Buderus 800-24 Installation And Servicing Instructions Download Page 21

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Installation

Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006

Subject to modifications resulting from technical improvements !

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

1.9.9

System examples

Prog

reference room / main living area

other rooms

TRV

LSV

Cylinder

radiator

CHF

CHR

Condensing gas boiler

Buderus 800

PRV

Prog

reference room / main living area

other rooms

TRV

LSV

Cylinder

radiator

CHF

CHR

Condensing gas boiler

Buderus 800

PRV

Boulter Buderus

programmable

room thermostat

reference room / main living area

other rooms

Condensing gas boiler

Buderus 800

BCT

BDV

TRV

LSV

Cylinder

radiator

CHF

CHR

PRV

Key to abbreviations :
AV

= Air Vent

BCT = Buderus cylinder thermostat
BDV = Buderus diverter valve
CB = Connection Block
CHF  = Central Heating Flow
CHR  = Central Heating Return
EV    = expansion vessel
JB

= Junction Box / RTH Relay

LSV = Lockshield Valve
PL

= Permanent Live

PRV = Pressure relief valve
TRV = Thermostatic radiator valve

Buderus 800 with Buderus controls

Buderus 800 with external 230V connection

Key to abbreviations :
AV

= Air Vent

CB = Connection Block
CHF = Central Heating Flow
CHR = Central Heating Return
CT

= Cylinder thermostat

DV = Diverter valve
EV = expansion vessel
JB

= Junction Box / RTH Relay

LSV = Lockshield Valve
PL

= Permanent Live

Prog = Programmer
PRV = Pressure relief valve
RT

= Room Thermostat

TRV = Thermostatic radiator valve
WC = Wiring Centre

Buderus 800 with external 230V connection and two port zone valves

Key to abbreviations :
AV

= Air Vent

CB = Connection Block
CHF = Central Heating Flow
CHR = Central Heating Return
CT

= Cylinder thermostat

EV = expansion vessel
JB

= Junction Box / RTH Relay

LSV = Lockshield Valve
PL

= Permanent Live

Prog = Programmer
PRV = Pressure relief valve
RT

= Room Thermostat

TRV = Thermostatic radiator valve
WC = Wiring Centre
ZV

= Two port Zone Valve

Summary of Contents for 800-24

Page 1: ...2 2006 GB EN For trade use Please read thoroughly before installation and servicing Installation and servicing instructions Gas wall hung Boiler condensing Buderus 800 24 29 43 60 and Buderus 800 24T2...

Page 2: ...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 Subject to technic...

Page 3: ...3 Category GB II2H3P 20 mbar 37 mbar natural gas H and LPG In this document LPG 3P G31 37 mbar 800 60 Category GB I2H 20 mbar natural gas H Power rating 230 VAC 50 Hz IP4X Fuse rating 1 25 slow blow G...

Page 4: ...90 396 EEC and with respect to EN 625 EN 483 and EN 677 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 En...

Page 5: ...g 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...

Page 6: ...152 mm 6 560 mm 22 335 mm 13 1 7 55 mm 2 1 7 46 1 4 5 46 1 4 5 30 1 1 5 30 1 1 5 431 mm 17 431 mm 17 55 1 7 2 75 3 75 3 150 6 150 6 55 1 7 2 75 3 4 x 75 3 150 6 152 mm 6 46 1 4 5 30 1 1 5 431 mm 17 75...

Page 7: ...mm 27 420 mm 1 2 16 75 3 40 1 1 2 30 1 1 5 431 mm 17 75 3 55 1 7 2 335 mm 13 1 7 115 mm 4 1 2 900 mm 35 1 2 75 3 300 11 5 4 152 mm 6 CH flow CH return CWDO GAS DHW warm DHW cold DHW warm out hot wate...

Page 8: ...ribution plate 320 Secondary gas air distribution plate 330 Burner plaque assembly 340 Gas air manifold 350 O ring gas air manifold to burner 360 Gas injector natural gas G20 incl O ring 370 Air restr...

Page 9: ...hat 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 t...

Page 10: ...it 1 3 3 Maximum Flue length The maximum pipe length of the air supply and flue gas exhaust pipes for the 800 Series condensing gas boilers see table 2 is determined by the total pressure loss of all...

Page 11: ...6 Do not carry the casing by the clasps Combination unit type 800 24T25V 29T25V Vertical boilers z Pull forward the casing of the hot water reservoir and lift it clear from the top holders This is on...

Page 12: ...re an optimum and efficient operation of the heating system care must be taken that the heating boiler always has the required minimum amount of circulation water In single circuit systems the require...

Page 13: ...propriate installation instructions using the connec tion kit On type 800 24T25 H V and 800 29T25 H V When using plastic pipes note the information provided by the pipe manufacturer This particularly...

Page 14: ...flue flows via the external condensate water outlet with odour trap syphon see fig 11 This additional component is required from 10 m expanded overall length of exhaust flue with 800 Series to boiler...

Page 15: ...e the boiler s adaptor plate onto the boiler fig 13 z Secure with 6 screws 1 8 2 Installation of the horizontal flue The standard 125 mm diameter horizontal flue system is suitable for length upto 595...

Page 16: ...wnwards 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 Refe...

Page 17: ...t 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 separation in both poles or by a three pin connector serving only the b...

Page 18: ...connection bridge connector STB Burner thermostat Internal three way reversing valve for mains water AC operation Digital Room Controller I O communication port Turn on voltage for external customer...

Page 19: ...ection z Remove the bridge in terminal 3 4 fig 22 item 2 and connect the control unit to the terminal strap z Remove the wire in terminal 1 2 fig 22 item 1 1 9 6 230V room temperature control device c...

Page 20: ...hnical improvements Buderus http buderus domestic co uk 1 9 8 Service tool The service tool allows you to determine the operating status of the boiler check components and carry out fast fault diagnos...

Page 21: ...rus diverter valve CB Connection Block CHF Central Heating Flow CHR Central Heating Return EV expansion vessel JB Junction Box RTH Relay LSV Lockshield Valve PL Permanent Live PRV Pressure relief valv...

Page 22: ...ge type water heater z If necessary open the CH flow and CH return maintenance valves z Connect temporary hose of the filling loop for pipe locations see page 6 and 7 z Open both stop valves z Fill th...

Page 23: ...2 1 5 Checking for leaks z Disconnect the system from power supply z Check all sections of gas pipework and connections for signs of leaks before starting up system for the first time If a leak is det...

Page 24: ...iption on type of gas label Category setting G 20 2E_20 mbar Formerly set to Wobbe index 15 0 kWh m3 referred to 0 C 1013 mbar applicable for Wobbe index range 12 0 to 15 7 kWh m3 LPG After change ove...

Page 25: ...w temperature in accordance with the system design and table 6 Factory setting 80 C controller poition 10 fig 31 Controls Key to fig 31 Item 1 Main switch Item 2 Flow temperature controller Item 3 Dom...

Page 26: ...ove the switch to position 2 when the system is controlled in accordance with the room temperature and if parts of the system outside the detection area of the room temperature controller are at risk...

Page 27: ...2 2 3 Measuring the gas supply pressure flow pressure z Open at least one radiator thermostat valve The gas boiler must not be turned on yet z Move the chimney sweeper switch fig 34 to position 1 On...

Page 28: ...tribution pressure 20 mbar for natural gas H and min 30 mbar max 50 mbar rated distribution pressure 37 mbar for LPG z Pull off the measuring hose and tighten up the screw plug on the test nipple Ensu...

Page 29: ...meter 10 to 0 Pa z In case of gas air ratio deviations adjust by using the setscrew fig 38 item 3 or fig 39 item 2 z Set mains switch and chimney sweeper switch to 0 z Remove the measuring equipment t...

Page 30: ...are correctly set provided these devices can be adjusted Measuring the ionisation current z Move the mains switch to 0 z Loosen the plug and socket connector of the monitoring cable and connect the m...

Page 31: ...handed over in good working order z Hand the User Manual to the householder and explain his her responsibilities under the relevant national regula tions z Explain and demonstrate the lighting and sh...

Page 32: ...ome into contact with any electrical components 3 3 Visual inspection z Check all gas bearing and water bearing pipes for signs of corrosion fig 43 z Replace corroded pipes if necessary For further in...

Page 33: ...e the gas service valve z Remove the boiler casing fig 5 on page 11 4 1 Cleaning the heat exchanger burner and syphon The heat exchanger can be cleaned with a brush and compressed air z Loosen the scr...

Page 34: ...ing clamps fig 47 item 2 of the burner cover and remove the burner cover and burner fig 47 item 3 Cleaning by using a brush and compressed air z Pull the syphon away from the condensate plate fig 47 i...

Page 35: ...ill with water before putting the syphon back in place z Put all components back in place in reversed order When plastic boiler connectors are used check the operation of the condensate water bypass z...

Page 36: ...ifications resulting from technical improvements Buderus http buderus domestic co uk When aluminium boiler connectors are used check the sealing cap of the condensate water bypass z Visual inspection...

Page 37: ...tself is malfunctioning Display Display after pressing the service button Meaning 0 800 Series is ready for operation A Burner interval circuit 10 minutes from start of burner C Waiting for the three...

Page 38: ...safety sensor temporarily with another one see subsection 5 3 9 and subsection 5 3 10 3 Problem with the pump or pump cabling no circulation Check if the pump cabling is faulty or if the pump is stuck...

Page 39: ...s are closed or clogged with dirt 2 Problem with the pump or pump cabling no circulation Check if the pump cabling is faulty or if the pump is stuck see subsection 5 3 7 3 Water pressure is too low in...

Page 40: ...is faulty Check the sensor and measure if resistance over the sensor is correct If not replace safety sensor see subsection 5 3 9 and subsection 5 3 10 2 A short or bad connection in the cable harness...

Page 41: ...ion message after ignition Possible cause Action 1 There is no flame ionisation electrode doesn t glow fan is turning Check wiring of the hot surface ignitor measure the resistance of the hot surface...

Page 42: ...up 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 ele...

Page 43: ...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 Check for a short circuit and replace the F3 fuse see subse...

Page 44: ...code remains then try to temporarily connect a different UBA see subsection 5 3 5 Code Meaning 9C KIM error Possible cause Action 1 Kim connected incorrectly or KIM defective Check the KIM connector a...

Page 45: ...UBA fitted Possible cause Action 1 Regulating device may have to cope with interference Check if for example induction fields interfere with the regulating device Check if the are any peaks in the el...

Page 46: ...o the chimney sweep switch should be set to 1 Remember to return the chimney sweep switch to 0 once work is complete z Remove cover of control level 2 z Set chimney sweep switch fig 54 to 1 5 3 3 Chec...

Page 47: ...ply by removing main fuse or power connection plug z Swivel the UBA to one side and pull the four pin plug of the mains power switch out at the back of the UBA z Disconnect all plug in cables Note the...

Page 48: ...ff the hoses at the differential pressure measuring point fig 58 item 4 z Pull out the plug of the burner thermostat fig 58 item 5 z Pull out the plug of the fan fig 59 item 1 z Turn and pull out the...

Page 49: ...z If the modulating pump is working correctly screw the plug in 5 3 8 Replacing the modulating pump z Disconnect the system from the power supply fig 62 item 1 z Close maintenance isolating valves z...

Page 50: ...safety and mains water sensors z Unplug cable connection from sensor z Measure resistance of sensor z Use a second reading thermometer to measure the temperature around the sensor z Check readings aga...

Page 51: ...ance values indicative values of the sensors fig 67 Replacing the flow return sensors fig 68 Boiler temperature sensor diagram Boiler temperature sensor C R 40 50 60 70 80 90 0 0 10 20 30 10 000 5 000...

Page 52: ...the sensors burner thermostat and in the UBA are in order Note that an incorrectly inserted plug can lead to the generation of error messages Start up the boiler by pressing the reset button z Set the...

Page 53: ...low burner thermostat to cool down activation tempera ture 107 C z Check burner thermostat for throughput If no throughput is detected the burner thermostat is defective z If the burner thermostat is...

Page 54: ...nnect system to mains power supply 5 3 16 Replacing the hot surface ignitor z Disconnect the system from the power supply z Disconnect the plug in cable z Loosen fixing screws and remove hot surface i...

Page 55: ...the same point with a measuring range of up to 1000 mA AC fig 81 item 1 z Set the mains switch to I z Unblock the 800 Series by pressing reset button and take current reading during start up procedure...

Page 56: ...to the screw in connection adapter z Connect all plug in cables in the correct order With the system running check for leaks at all joints likely to have been affected by the fitting of replacement p...

Page 57: ...able terminals z Attach cables in the right order to the new room tempera ture control device z Carry out the corresponding adjustment settings on the room temperature control device 5 3 24 Checking t...

Page 58: ...nnectors z Remove three way valve and fit new unit Refit screw in tube connectors z Fit regulating motor and lock into place by twisting the bayonet connector z Plug cable in z Open maintenance isolat...

Page 59: ...4 090 12 9 42 9 44 015 146 375 21 4 55 1 73 016 188 000 23 7 60 0 80 865 204 720 Seasonal efficiency SEDBUK 90 0 90 4 90 1 90 5 90 3 90 2 Boiler efficiency Heating curve 75 60 C max capacity Heating c...

Page 60: ...g kWh 15 15 15 15 15 15 Standard emission factor NOx mg kWh 20 20 20 20 20 20 Free feed pressure of fan Pa up to 140 up to 140 up to 140 up to 140 up to 140 up to 140 Gasrate G20 m3 h 2 33 2 33 2 96 2...

Page 61: ...600 1800 2 800 24 1 2 maximum modulation minimum modulation in heating mode only T 20K 1 2 T 20K 0 200 400 600 800 1000 1200 1400 1600 1800 Flow l h Residual pump lift mbar 800 29T25 1 2 maximum modul...

Page 62: ...2 5 set of 10 pieces 15022s 600 Pump power cable complete with connector 73319 610 Ring set of 5 pieces 73480s 620 Nut for heat exchanger 1 set of 5 pieces 73481s 630 Swivel nut for pump 15020s 640 R...

Page 63: ...2 1 on page 24 5 Carry out adjustment settings see chapter 2 2 2 on page 25 6 Measure the gas supply pressure flow pressure see chapter 2 2 3 on page 27 mbar 7 Check and set the gas air ratio CO2 cont...

Page 64: ...page 32 ageing 4 Check pollution of the burner heat exchanger and siphon see chapter 4 1 on page 33 5 Check the ionization electrode and incandesent firing electrode see chapter 4 1 on page 33 6 Measu...

Page 65: ...modifications resulting from technical improvements Buderus http buderus domestic co uk Inspection and service reports cont d Date _____________ Date _____________ Date _____________ Date ___________...

Page 66: ...related maintenance tasks Date ___________ Date ___________ 1 Clean heat exchanger and burner see chapter 4 1 on page 33 2 Check and adjust the gas air ratio CO2 content at full load at partial load...

Page 67: ...al improvements Buderus http buderus domestic co uk Date ___________ Date ___________ Date ___________ Date ___________ Date ___________ ______________ Pa _______________ _______________ _____________...

Page 68: ...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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