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Installation

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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

1.2

Boiler assembly - exploded view

Single unit (type 800 – 24 / 800 – 29)

Legend

10

Casing complete

20

Door

30

Casing clamp

40

Casing seal

50

Back panel

60

Mounting bracket

70

Seal lid for air vent

80

Heat exchanger

90

Revision set for air vent

100 Seal
110 Sight glas complete with

sealing rings

120 Restriction plate
130 Seal for condensate collector
140 Condensate collector incl. seal
150 Sensor complete with O-ring
160 Mounting clip
170 Seal for hot surface ignitor/

ionisation electrode

180 Hot surface ignitor
190 Ionisation electrode with cable and

connector

200 Safety sensor-ntc complete
210 Flue gas collector
220 Lip ring seal DN 80mm
230 Condensate by-pass
240 Syphon complete
260 Safety valve pipe
270 Seal set for syphon
280 Burner housing
290 Burner thermostat 107 °C
300 Burner seal
310 Gas/air distribution 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 restrictor natural gas (G20)
375 Connection tube, fan/burner
380 Connection tube, fan/burner

430

420

360

340

350

290

280

370

230

220

330

320

310

300

210

70

100

110

90

80

120

260

270

240

60

530

550

560

565

540

545

570

520

510

470

500

480

490

40

30

630

540

640

590

620

610

650

580

600

375 380

410

390

400

460

430

440

170

180

190

200

160

130

140

20

10

150

150

50

660

390 Air inlet pipe incl. gasket
400 Support mounting bracket fan anti

vibration

410 Fan
420 Connection pipe gas valve/burner
430 Connection nipple 3/4"x1/2" with O-ring
440 Gas unit
460 Gas inlet pipe 1/2"
470 Control uba
480 Temperature / pressure gauge

490 Bracket for uba
500 Power switch
510 230V cable
520 Cable harness complete
530 Supply pipe heat exchanger
540 O-ring
550 Spring clip heat exchanger/supply
560 Pressure relief valve
570 Non return valve R 1/4''
580 Pump

590 Gasket for pump DN 44 x 2.5
600 Pump power cable complete with

connector

610 Ring
620 Nut for heat exchanger 1 1/2''
630 Nut for heat exchanger 1 1/2''
640 Return pipe
650 Filling-, draining valve
660 RTH converter

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Содержание 800-24

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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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