3).
1
2
3
fig. 72 Remove suction tube
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 49
Servicing5
z Remove both plugs from the fan (Æ fig. 73, item 1) and the
nut (Æ fig. 73, item 2).
z Remove the fan by moving it in the direction of the arrow
(Æ fig. 74).
z Check if the fan is dirty, wet or if the impellor is loose to the
axle.
1
2
fig. 73 Remove plugs and nut
z Remove the gas valve (Æ fig. 75).
fig. 74 Remove fan
fig. 75 Remove gas valve
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50 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
z Remove the venturi (Æ fig. 76).
z Insert the venturi into the new fan.
z Place a new flat seal between the gas pipe and the gas
valve.
z Reassemble in reverse order.
z Check all couplings for leaks.
5.3.4 Checking the mains supply
If the mains supply is interrupted or seems faulty, carry out a
power test procedure for safe testing of the mains electrical
supply.
z Loosen the screw (Æ fig. 69, item 1) and remove the UBA
(Æ fig. 69, item 2).
z Carry out the power test on position 15 and 16 of the high
voltage pin connector (Æ fig. 69, item 3).
z Refit the UBA and tighten the screw.
fig. 76 Remove venturi
55
28
Pin 1
81 pin low voltage
Pin 16
16 pin high voltage
KIM
Pin 1
Pin 81
Servicing 5
3
fig. 77 Checking the mains supply
5.3.5 Checking the fuse
z Disconnect the system from the mains power supply.
z Remove the UBA (Æ fig. 69).
z Release the fuse clamp (Æ fig. 78, item 2) by turning it to
2
1
the left with a screw driver.
z Remove and check the fuse (Æ fig. 78, item 1).
z Replace with a new fuse (5 AF) if necessary.
z Reassemble in reverse order.
fig. 78 Checking the fuse
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 51
Servicing5
5.3.6 Checking the pump
z Remove screw plug on the pump (Æ fig. 79).
z Turn the mains power switch to “I”.
z Wait about 4 minutes until "2L" appears in the display.
z Check to ensure that the pump is running. The pump’s
running mechanism may become blocked if the heating
system has been out of use for an extended period.
Use a screwdriver to rotate the pump in its normal running
direction and release the blockage in question. If this
procedure does not work, replace the pump.
z If the pump is working correctly, screw the plug back in.
5.3.7 Replacing the pump
z Disconnect the system from the power supply.
z Shut the servicing valve.
z Drain the system (Æ page 23).
z Loosen both swivel nuts (Æ fig. 80, item 1)
z Take out the pump.
z Replace it with new pump and reassemble in reverse
order.
z Purge the system and the pump of air.
z Connect system to mains power supply.
z Open servicing valves.
fig. 79 Checking the pump
1
NOTE
Fill the Buderus 600 - 28C and purge the
system of air.
5.3.8 Checking the bi-sensor, return sensor and hot water sensors.
z Remove the cable connection (Æ fig. 81) of the bi-sensor.
fig. 80 Replacing the pump
fig. 81 Remove cable connection of bi-sensor
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52 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
z Measure the resistance of both parts of the bi-sensor
(Æ fig. 82).
z Disconnect the return sensor (Æ fig. 83).
Servicing 5
fig. 82 Measure resistance of bi-sensor
fig. 83 Disconnect return sensor
z Measure the resistance of the return sensor (Æ fig. 84).
fig. 84 Measure resistance return sensor
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 53
Servicing5
z Disconnect the plugs of the hot water out flow sensor
(Æ fig. 85, item 1) and the hot water heat retaining sensor
(Æ fig. 85, item 2).
z Measure the resistance of both sensors (Æ fig. 86 and
fig. 87).
z Use a second-reading thermometer to measure the
temperature around the sensor.
z Compare readings with values shown in the table below. If
there is any mismatch (i.e. ≤ 10%), the sensor is defective.
2
1
fig. 85 Disconnect plugs of hot water sensors
Resistance values of the sensors
Temperature
[°C]
0 29,490
5 23,462 55 3,271
10 18,787 60 2,760
15 15,136 65 2,339
20 12,268 70 1,990
25 10,000 75 1,700
30 8,197 80 1,458
35 6,754 85 1,255
40 5,594 90 1,084
45 4,656 95 940
50 3,893 100 817
table 11 Resistance values of the sensors
Resistance
[Ω]
Temperature
[°C]
Resistance
[Ω]
fig. 86 Measure resistance of hot water out flow sensor
fig. 87 Measure resistance of hot water heat retaining sensor
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54 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Servicing 5
z Check each sensor's cable by measuring its resistance
(Æ fig. 87, 88, 89 and 90).
55
28
Pin 1
81 pin connector laagspanning
Pin 16
KIM
Pin 81
16 pin connector hoogspanning
Pin 1
fig. 88 Measure resistance of bi-sensor
55
28
Pin 1
Pin 16
z Reconnect all cables and connections.
81 pin connector laagspanning
KIM
Pin 81
16 pin connector hoogspanning
Pin 1
fig. 89 Measure resistance of return sensor
55
28
Pin 1
81 pin connector laagspanning
Pin 16
KIM
16 pin connector hoogspanning
Pin 1
Pin 81
fig. 90 Measure resistance of hot water heat retaining sensor
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 55
Servicing5
5.3.9 Replacing the bi-sensor
z Disconnect the boiler form the mains power supply.
z Close gas valve.
z Drain the system (Æ page 23).
z Disconnect the plug of the bi-sensor (Æ fig. 91, item 1).
z Remove spring clip (Æ fig. 91, item 2)
z Remove the bi-sensor (Æ fig. 91, item 3).
Some remaining water may leak out.
z Replace with new sensor and reassemble in reverse order.
z Fill the system and purge the system of air
(Æ subsection 2.1.1).
z Disconnect the boiler form the mains power supply.
z Close gas valve.
z Drain the system (Æ page 23).
z Disconnect the plug of the return sensor (Æ fig. 92).
z Remove the return sensor.
Some remaining water may leak out.
z Replace with new sensor and reassemble in reverse order.
z Fill the system and purge the system of air
(Æ subsection 2.1.1).
2
3
1
fig. 91 Replace bi-sensor
5.3.10 Replacing the hot water out flow sensor and the hot water heat retaining sensor.
z Disconnect the system from the mains power supply.
z Disconnect the plug of the hot water out flow sensor
(Æ fig. 93, item 1) or the hot water heat retaining sensor
(Æ fig. 93, item 2).
z Turn on the hot water faucet and wait until the water flowing
out is cold.
z Turn off the the hot water faucet.
z Turn off the main DHW valve.
z Remove the spring clip(s).
z Remove the sensor(s) and replace with new ones.
z Connect the plugs.
z Turn on a warm water faucet.
z Open the main DHW valve and purge of air.
z Turn the warm water faucet off.
z Reconnect the system to the mains power supply.
fig. 92 Disconnect plug return sensor
2
1
fig. 93 Disconnect plugs of hot water sensors
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56 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
5.3.11 Checking the ignition unit
z Checking the ignition unit.
z Disconnect the boiler from the mains power supply.
z Disconnect the plug (Æ fig. 94, item 1) of the ignition unit.
z Set multimeter to measuring VAC.
z Connect the boiler to the mains power supply and set in
service mode (Æ subsection 2.1.2).
z Check if you measure 120 VAC when the code "0C" is
visible in the display.
z Disconnect the multimeter from the plug and set the
multimeter to measuring resistance.
z Check if the resistance of the ignition unit is between 50 -
300 Ω.
z Disconnect the boiler from the mains power supply.
z Reconnect the plug to the ignition unit.
z Reconnect the boiler to the mains power supply.
Servicing 5
1
fig. 94 Disconnect plug of ignition unit
To check the connection lead to the UBA:
z Disconnect the boiler from the mains power supply.
z Remove the UBA 3 (Æ subsection 5.3.2).
z Disconnect the plug of the ignition unit (Æ fig. 94, item 1).
z Measure the resistance of the cable (Æ fig. 95).
z Reconnect the plug of the ignition unit.
z Remount the UBA 3 and connect the boiler to the mains
power supply.
5.3.12 Replacing the ignition unit
z Disconnect the boiler from the mains power supply.
z Disconnect the plug of the ignition unit (Æ fig. 94, item 1).
z Disconnect the ignition unit (Æ fig. 96, items 1, 2 and 3).
CAUTION
Be careful, the ignition unit is made of ceramic
material and can be damaged easily.
fig. 95 Measuring resistance of ignition unit
1
2
z Connect a new ignition unit with latch and nut in reverse
order.
z Check all couplings for gas leaks.
3
fig. 96 Replacing the ignition unit
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 57
Servicing5
5.3.13 Replacing the ionisation electrode
z Disconnect the boiler from the mains power supply.
z Disconnect the plug of the ionisation electrode
(Æ fig. 97).
fig. 97 Disconnecting plug
z Remove the ionisation electrode (Æ fig. 98, items 1, 2, 3
and 4).
z Measure the resistance of the ionisation electrode
(Æ fig. 99).
1
2
3
4
fig. 98 Remove ionisation electrode
fig. 99 Measure resistance ionisation electrode
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58 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
z Check if the ionisation electrode has been damaged, soiled
or is shows signs of wear (Æ fig. 100).
z Replace ionisation electrode if necessary.
z Place a new seal with latch and nut (Æ fig. 98, items 2, 3
and 4).
z Reassemble in reverse order.
z Check all couplings for gas leaks.
5.3.14 Checking the three-way valve for correct operation
z Set DHW temperature knob to "0".
z Disconnect the boiler from the mains power supply.
z Remove the securing pin (Æ fig. 101, item 1) and remove
the servomotor.
z Connect the boiler to the mains power supply.
z Set the DHW temperature knob on the BC10 to 60 °C.
z Open a warm water faucet.
z Check if the servomotor of the internal three way valve is
turning to the DHW position.
z Set the DHW temperature knob to "0".
z Close the warm water faucet.
z Check if the servomotor of the internal three-way valve
turns to the central heating position.
z Reconnect the the servomotor to the three-way valve in
reverse order.
z Check to see if the BC10 knobs are returned to the desired
settings.
Servicing 5
fig. 100 Check ionisation electrode
1
fig. 101 Remove securing pin
5.3.15 Replacing the servomotor of the three-way valve.
z Set DHW temperature knob to "0".
z Disconnect the boiler from the mains power supply.
z Remove the securing pin (Æ fig. 101, item 1) and remove
the servomotor.
z Disconnect the plug (Æ fig. 102, item 1) of the servomotor.
z Install new servomotor in reverse order.
z Check to see if the BC10 knobs are returned to the desired
settings.
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 59
Servicing5
5.3.16 Replacing the internal mechanism of the three-way valve
z Disconnect the system from the mains spower supply.
z Drain the system.
z Remove the securing pin (Æ fig. 101, item 1).
z Remove the servomotor of the three-way valve.
z Remove the internal mechanism of the three-way valve
(Æ fig. 103).
fig. 102 Disconnect plug
CAUTION
Some remaining water may come out.
z Install the new internal mechanism in reverse order.
Making sure that the flat side is facing down (Æ fig. 104).
z Reconnect the servomotor to the three-way valve in
reverse order.
z Fill and purge the system (Æ subsection 2.1.1).
fig. 103 Remove the internal mechanism of three-way valve
fig. 104 Internal mechanism of three-way valve
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60 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
5.3.17 Replacing the terminal strip
z Note order of cable terminals. Loosen all cables.
z Connect the cables, in the right order, to the new terminal
strip.
5.3.18 Checking KIM connections
z Disconnect the boiler from the mains power supply.
z Remove the UBA 3 (Æ subsection 5.3.2).
z Check if 4 pin connector (Æ fig. 105, item 1) is fitted and
secure.
NOTE
This is not a serviceable part and any fault
identified with this component, contact
Buderus.
55
28
Pin 1
81 pin connector laagspanning
Pin 16
KIM
16 pin connector hoogspanning
Pin 1
Pin 81
Servicing 5
5.3.19 Checking the burner thermostat
z Disconnect the boiler from the mains power supply.
z Remove both plugs from the burner thermostat.
z Check the resistance of the burner thermostat.
The resistance must be near 0 Ω (the switch temperature
is approx. 165 °C).
z Connect both plugs to the burner thermostat.
1
fig. 105 KIM connections
fig. 106 Remove plugs from the burner thermostat
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Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 61
Servicing5
5.3.20 Replacing the burner thermostat
z Disconnect the boiler from the mains power supply.
z Remove both plugs from the burner thermostat.
CAUTION
Lead the cable of the burner thermostat behind
the heat exchanger (Æ fig. 107).
z Unmount the burner thermostat.
z Mount the new burner thermostat at the same location as
the old one was.
z Connect both plugs at the burner thermostat.
z Check all couplings for gas leaks.
fig. 107 Leading the cable of the burner thermostat
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62 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
6 Appendix
6.1 Technical specifications
Appendix 6
Dimensions Unit
Type of gas supply as established in
EN 437 (GB/IE)
Rated thermal load for heating
Rated thermal load for preparing hot water
Rated heating capacity for system temperature
(modulating from 30° to 100°)
Heating curve 75/60 °C
Heating curve 40/30 °C
Seasonal efficiency (SEDBUK) for natural gas
for LPG
Max. gas rate for heating
Max. gas rate preparing hot water
Central heating installation
Heating water temperature °C 30 - 80
ΔT at residual head of 200 mbar K <20
Max. operating pressure of boiler bar 3.0
Volume heat exchanger heating circuit l 1.0
kW
kW
kW
kW
%
%
3
m
m3/h
/h
gas wall hung boiler condensing
Buderus 600 - 28C
GB/IE II
(natural gas H and LPG)
20 mbar, 37 mbar
2H3P
5.7 - 23.0
5.7 - 28.5
5.3 - 22.0
6.0 - 24.0
90.2
92.3
2.43
3.02
Pump over run time
Expansion vessel
Capacity of expansion vessel l 12
Admission pressure of expansion vessel bar 0.75
Hot water tank (type 24C)
Hot water capacity of heat exchanger l 0.95
Hot water flow at 60 °C (ΔT = 50 °C)
(ΔT = 35 °C)
Adjustable hot water temperature °C 30 - 60
Minimum connection pressure bar 0.9
Maximum connection pressure bar 10
min
h
l/min
l/min
0 - 60
24
7.8
13.0
Subject to modifications resulting from technical improvements! Buderus • http://www.buderus.co.uk
Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 63
Appendix6
Dimensions Unit
gas wall hung boiler condensing
Buderus 600 - 28C
Pipe connections
Gas mm Ø 22 mm compression fitting
Heating water mm Ø 22 mm compression fitting
Domestic water mm Ø 15 mm compression fitting
Condensate-water outlet inch G1"
Safety valve inch R¾" (¾" -½" adaptor supplied with boiler)
Flue gas values
Condensate water quantity, natural gas, 40/30 °Cl/h 1.6
pH value of condensate water 3.5 - 4.5
Exhaust-fume mass-flow rate
Full load
Part-load
g/s
g/s
10.6
4.3
Exhaust-fume temperature, full load
Heating curve 75/60 °C
Heating curve 40/30 °C
°C
°C
95
55
Exhaust-fume temperature, part-load
Heating curve 75/60 °C
Heating curve 40/30 °C
°C
°C
70
45
CO2 full load, natural gas
standard test gas G20 % 9.2
CO
full load, natural gas
2
standard test gas LPG % 10.3
Standard emission factor CO mg/kWh <22
Standard emission factor NO
x
mg/kWh <30
Flow pressure available for use Pa 75
Flue-gas system
Type of exhaust-fume connection C
, C33, C
13
53
Diameter of flue gas system mm 80/125, 60/100 (accessory)
Electrical data
Mains connection voltage V
230
Electrical power consumption
Full/Part load W 115/105
Electrical protection rating
IP X4D
Boiler dimensions and weight
Height x Width x Depth mm 850 x 480 x 370
Weight (without casing) kg 42
Casing kg 5
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
64 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
6.2 Residual pump lift
This graphic shows the amount of pump lift remaining for the
heating system.
Buderus 600 - 28C series
350
300
250
200
150
100
Residual pump lift [mbar]
Appendix 6
247 mbar
at 900 l/h
50
0
3001000 200 600400 500 900700 800 1000
Flow [l/h]
Subject to modifications resulting from technical improvements! Buderus • http://www.buderus.co.uk
Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 65
Appendix6
6.3 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 7.
Description Product No.
1 Casing (incl. insulation) 73624
2 Door control panel 73782
3 Ventilation cover 73647
4 Sealing ventilation cover 73649
5 Latches (set of 2 pc.) 73648s
6 Assembly casing block (set of 2 pc.) 38458s
7 Insulation frame 73733
8 Bracket 38092
9 Seal top (2 pc.) 73632s
10 Seal bottom (2 pc.) 73633s
11 Seal (set of 10 pc.) 73677s
12 Cover flue gas adaptor (80/125) 73628
13 Flue gas adaptor 73626
14 Seal 60 mm 73563
15 Exhaust pipe 73629
16 Seal 60 mm 73736
17 Condensate collector 73630
18 Flue gas sensor 87105062670
19 Seal exhaust pipe 73579
20 Condensate trap 73631
21 Drain pipe condensate trap 75988
22 Syphon 75986
23 Flex. drain pipe condensate trap 73508
24 Flow connection piece 73672
25 Automated air vent 38618
26 Bi-sensor 73673
27 Seal (set of 2 pc.) 73584s
28 O-ring (set of 10 pc.) 73580s
29 Supply pipe 73671
30 Clip (set of 5 pc.) 73653s
Service set GLE complete (also
31
includes item 32, 33, 35, 36, 37, 38,
47 and 89)
32 Ignition unit 8718600054
33 Ionisation electrode 38320
35 Seal (set of 5 pc.) 73666s
36 Gas/air supply valve (set of 5 pc.) 73756s
37 Seal fan (set of 5 pc.) 73640s
40 Heat exchanger 73659
41 Front panel heat exchanger 8718600024
42 Latches (set of 2 pc.) 73661s
43 Divider combustion gas 73670
44 Sight glass 73662
45 Seal heat exchanger 8718600141
46 Back panel heat exchanger 8718600023
47 Seal heat exchanger / gas/air supply 73728
7746700163
Description Product No.
48 Fan 73639
49 Gas valve 73645
50 Venturi 24 kW 73641
51 Gas pipe 73644
52 Suction pipe 73646
53 UBA 3 8718600083
54 Room control converter 78079
55 Cable harness 24V 73695
56 Cable harness 230V 73779
57 BC10 mount 73692
58 Backpanel mounting plate 73693
59 Backpanel KIM 73694
60 Sensor flow detection 38353
61 Transformer 73697
62 Sensor CH and outflow 38352
63 Hot water tank 73654
64 DHW pipe (hot) 73650
65 DHW pipe (cold) 73652
66 Hot water flow regulator 73656
67 Connection assembly 73655
68 Pump Uper 15-50-130 73674
69 Electronic pressure sensor 73678
70 Return pump connection 73676
71 Return connection 73583
72 Actuator three-way valve 73686
73 Cartridge three-way valve 73685
74 Three-way valve without actuator 73688
75 Clip actuator 73687
76 Power switch 73660
Return pipe 73781
77
78 Pressure relief valve 3 bar 73199
79 Sanitary supply pipe 73683
80 Supply manifold 73682
81 By-pass 73681
82 Expansion vessel pipe 73691
83 Expansion vessel 73718
84 Seal 125 mm 73737
85 Seal frame/condensate trap 73561
86 Insulation casing 73732
87 RCC connection box 73720
88 Manifold assembly 20378
89 Burner thermostat 7746900412
KIM 1024 73778
Nipple ½" 73780
Connection green 73773
Connection orange 73777
Connection red 73776
Connection blue 73775
Connection turquoise 73772
Buderus • http://www.buderus.co.uk Subject to modifications resulting from technical improvements!
66 Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009
Notes
Subject to modifications resulting from technical improvements! Buderus • http://www.buderus.co.uk
Installation and maintenance instructions for gas wall hung boiler condensing Buderus 600-28C • 07/2009 67
Heating system specialist:
Buderus
Cotswold Way, Warndon, Worcester WR4 9SW
Customer Services: 0870 - 421 5933
Technical Support: 0870 - 421 5944
Fax: 01905 - 753 130
www.buderus.co.uk
721.279A 0008
In the UK and IE, Buderus is a brand name of Bosch Thermotechnology Ltd.
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