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

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

Subject to modifications resulting from technical improvements!

Installation

1.3

Boiler assembly - exploded view

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

Legend

Casing

Door complete

Ventilation cover

Bracket

Concentric adaptor

Clip adaptor

100 mm Lipring

Fan

Seal Fan / Venturi

10. 60 mm Lipring

11. Flue gas pipe

12. Condensate collector

13. Seal flue gas pipe

14. Flue gas thermostat (STL)

15. Condensate trap

16. Air silencer tube

17. 50 mm Lipring

18. Gas valve

19. Rectifier

20. Venturi

21. Gas pipe

22. Gas service valve

23. Pipe return/flow top

24. Pipe connection

25. Clip

26. Return pipe

27. Drain cock

28. Connection return

29. Sensor

30. Flow pipe

31. Connection supply

32. Spring heat exchanger

33. Automatic air vent

34. O-ring heat exchanger

35. Seal heat exchanger

36. Safety sensor

37. O-ring

38. Rearpart heat exchanger

39. Gasket heat exchanger

40. Insulation rearpart heat

exchanger

41. Burner 11 kW

Burner 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

52. Ionisation electrode

53. Cable fan

54. Cable harness

55. Frame

56. RTH converter 230V

57. Seal ventilation cover

58. Assembly casing block

59. Seal

60. Air seal bush

61. Bracket ionisation electrode &

glow ignitor

62. Syphon seal condensate trap

63. Seal syphon

64. Insulation divider

65. Clip & screw insulation divider

66. Cap

67. Seal ionisation electrode

68. Clip air silencer

69. Gas air supply

70. Valve fan / gas air supply

71. Seal glow ignitor

72. Shield glow ignitor

73. Seal venturi / gasket

74. Seal fan / gas air supply

75. Gas air supply valve

76. Plate screw

77. Casing clip

78. Clip

79. Screw M5

80. Gasket

81. Clip

82. Seal flue gas thermostat

83. Seal condensate pipe

84. Swivel dreg with pinchring

85. Screw

86. Syphon

87. Drain pipe condensate trap / syphon

88. 60 mm Lipring

Содержание 600 - 11R

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 _________________...

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

Страница 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...

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

Страница 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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