Buderus 600 - 11R Installation And Servicing Instructions Download Page 15

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Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Subject to modifications resulting from technical improvements!

Buderus • http://www.buderus-domestic.co.uk

Installation

1.2

Dimensions and connections

460 mm

230 mm

50 mm

Ø100 mm

Ø60 mm

290 mm

105 mm

700 mm

604 mm

20 mm

70 mm

82 mm

328 mm

376 mm

25 mm

145 mm

130 mm

CH RETURN

CH FLOW

695 mm

GAS

CWDO

119 mm

8 mm

200 mm

21 mm

8 mm

CH Flow

Ø22 mm copper

CH return

Ø22 mm copper

GAS

Ø22 mm compression fitting

CWDO

Condensate water drainage outlet G1" OUTSIDE

Summary of Contents for 600 - 11R

Page 1: ...7212 2900 02 2006 GB EN For the installer Please read thoroughly Installation and servicing instructions Gas wall hung Boiler condensing Buderus 600 11R 19R 24R...

Page 2: ...tant development efforts may result in changes to illustrations functional steps and technical data Updating the documentation If you have suggestions for improvement or have found discrepancies pleas...

Page 3: ...G31 37 mbar Fuse rating 1 25 Ampere slow blow on boiler Power rating 230 VAC 50 Hz IPX4D A fuse main supply of 3 amp required BS 1362 The boiler consists of the following components 600 Gas condensin...

Page 4: ...ns The design and construction of the Buderus wall mounted condensing gas boiler 600 11R 19R 24R conforms to the basic specifications listed in the European directive governing gas fired appliances 90...

Page 5: ...ter or water treatment product such as Sentinal X100 to fill and top up the system When using water treatment only prod ucts suitable for use with Buderus heat exchangers are permitted e g Sentinel X1...

Page 6: ...en With the minimum flow circuit allowed by the controls the differential must not exceed 25 C see also the graph on page 5 The vertical distance between the pump and feed expansion cistern MUST compl...

Page 7: ...ce served by radiators not fitted with such a valve Such an arrangement will provide for potentially more efficient control of the environment and will also avoid the continuous running of the circula...

Page 8: ...eed Expansion Cistern JB Junction Box RTH Converter LSV Lockshield Valve PL Permanent Live PM Pump Prog Programmer RT Room Thermostat TRV Thermostatic Radiator Valve WC Wiring Centre fig 3 fig 4 Y pla...

Page 9: ...RTH Converter LSV Lockshield Valve PL Permanent Live PM Pump Prog Programmer RT Room thermostat TRV Thermostatic Radiator Valve WC Wiring Centre ZV Two port Zone Valve fig 5 fig 6 S plan 230V Prog re...

Page 10: ...to accept the expansion of the system water when heated to 110 C The charge pressure must not be less than the static water head above the vessel The pressure attained in the system when heated to 110...

Page 11: ...art 2 the hose from the draw off tap shall be connected to this fitting A test cock A double check valve of an approved type Sizing procedure for expansion vessel The volume of the expansion vessel li...

Page 12: ...ock Shield Valve MCW Mains Cold Water N Neutal JB Junction Box RTH Converter PL Permanent Live PM Pump Prog Programmer PRV Pressure relief valve safety valve RT Room Thermostat T Timer TRV Thermostati...

Page 13: ...ng installation Heating water temperature C 40 80 T at residual head of 200 mbar C 20 Max operating overpressure of boiler bar 3 0 Volume heat exchanger heating circuit l 1 0 Pipe connections Gas comp...

Page 14: ...Type of flue gas connection C13 C33 C53 Standard diameter of flue gas system mm 60 100 Electrical data Mains connection voltage V 230 Electrical power consumption Full Part load W 40 25 40 25 40 25 El...

Page 15: ...http www buderus domestic co uk Installation 1 1 2 Dimensions and connections 460 mm 230 mm 50 mm 100 mm 60 mm 290 mm 105 mm 700 mm 604 mm 20 mm 70 mm 82 mm 328 mm 376 mm 25 mm 145 mm 130 mm CH RETUR...

Page 16: ...r 19 24kW 42 Burner seal 43 Heat exchanger 44 Restrictor baffle 45 Front heat exchanger insulation 46 Frontpart heat exchanger 47 Sight glass 48 Securing latch 49 UBA 50 Power switch 51 Glow ignitor 5...

Page 17: ...ll fixing screws 2 x wall plugs 2 x washers Seals 2 x Square wrench Initial start up sticker Second identification plate 1 5 Hanging the boiler The boiler is transported in a horizontal position z Ope...

Page 18: ...roved P T F E tape Connect to gas supply according to the relevant standards 1 6 3 Water circulation system The central heating system should be installed in accordance with BS 6798 and in addition fo...

Page 19: ...BS acrylonitrile butadienestyrene PP polypropylene polyprolene or PVC C cross linked polyvinyl chloride The condensate drain can be attached to the syphon fig 5 Any internal pipework should be of a di...

Page 20: ...other services See fig 9 for information Fig 7 External termination of condensate drainage pipe via internal discharge branch e g sink waste and condensate syphon 75 mm min trap No length restriction...

Page 21: ...vel 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...

Page 22: ...e 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 horizon...

Page 23: ...em boilers is determined by the total pressure loss of all components in the flue gas exhaust air supply system Maximum length of horizontal or vertical extensions for 60 100 flue system is L 7 5 m Ma...

Page 24: ...0 100 and 80 125 Flat roof pitched roof Fig 15 Horizontal flue length A L 60 100 flue system For every bend or extension the max flue length L has to be reduced by 500 mm extension 0 5 m 1000 mm exten...

Page 25: ...losed installation on page 22 1 7 6 Connecting the vertical flue adaptor z Fit the vertical flue adaptor fig 16 onto the appli ance flue connector 1 7 7 Connecting the horizontal flue turret z Fit the...

Page 26: ...sembly 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 to figure 17...

Page 27: ...BS 6500 Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having 3 mm contact separation in both poles or by a three pin connector s...

Page 28: ...0V 50 Hz 2 1 2 1 1 2 1 2 external 230V controls Volt free external control device remove wirebridge when used Volt free room thermostat when used with 230V timer 1 1 1 IMPORTANT The wires in this main...

Page 29: ...ig 22 z Remove the cover of the RTH converter fig 23 item 1 z Feed the 230V switch live and neutral from external controls through the cable gland z Identify the 230V terminal block by the shaded area...

Page 30: ...up again If no flame develops then the gas valve closes and the fan continues to run to post purge The boiler will try to start up three times If there still is no flame developing after three times t...

Page 31: ...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 2 2 2 Purging air from the gas supply system z Loose...

Page 32: ...t of a code can be seen 4 Display see fig 27 item 4 The display visualizes settings adjustments and fault codes 5 Heat capacity Jumper see fig 27 item 5 Do not use 6 Chimney sweep switch see fig 27 it...

Page 33: ...troller see fig 27 item 10 This controller with the radiator symbol allows the installer to set the maximum flow temperature see table 4 on page 36 2 2 4 Checking the gas type It is very important tha...

Page 34: ...e fig 29 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 fig 30 z Slowly open the gas shut off valve fig 29 item 2 z Open at least two...

Page 35: ...TTENTION If the required connection pressure is incorrect contact your gas supplier Fig 30 Measuring the gas supply pressure Fig 31 Control box Key to fig 31 item 1 Cover for second operating level it...

Page 36: ...1 z Set the heating capacity table 5 according to the amount of heat output required for the system fig 31 item 4 Controller setting Flow temperature C 1 40 2 44 3 48 4 53 5 58 6 62 7 67 8 71 9 76 10...

Page 37: ...5 Pa 0 05 mbar 0 05 mbar display on measuring gauge 10 Pa to 0 Pa z If the gas air ratio does not conform to specifications re adjust at the setscrew fig 33 item 1 z Turn power switch and chimney swe...

Page 38: ...rvice button is pressed the display turns to c Press the Reset button The display shows r z Fit the casing see fig 36 item 1 z Tighten the fixing screw see fig 36 item 2 2 2 11 Balancing 1 Set the pro...

Page 39: ...uel economy consistent with the household require ments of heating Advise the user of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining...

Page 40: ...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 cylinder for leakage 3 2 7 Check the programmin...

Page 41: ...power lead fig 37 item 1 burner control unit fan control lead fig 37 item 2 and gas burner assembly fig 37 item 3 z Loosen union nut on gas valve assembly fig 37 item 4 z Push safety plate out of way...

Page 42: ...rth ground leads and remove the retaining plate of the glow ignitor by pulling it upwards withdraw the glow ignitor by pulling it upwards In the case of the ionisation electrode Swivel the retaining p...

Page 43: ...ghten the draining nipple screw z Release plug in connection of fan power lead fig 37 item 1 page 41 burner control unit fan control lead fig 37 item 2 page 41 and gas burner assembly fig 37 item 3 pa...

Page 44: ...ing it upwards z Remove securing pin on flow and return connection conduit fig 44 of heat exchanger z Remove spiral heat exchanger by pulling towards front fig 44 Drain any water remaining in the heat...

Page 45: ...d back cover of the heat exchanger z Check O ring seals spiral and replace as required z Smear the O ring seal with a thin layer of silicone grease 4 1 3 Cleaning the condensate trap and syphon z Remo...

Page 46: ...ioning Display Display after pressing the service button Meaning 0 Buderus 600 11R 19R 24R is ready for operation A Burner interval circuit 10 min from burner start up H Standby activated Buderus 600...

Page 47: ...5 K Possible cause Action 1 Resistance in the installation is too high Check if thermostatic radiator valves are closed or clogged with dirt 2 Safety sensor is dirty or faulty Check the safety sensor...

Page 48: ...Meaning 3C Bad plug in connection at cable harness or damaged wiring Possible cause Action 1 Cable harness is faulty Check cable harness for faults and bad connections 2 Connectors at the back of the...

Page 49: ...the sensor is correct If not replace safety sensor see subsection 5 3 8 subsection 5 3 9 subsection 5 3 10 2 A short or bad connection in the cable harness Check the cable harness and or connector of...

Page 50: ...istance of the glow ignitor should be between 50 and 300 Ohm Replace glow ignitor if necessary see subsection 5 3 14 and subsection 5 3 15 Check the UBA s F1 fuse replace if necessary 2 There is no fl...

Page 51: ...t close properly If there is still more than 20 V on the gas valve when there is no heat demand then check the UBA by temporarily connecting a different UBA Check ionisation electrode circuit see sub...

Page 52: ...ss the Reset button until r appears in the display Code Meaning 7F F3 fuse defect or burner control unit error Possible cause Action 1 Short circuit in the 24V circuit three way valve or connector Che...

Page 53: ...ing 9C KIM error Possible cause Action 1 Kim connected incorrectly or KIM defective Check the KIM connector and fan connector If the connectors are fine then contact the technical support of Buderus C...

Page 54: ...eaks in the electrical network 2 UBA may be defective Press reset If fault code remains then try to temporarily connect a different UBA see subsection 5 3 3 Code Meaning EP Non compatible UBA fitted P...

Page 55: ...rmostat is working correctly plug it in once more 5 3 2 Replacing the flue gas thermostat z Unscrew the flow backup mounting z Detach the cable plug at the flue gas thermostat z Loosen both retaining...

Page 56: ...n now fails to run it must be replaced z If the fan runs at only partial load i e effective oper ation of the boiler is not possible troubleshooting should start at the connection cable to the UBA or...

Page 57: ...bove procedure in reverse 5 3 6 Checking the wiring connections of the UBA z Disconnect the system from the power supply z Loosen the two fixing screws and carefully turn the UBA around fig 49 item 1...

Page 58: ...sure resistance of sensor fig 58 item 1 z Use a second reading thermometer to measure the temperature around the sensor z Compare readings with values shown in table 6 on page 60 If there is any misma...

Page 59: ...Disconnect 18 pin plug from UBA fig 60 item 2 z Use a continuity tester to check the cable between the plug in connection and the 18 pin plug in the UBA The test should be carried out on connections...

Page 60: ...set button z Set the power switch to 0 z Disconnect the system from the power supply z Unplug cable connection from flow sensor z Disconnect 20 pin plug from UBA z Use a continuity tester to check the...

Page 61: ...er plug the cable into the UBA housing z Turn the UBA around and place back onto the bracket z Tighten the two screws z Connect system to mains power supply 5 3 15 Replacing the glow ingitor z Disconn...

Page 62: ...de z Remove the gas air unit z Loosen the plug and socket connection of the ionization electrode z Loosen screw fig 67 item 1 by a half turn and slide bar to remove z Pull electrode to remove and fit...

Page 63: ...ews on the ventilation cover fig 69 z Remove the ventilation cover z Loosen union nut on gas valve assembly fig 70 item 4 z Release plug in connection of fan power lead fig 70 item 1 burner control un...

Page 64: ...rt new seal fig 73 item 4 z Remount all components in the reverse sequence z Cover stickers fig 74 item 1 with the new stickers 2 pieces included in conversion kit Starting up z Start up the appliance...

Page 65: ...mall 2 big 79 73572s Screw M5 set of 10 pc 80 73488s Gasket set of 5 pc 81 38475s Clip set of 5 pc 82 77486s Seal flue gas thermostat set of 5 pc 83 73561 Seal condensate pipe 84 75882 Swivel dreg wit...

Page 66: ...page 33 5 Carry out adjustment settings see subsection 2 2 6 on page 35 6 Measure the gas connection pressure working pressure see subsection 2 2 5 on page 34 _____________________ mbar 7 Checking and...

Page 67: ...n and servicing instructions for wall mounted condensing gas boiler Buderus 600 11R 19R 24R 02 2006 67 Subject to modifications resulting from technical improvements Buderus http www buderus domestic...

Page 68: ...nitor and ionisation electrode after disconnecting the system see subsection 4 1 1 on page 41 6 Measuring the ionisation current see subsection 2 2 10 on page 38 _________________ A _________________...

Page 69: ...____ A _______________ A _______________ A _______________ A _____________ mbar _____________ mbar _____________ mbar _____________ mbar _____________ mbar _______________ Pa _______________ Pa ______...

Page 70: ..._______ Date _____________ 1 Clean heat exchanger burner condensate trap and syphon see subsection 4 1 on page 41 2 Check and adjust the gas air ratio CO2 content at full load at part load see subsect...

Page 71: ...eports 8 Date ___________ Date ___________ Date ___________ Date ___________ Date ___________ ___________________ Pa ____________________ ____________________ ___________________ Pa __________________...

Page 72: ...buderus domestic co uk Buderus is a trading name of BBT Thermotechnology UK Ltd Customer Services Technical Product Support Sales Returns Spares Tel 0870 421 5933 Tel 0870 421 5944 Tel 01905 752 640 T...

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