Boulter Buderus Benchmark 600 Series Installation And Servicing Instruction Download Page 60

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Servicing

Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004

Subject to modifications resulting from technical improvements!

Boulter Buderus Ltd. • http://www.boulter-boilers.com

Install the new internal mechanism in reverse order.
Making sure that the flat side is facing down (see fig. 98).

Reconnect the servomotor to the three-way valve in
reverse order.

Fill and purge the system.

5.3.17 Replacing the terminal strip

Note order of cable terminals. Loosen all cables.

Connect the cables, in the right order, to the new terminal
strip.

5.3.18 Checking KIM connections

Disconnect the boiler from the mains power supply.

Remove the UBA 3 (see subsection 5.3.2).

Check if 4 pin connector (fig. 99, item 1) is fitted and
secure.

fig. 98 Internal mechanism of three-way valve

fig. 99 KIM connections

28 55

KIM

81 pin connector laagspanning

16 pin connector hoogspanning

NOTE

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

Summary of Contents for Benchmark 600 Series

Page 1: ...7212 7900 01 2004 GB IR EN For trade use Please read thoroughly before installing or servicing Installation and servicing instructions Wall mounted condensing gas boiler 600 28C...

Page 2: ...elopment 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 plea...

Page 3: ...Hz IPX4D Fuse rating 1 25 Ampere slow blow Important general instructions for use Only use the boiler in accordance with its designated use and the installation and servicing instructions Servicing a...

Page 4: ...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...

Page 5: ...ral 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 fire...

Page 6: ...50 2 35 1 1 2 5 3 4 850 mm 33 5 4 2 110 4 175 7 240 9 305 12 370 14 440 17 100 4 7 1 3 6 80mm 125mm 3 5 6 100 mm 4 100 mm 4 120 130 5 5 excentrical connections 500 20 for expansion vessel disassembly...

Page 7: ...hes 42 Divider combustion gas 43 Sight glass 44 Seal heat exchanger 45 Backside heat exchanger 46 Seal heat exchanger gas air supply 26 27 29 24 23 25 28 43 40 41 42 6 1 2 85 60 62 56 75 57 64 66 65 6...

Page 8: ...bly 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 com...

Page 9: ...pos 3 1 Flue finishing kit 1 3 3 Maximum Flue length The maximum pipe length of the air supply and flue gas exhaust pipes for the 600 Series condensing gas boilers see table 2 is determined by the tot...

Page 10: ...p 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 G 1 2 x 22 mm 2 x 15 mm Initial start up sticker Second identificati...

Page 11: ...onnections 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 E...

Page 12: ...he 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 a...

Page 13: ...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 boile...

Page 14: ...e gas duct or flue gas adaptor 80 125 to 60 100 fig 14 onto the appliance flue connector z For remaining installation of the vertical flue assembly refer to the relevant installation instructions fig...

Page 15: ...ards The assembly will be made easier if a solvent free grease is lightly applied to the male end of the ducts z Push the assembly through the wall and slide the turret onto the flue connector Refer t...

Page 16: ...less than 0 75 mm2 24 x 0 2 mm and to BS 6500 Table 16 Connection must be made in a way that allows complete isola tion of the electrical supply such as a double pole switch having 3 mm 1 8 contact se...

Page 17: ...0 VAC 230 VAC 0 VAC 50 78 Flue gas monitor ModuLine roomtemp controller Supply Safety sensor 3 4 5 6 7 8 9 10 11 12 13 green orange red blue grey light blue 1 2 1 2 1 2 1 2 1 2 1 2 3 24Vac 0Vac 1 2 Co...

Page 18: ...er 1 10 2 230V Room temperature control device connection z Remove the cover of the room control converter fig 21 item 1 z Lead the 230V control device wire through the cable lead see fig 21 z Fix the...

Page 19: ...stem External temperature sensor fig 24 RCC connection box 0V ac 24 V ac ModuLine RCC 1 fig 25 Connection box 14 15 11 12 13 5 6 1 2 9 10 7 8 3 4 ModuLine RCC 1 2 green The room control converter is c...

Page 20: ...nstream heating circuit without actuator Key to abbreviations Note that example systems are to be regarded as schematic representations only 1 Thermostat valve not required or to be opened fully if re...

Page 21: ...ration 2 1 1 Fill the heating system z Remove the ventilation cover fig 27 z Adjust the knobs for central heating fig 28 item 1 and domestic hot water fig 28 item 2 to 0 CAUTION DO NOT operate the con...

Page 22: ...t the switch on the BC10 to 1 see fig 28 item 3 z Press the service button fig 28 item 4 until the system pressure for example P1 1 appears in the display z If necessary open the CH flow and CH return...

Page 23: ...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 To...

Page 24: ...wise 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 Eme...

Page 25: ...s in the display F 5 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...

Page 26: ...d ings 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 connectio...

Page 27: ...sure 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 T...

Page 28: ...r one see fig 43 item 2 z Slowly open the gas shutoff valve z Open at least two radiators z Set the mains switch fig 41 item 1 to 1 z Create a heat demand by pressing the chimney sweep button fig 41 i...

Page 29: ...y 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 see fig 45 If this is not the case then adjustment is needed z Remove th...

Page 30: ...ler is in operation z Use an approved leak detector to check all connections for possible leaks The product must be certified as a gasleak testing agent z Do not allow the product to come into contact...

Page 31: ...e ionisation current being checked must measure 2 A direct current z Enter the reading on the report form z Set the mains power switch to 0 fig 41 item 1 z Remove multimeter and restore the plug and s...

Page 32: ...to 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 Ch...

Page 33: ...itch to 0 fig 41 item 1 z Close the gas shutoff valve fig 42 item 1 z Remove the security screw and casing fig 49 item 1 z Remove the ventilation cover see fig 49 z Loosen the gas connection between t...

Page 34: ...urner when necessary The burner may only be cleaned with a soft brush or compressed air z Now the front cover of the heat exchanger can be removed by opening the latches fig 52 item 1 z Remove the flu...

Page 35: ...water pipe z Pull out the safety clips fig 55 item 1 z Pull out the standby and hot water sensor and place the flushing connections in their place see fig 56 z Connect the descaling device and flush...

Page 36: ...now 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 fau...

Page 37: ...0 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 600 28C ready to provide he...

Page 38: ...n is too high Check if not all thermostatic radiator valves are closed or clogged with dirt 2 Water pressure is too low in the installation Top up the system see subsection 2 1 1 3 Problem with the pu...

Page 39: ...if resistance over the sensor is correct If not replace bi sensor see subsection 5 3 8 subsection 5 3 9 subsection 5 3 10 5 Return sensor may be faulty Check return sensor and when necessary replace...

Page 40: ...bling no circulation Check if the pump cabling is faulty or if the pump is stuck Replace pump when necessary see subsection 5 3 6 and subsection 5 3 7 4 Bi sensor is dirty or faulty Check the bi senso...

Page 41: ...or disconnected Check the sensor and measure if resistance over the sensor is correct If not replace bi sensor see subsection 5 3 8 subsection 5 3 9 subsection 5 3 10 2 A short or bad connection in th...

Page 42: ...tions yellow green wire Check the cabling on the hot surface ignitor Press reset If fault code remains then try to temporarily connect a different UBA see subsection 5 3 2 Code Meaning 6C Blinking fau...

Page 43: ...6P Blinking fault code Glow ignitor has been on too long Possible cause Action 1 Try to reset the boiler by pressing the reset button for 2 seconds 2 KIM may be defect Check if UBA 3 is fitted tightly...

Page 44: ...may be defective Press reset If fault code remains then try to temporarily connect a different UBA see subsection 5 3 2 3 KIM may be defective Call the service department of Boulter Buderus Code Meani...

Page 45: ...ng device Check if the are any peaks in the electrical network caused by maybe windmills or a power generator 2 UBA may be defective Press reset If fault code remains then try to temporarily connect a...

Page 46: ...flue gas thermostat see fig 58 item 1 z Measure the resistance of the flue gas thermostat see fig 59 z Measure the temperature of the flue gas Compare the outcome to the measured resistance using the...

Page 47: ...ilers com 5 3 2 Remove or replace the UBA z Disconnect the system from the mains power supply z Loosen the screw fig 62 item 1 and remove the UBA fig 62 item 2 When necessary install a new UBA and sec...

Page 48: ...tions 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 see fig 62 and set t...

Page 49: ...ents Boulter Buderus Ltd http www boulter boilers com z Remove both plugs from the fan fig 66 item 1 and the nut fig 66 item 2 z Remove the fan by moving it in the direction of the arrow fig 67 z Chec...

Page 50: ...mains electrical supply z Loosen the screw fig 62 item 1 and remove the UBA fig 62 item 2 z Carry out the power test on position 15 and 16 of the high voltage pin connector fig 62 item 3 z Refit the...

Page 51: ...t 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...

Page 52: ...derus Ltd http www boulter boilers com 5 3 8 Checking the bi sensor return sensor and hot water sensors z Remove the cable connection see fig 74 of the bi sensor z Measure the resistance of both parts...

Page 53: ...80 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 fig 7...

Page 54: ...Check each sensor s cable by measuring its resistance see fig 81 fig 82 fig 83 and fig 83 fig 80 Measure resistance of hot water heat retaining sensor fig 81 Measure resistance of bi sensor Pin 1 28...

Page 55: ...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 see subsection 2 1 1 z Disconnect the boiler form the mains...

Page 56: ...ingnitor z Disconnect the boiler from the mains power supply z Disconnect the plug fig 87 item 1 of the hot surface ignitor z Set multimeter to measuring VAC z Connect the boiler to the mains power s...

Page 57: ...surface ignitor fig 87 item 1 z Disconnect the hot surface ignitor see fig 89 item 1 z Connect a new hot surface ignitor in reverse order 5 3 13 Replacing the ionisation electrode z Disconnect the boi...

Page 58: ...ve for correct operation z Set DHW temperature knob to 0 z Disconnect the boiler from the mains power supply z Remove the securing pin see fig 95 item 1 and remove the servomotor z Connect the boiler...

Page 59: ...s power supply z Remove the securing pin see fig 95 item 1 and remove the servomotor z Disconnect the plug fig 96 item 1 of the servomotor z Install new servomotor in reverse order z Check to see if t...

Page 60: ...the system 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 Dis...

Page 61: ...ng from 30 to 100 Heating curve 75 60 C Heating curve 40 30 C kW kW 5 3 22 0 6 0 24 0 Seasonal efficiency SEDBUK for natural gas for propane 90 3 92 3 Max gas rate for heating Max gas rate preparing h...

Page 62: ...ter 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...

Page 63: ...ions resulting from technical improvements Boulter Buderus Ltd http www boulter boilers com 6 2 Residual pump lift This graphic shows the amount of pump lift remaining for the heating system 600 28C s...

Page 64: ...sion vessel pipe 73691 820 Expansion vessel 73718 830 Seal 125 mm 73737 840 Seal frame syphon 73561 850 Insulation casing 73732 860 RCC connection box 73720 KIM 1024 73778 Nipple 73780 Connection gree...

Page 65: ...of gas if necessary see subsection 2 1 5 on page 27 5 Carry out adjustment settings see subsection 2 1 6 on page 27 6 Measure the gas connection pressure flow pressure see subsection 2 1 7 on page 27...

Page 66: ...5 Check the burner hot surface ignitor and ionisation electrode after disconnecting the system see subsection 3 2 3 on page 32 6 Measuring the ionisation current see subsection 2 1 11 on page 30 ____...

Page 67: ...___ A _______________ A _______________ A _______________ A _____________ mbar _____________ mbar _____________ mbar _____________ mbar _____________ mbar _______________ Pa _______________ Pa _______...

Page 68: ...1 3 Measure gas supply pressure see subsection 2 1 7 on page 27 ________________ mbar ________________ mbar 4 Check and adjust the gas air ratio CO2 content at full load at part load see subsection 2...

Page 69: ...____________ mbar _____________ mbar _____________ mbar _____________ mbar _____________ mbar ___________________ Pa ____________________ ____________________ ___________________ Pa __________________...

Page 70: ...Installation and maintenance instructions for wall mounted condensing gas boiler 600 28C 01 2004 Subject to modifications resulting from technical improvements Boulter Buderus Ltd http www boulter boi...

Page 71: ...tallation and maintenance instructions for wall mounted condensing gas boiler 600 28C 01 2004 71 Subject to modifications resulting from technical improvements Boulter Buderus Ltd http www boulter boi...

Page 72: ...Heating system specialist Boulter Buderus Ltd Magnet House Whitehouse Road Ipswich Suffolk IP1 5JA http www boulter boilers com 721 279A 2155A 01 2004...

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Boulter Buderus Benchmark 600 Series, Installation And Servicing Instruction

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