Installation and maintenance instructions

Installation and maintenance instructions
7209 6700 - 02/2006 GB (EN)
Installation and maintenance
instructions
Gas wall hung Boiler condensing
600 - 11S / 19S / 24S / 24C
U122
K
Please read thoroughly
For the installer
The boiler meets the basic requirements of 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 technical modifications!
Constant 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, please do not hesitate to contact us.
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2
Subject to modifications resulting from technical improvements!
Installation and servicing instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Contents
Preface
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions, connections and assembly . . . . . . . . 6
Boiler assembly - exploded view . . . . . . . . . . . . . . 7
Flue Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Items supplied with unit . . . . . . . . . . . . . . . . . . . . 11
Hanging the boiler . . . . . . . . . . . . . . . . . . . . . . . . 11
Water circulation system . . . . . . . . . . . . . . . . . . . 12
Pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical connections. . . . . . . . . . . . . . . . . . . . . . 17
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
These installation and servicing instructions apply to:
Buderus wall-mounted condensing gas boilers
600 - 11S / 19S / 24S / 24C.
2
2.1
Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preparing the boiler for operation . . . . . . . . . . . . . 22
3
3.1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Preparing the heating boiler for inspection . . . . . . 30
4
4.1
4.2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Clean the heat exchanger, burner and condensate
trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Flushing out the hot-water heat exchanger . . . . . 35
5
5.1
5.2
5.3
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operating codes . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking and replacing parts . . . . . . . . . . . . . . . . 45
Model C13, C33, C53
Type GB II2H3P 20 mbar, 37 mbar
In this document: NG = 2-G20-20 mbar
LPG = 3P-G31-37 mbar
Power rating: 230 VAC, 50 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 and repair
must be carried out by CORGI registered installer. Only use
the boiler in combinations and with the accessories and spare
parts indicated in the installation and servicing instructions.
Other combinations, accessories and consumables may only
be used if they are expressly provided for the designated use
and if system performance and safety are not affected in any
way.
6
Changing to another type of gas . . . . . . . . . . . 59
7
7.1
7.2
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Technical specifications . . . . . . . . . . . . . . . . . . . . 62
Short list of spare parts . . . . . . . . . . . . . . . . . . . . 64
The boiler is suitable for connection to fully pumped, sealed
water systems ONLY. Adequate arrangements for completely
draining the system by provision of draining valves must be
provided in the installation pipework.
8
8.1
8.2
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Start-up report . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Inspection and maintenance reports . . . . . . . . . . 66
Pipework from the boiler is routed downwards as standard, but
may be routed upwards behind the boiler using the distance
frame (supplied in a separate kit).
Subject to technical modifications.
As a result of our policy of constant development, there may be
small differences between illustrations, functional steps and
technical data.
G. C. Aplliance No. :
Buderus 600 - 11S
Buderus 600 - 19S
Buderus 600 - 24S
Buderus 600 - 24C
41-110-16
41-110-17
41-110-18
47-110-01
BENCHMARK' Log Book
All Buderus gas fired boilers now include an installation,
commissioning and service record log book. The details of the
log book will be required in the event of any warranty work
being requested.
Please complete the appropriate sections on completion of the
installation and commissioning.
REMEMBER: Please hand the log book back to the user.
Subject to modifications resulting from technical improvements!
Buderus • http://www.buderus-domestic.co.uk
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
3
Regulations and directives
It is law that all gas appliances are installed and serviced by a
CORGI registered installer in accordance with the regulations.
Failure to install appliances correctly could lead to prosecution.
It is in your own interest, and that of safety, to ensure the law
is complied with.
The installation must also be in accordance with the latest
I.E.E (BS.7671) Wiring Regulations, water regulations, the
building regulations and the Building Standards (Scotland) and
any relevant requirements of the local authority.
It is a requirement and in your own interest, and that of safety
that this boiler must be installed by a CORGI registered
installer, in accordance with the relevant requirements of the
current Gas Safety (Installation and Use) Regulations,
The Building Regulations, current I.E.E. Wiring Regulations
and the relevant British Standard Codes of Practise.
Detailed recommendations are contained in the following
British Standard Codes of Practice:
BS. 5440:1 Flues (for gas appliances of rated input not
exceeding 70 kW).
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 70 kW).
BS. 5449
Forced circulation hot water systems.
BS. 5546
Installation of gas hot water supplies for domestic
purposes (2nd. family Gases).
BS. 6798
Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS. 6891
Low pressure installation pipes.
IGE/UP/1b Tightness testing and purging domestic sized gas
installations.
NOTE
It is mandatory to clean and service the system
once a year. This includes an inspection of the
entire system to see if it is in full working order.
Defects and faults must be eliminated
immediately.
NOTE
When instructions aren’t followed, warranty
expires.
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 Engineering
document IGE/UP/7:1998.
Bathroom Installations
This appliance is rated IPX4D.
The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of
the current IEE (BS.7671) Wiring Regulations and, 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 appliance is to be installed in a room containing a bath or
shower then, providing water jets are not going to be used for
cleaning purposes (as in communal baths/showers), the
appliance can be installed in Zone 3, as detailed in BS.7671.
Health and & Safety Document No. 635.
Compartment Installations
The Electricity at Work Regulations, 1989.
The manufacturer's notes must not be taken, in any way, as
overriding statutory obligations.
The design and construction of the Buderus wall-mounted
condensing gas boiler 600 - 11S/19S/24S/24C conforms to the
basic specifications listed in the European directive governing
gas-fired appliances 90/396/EEC, and with respect to EN 625,
EN 483 and EN 677.
NOTE
Observe the corresponding technical rules and
the building supervisory and statutory
regulations when installing and operating the
system.
WARNING!
Keep the burner-control unit housing CLOSED
when working on water-bearing components.
A compartment used to enclose the boiler should be designed
and constructed especially for this purpose.
An existing cupboard or compartment may be used, provided
that it is modified for the purpose.
In both cases, details of essential features of cupboard/
compartment design, including airing cupboard installation,
are to conform to the following:
BS 6798 (No cupboard ventilation is required - see 'Air Supply'
for details).
It is not necessary to have a purpose-provided air vent in the
room or internal space in which the boiler is installed. Neither
is it necessary to ventilate a cupboard or compartment in which
the boiler is installed, due to the low surface temperatures of
the boiler casing during operation; therefore the requirements
of BS 6798, Clause 12, and BS 5440:2 may be disregarded.
The position selected for installation MUST allow adequate
space for servicing in front of the boiler.
For the minimum clearances required for safety and
subsequent service, see the wall mounting template.
In addition, sufficient space may be required to allow lifting
access to the wall mounting plate.
Wall-mounted condensing gas boilers must only be operated
with the combustion air/flue gas systems especially devised
and authorised for this type of boiler.
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4
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Observe the relevant standards, regulations and legislation of
the country of final use.
CAUTION
Use this device for its intended purpose only.
NOTE:
Notes relating to domestic hot water.
z The domestic hot water service must be in
accordance with BS 5546 and BS 6700.
z The boilers are suitable for connection to
most types of washing machine and
dishwasher appliances.
DANGER!
Notes relating to the heating system water.
Thoroughly flush the system before it is filled
with water. Use only untreated water or water
treatment product such as Sentinel X100 to fill
and top up the system.
When using water treatment, only products
suitable for use with Buderus heat exchangers
are permitted (e.g. Sentinel X100). Your
warranty is at risk if an incorrect water
treatment product is used in conjunction with
this appliance. For more information, contact
Buderus Product Support Department.
It is most important that the correct
concentration of the water treatment product is
maintained in accordance with the
manufacturer's instructions.
If the boiler is used in an existing 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
scale may be necessary - however, the use of
artificially softened water is NOT permitted.
z When connecting to suitable showers,
ensure that:
a. The cold inlet to the boiler is fitted with
an approved anti-vacuum or syphon
non-return valve.
b. Hot and cold water supplies to the
shower are of equal pressure.
z Where the water hardness exceeds
150 mg/litre, it is recommended that a
proprietary scale reducing device is fitted
into the boiler cold supply with the
requirements of the local water company.
CAUTION
Provision must be made to accommodate the
expansion of DHW contained within the
appliance, if a non-return valve is fitted to the
DHW inlet, as detailed in BS. 67989: §5.4.3.
Safe handling of substances
Care should be taken when handling the boiler's insulation,
which can cause irritation to the skin.
No asbestos, mercury or CFCs are included in any part of the
boiler and its manufacture.
Under no circumstances should the boiler be
fired before the system has been thoroughly
flushed.
Do not use water softened in a salt bedding
exchanger.
Do not use inhibitors, anti-freeze or other
additives.
The expansion vessel must be of sufficient
size.
When oxygen-permeable pipes are used (e. g.
for floor heating systems) the system must be
separated by means of heat exchangers.
Unsuitable heating water promotes sludge
formation and corrosion. This may cause
malfunctions and damage in the heat
exchanger.
Subject to modifications resulting from technical improvements!
Buderus • http://www.buderus-domestic.co.uk
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
5
Installation
1
Installation
1.1
Dimensions, connections and assembly
480 mm (19")
370 mm (14½")
240 mm (9½")
13 mm (½")
185 mm (7¼")
Ø100 (4")
1.5 mm ( 1 17 ")
950 mm (37½")
12.5 mm (½")
845.5 mm (33 1 3 ")
840 mm (33")
850 mm (33½")
Ø60 (23 8")
105 mm (4 1 8 ")
1
CH Flow, CH return, GAS / 50 mm (2")
CH Flow
GAS
=
=
CH Return
CWDO
DHW Hot
DHW Cold
PRV
=
=
=
=
=
PRV
65
(2½")
CH Return
CWDO
DHW Cold
GAS
DHW Hot
CH Flow
65
65
65 65
(2½") (2½") (2½") (2½")
DHW Hot, DHW Cold / 35 mm (1¼")
CH flow Ø22 mm compression fitting
Gas connection for 24C: Ø22 mm compression fitting
for 11S/19S/24S: R¾"
CH return Ø22 mm compression fitting
Condensate drain G1" OUTSIDE
DHW warm out Ø15 mm compression fitting
DHW cold in Ø15 mm compression fitting
Pressure relief valve R¾" (¾" - ½"-adapter supplied with boiler)
NOTE
See wall-mounting template for the necessary clearances.
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6
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Installation
1.2
1
Boiler assembly - exploded view
Single unit (11S / 19S / 24S)
Legend
3
83
54
82
32
2
53
1. Flow connection piece
31
2. Automated air vent
1
3. Hairpin heat exchanger
4. Flow sensor
8
33
5
9
35
34
4
40
5. Clip
27
6. Flow pipe
7. Clip flow pipe
39
8. Back part heat exchanger
41
6
9. Seal heat exchanger
28
36
10. Sealing ring burner
42
10
11. Burner
43
7
11
28
12. Heat exchanger
44
37
13. Front panel heat
exchanger
38
47
48
12
13
14. Sight glass
14
43
15. Fastener
16. Ventilation cover
17. Casing
50
51
25
43
45
46
18. Condensate trap
80
60
100
40
120
20
2
C
1
30
15
16
4
bar
43
26
29
3
0
49
24
20. Drain pipe condens. trap
21. Syphon
52
22. Sealing ring
27
23. Flue gas sensor
23
3
17
54
20
22
53
24. Sealing ring
5
25. Flue gas pipe
26. Flue gas pipe seal
55
27. Condensate collector
18
21
19
56
57
28. Lipring
60
29. Combustion divider
30. Insulation divider
31. Fan
7
7
19. Syphon cap with seal
67
7
68
32. Gas/air supply pipe
62
61
63
33. Fan seal
58
34. Venturi
69
65
35. Gas valve
64
7
36. Rectifier
65
37. Suction pipe
38. Gas pipe
39. Concentric adapter
66
59
40. Lip ring
41. Adapter clip
42. Bracket
43. Cable duct
44. Ventilation cover seal
53. O-ring
62. Connection house by-pass
82. Hot surface ignitor
45. Pipe duct
54. O-ring
63. Clip by-pass
83. Ionisation electrode
46. Sealing ring
55. Return pump connection pipe
64. Connection house three-way valve
47. Cable harness
56. Pump
65. Spring set
48. UBA
57. Expansion vessel
66. Connection housing pump
49. Power switch
58. Expansion vessel pipe
67. Connection housing
50. Temp-pressure gauge
59. Manifold assembly
68. Clip
51. UBA panel
60. Pressure relief valve
69. By-pass pipe
52. 230V cable
61. Spring set
Subject to modifications resulting from technical improvements!
Buderus • http://www.buderus-domestic.co.uk
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
7
1
Installation
Combi unit (24C)
Legend
3
83
54
82
32
2
53
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
31
1
40
33
8
5
9
35
34
4
28
39
41
28
6
36
10
42
43
42
11
7
44
37
28
38
47
13
43
48
12
45
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
43
14
51
25
46
50
80
60
100
40
120
20
2
C
1
30
3
4
0
bar
26
29
43
49
24
52
15
27
16
23
3
17
20 54
22
53
5
55
18
21
57
19
60
56
62
84
61
80
81
79
78
63
58
64
65
7
71
68
71
76
72
7
65
7
60.
61.
62.
63.
64.
65.
66.
67.
68.
Pressure relief valve
Spring set
Connection house by-pass
Clip by-pass
Connection house three-way valve
Spring set
Connection housing pump
Connection housing
Clip
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8
70
75
73
UBA panel
230V cable
O-ring
O-ring
Return pump connection pipe
Pump
Expansion vessel
Expansion vessel pipe
Manifold assembly
69
7
71
51.
52.
53.
54.
55.
56.
57.
58.
59.
59
77
67
7
68
68
66
7
74
7
69.
70.
71.
72.
73.
74.
75.
76.
77.
By-pass pipe
DHW pipe (hot)
Clip
DHW supply pipe
Hot water sensor
Boiler sensor
Insulation hot water tank
DHW pipe (cold)
Flow regulator
78.
79.
80.
81.
82.
83.
84.
Flow connection piece
Automated air vent
Hairpin heat exchanger
Flow sensor
Clip
Flow pipe
Clip flow pipe
Back part heat exchanger
Seal heat exchanger
Sealing ring burner
Burner
Heat exchanger
Front panel heat
exchanger
Sight glass
Fastener
Ventilation cover
Casing
Condensate trap
Syphon cap with seal
Drain pipe condens. trap
Syphon
Sealing ring
Flue gas sensor
Sealing ring
Flue gas pipe
Flue gas pipe seal
Condensate collector
Lipring
Combustion divider
Insulation divider
Fan
Gas/air supply pipe
Fan seal
Venturi
Gas valve
Rectifier
Suction pipe
Gas pipe
Concentric adapter
Lip ring
Adapter clip
Bracket
Cable duct
Ventilation cover seal
Pipe duct
Sealing ring
Cable harness
UBA
Power switch
Temp-pressure gauge
Three-way valve body
Three-way valve cartridge
Three-way valve cover
Three-way valve head
Hot surface ignitor
Ionisation electrode
Hot water tank
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Installation
1.3
Flue Installation
1.3.1
Siting the flue terminal
The flue must be installed in accordance with the
recommendations of BS. 5440-1:2000.
A
C
B,C
B,C
Pluming will occur at the terminal so terminal positions where
this could cause a nuisance should be avoided.
M
F
K
L
K
F
F
M
G
The boiler MUST be installed so that the terminal is exposed
to external air.
L
K
A
The air supply and the flue gas exhaust must meet the
applicable general regulations. Please consult the instructions
provided with the flue terminal kits prior to installation.
1
G
G
under carport
It is important that the position of the terminal allows the free
passage of air at all times.
D
Minimum acceptable spacing from the terminal to obstructions
and ventilation openings are specified in table 1.
J
F
K
H, I
If the terminal is fitted within 1000 mm of a plastic or painted
gutter or within 500 mm of painted eaves, an aluminium shield
of at least 1000 mm long should be fitted to the underside of
the gutter or painted surface.
If the lowest part of the terminal is less than 2 metres above the
level of the ground, balcony, flat roof or place to which any
person has access, the terminal must be protected by a guard.
Protective guards are available from Quinnell Barrett and
Quinnell, Old Kent Road, London.
Ensure that 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 the boiler
MUST NOT be closer than 25 mm (1'') to combustible material.
Detailed recommendations on the protection of combustible
material are given in BS. 5440- 1:2000.
NOTE
It is absolutely essential to ensure, in practice,
that products of combustion discharging from
the terminal cannot re-enter the building or any
other adjacent building through ventilators,
windows, doors, other sources of natural
air infiltration, or forced ventilation/airconditioning.
If this could occur the appliance MUST be turned off (with the
owners permission), and labelled as unsafe until corrective
action can be taken.
Subject to modifications resulting from technical improvements!
G
Fig. 1
Flue terminal position
Minimum
Spacing
Terminal Position
A. Directly below or alongside an opening
window, air vent or other ventilation opening
300 mm (12")
B. Below guttering, drain pipes or soil pipes
75 mm (3")
C. Below eaves
200 mm (8")
D. Below balconies or a car port roof
200 mm (8")
E. From vertical drain pipes or soil pipes
150 mm (6")
F. From internal or external corners
300 mm (12")
G. Above adjacent ground, roof or balcony level
300 mm (12")
H. From a surface facing the terminal
600 mm (24")
I.
1200 mm (48")
From a terminal facing a terminal
J. From an opening in a car port (e.g. door or
window) into dwelling
1200 mm (48")
K. Vertically from a terminal on the same wall
1500 mm (60")
L. Horizontally from a terminal on the wall
300 mm (12")
M. Adjacent to opening
300 mm (12")
Table 1 Balanced flue terminal position
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
9
1
1.3.2
Installation
Air supply and flue gas exhaust in a closed
installation
1
A ventilation cover is integrated into the 600 Series condensing
gas boilers. This cover houses a number of components, such
as the burner and the heat exchanger. Since this ventilation
cover is part of the air supply system, it is vital that it is always
installed correctly.
2
To ensure optimal operation, the 600 Series appliances must
be connected to a Buderus wall-mounted or roof-mounted flue
terminal. These terminals have been developed specifically for
the 600 Series condensing gas boilers and have been
comprehensively tested. The Buderus wall and roof-mounted
flue terminal kits ensure trouble-free operation.
The following items for the flue (see fig. 2) are included in the
delivery of the boiler:
–
pos. 1: 1 Concentric bend 60/100;
–
pos. 2: 1 Horizontal flue terminal 60/100;
–
pos. 3: 1 Flue finishing kit.
3
Fig. 2
Horizontal flue pack
L
1.3.3
Maximum Flue length
550 mm
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 total pressure loss of all
components in the flue gas exhaust / air supply system.
50 mm
Flow pressure available for use [Pa]
600 Series
11 S
19 S
24 S
24 C
35
60
100
10
Fig. 3
Side flue and rear flue installation
Take the flue conduit clearances into account when planning
the layout of the place of installation (see subsection 1.3.1:
"Siting the flue terminal" on page 9).
Boiler
Maximum
pipe length
Maximum wall thickness without extensions is 550 mm.
Maintain a minimum side wall clearance of 50 mm (see fig. 3).
For every 90° bend the
maximum pipe length has
to be reduced by
600 Series
L = 7.5 m
1.2 m
Table 2 Pipe length
1.3.4
Additional flue parts
Additional flue parts (see table 3) can be ordered from your
supplier.
Flue parts
Order No.
Concentric pipe, 500 mm long, adjustable
NE 83703
Concentric pipe, 1000 mm long, not adjustable
NE 83704
Concentric bend 90°
NE 83705
Concentric bend 45°
NE 83706
Table 3 Additional flue parts
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10
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Installation
1.4
1
Items supplied with unit
2
z Check the contents against the packing list to ensure that
nothing is missing.
Requirements to be met by the place of installation
NOTE
Observe all statutory building regulations
applying to the place of installation.
3
DANGER!
Inflammable materials or liquids must not be
stored or used near wall-mounted condensing
gas boilers. The site of installation must be
frost-protected.
4
1
6
Fig. 4
5
Items supplied with unit
Key to fig. 4:
1: Wall-mounted condensing gas boiler
2: Wall bracket
3: Technical documents
4: Manifold assembly
5: Filling loop
1.5
Hanging the boiler
CAUTION
DO NOT remove the polystyrene foam bottom
slab protecting the connection nozzles.
During installation work, cover the wallmounted condensing gas boiler and the flue
gas adapter to prevent site dirt from entering,
e. g. using aluminium foil.
6: Plastic bag containing the following accessories:
4 x wall fixing-screws
4 x wall plugs
4 x washers
Seals (1 x 1“, 2 x ¾“, 2 x ½“)
Square wrench
Initial start-up sticker
Second identification plate
Safety valve nipple (from ¾“ to ½“)
z Attach the manifold assembly to the wall (see fig. 5,
item 1).
z Attach the pipes.
z Attach the wall bracket.
z When using a stand-off frame, refer to the manual of the
stand-off frame for the correct mounting instructions.
z Loosen the retaining screw on the bottom of the
condensing gas boiler.
z Detach the outer casing of the condensing gas boiler.
z Hang the condensing gas boiler onto the wall bracket
(fig. 5).
NOTE
If the boiler isn't connected to the pipework
immediately, place caps on the pipe
connections.
Subject to modifications resulting from technical improvements!
1
Fig. 5
Installation
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
11
1
1.6
Installation
Water circulation system
The central heating system should be in accordance with
BS.6798 and, in addition, for smallbore and microbore
systems, BS.5449.
1.7
Pipe connections
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. 6. Ensure that all pipework
is routed so as to minimise any strain on the boiler fittings.
1.7.1
Gas Supply
The gas installation must be installed in accordance with
BS6891.
CAUTION!
Pipework from the meter to the boiler MUST be
of adequate size.
1
Fig. 6
2
3
4
5
6
Pipe connections
Key to fig. 6:
1: CH flow
2: DHW warm out (combi only)
The complete installation MUST be tested for gas tightness
and purged as described in IGE/UP/1b.
1.7.2
Gas connection
3: Gas
4: DHW cold in (combi only)
5: CH return
6: Condensate trap
z Connect to gas supply according to relevant standards,
installing a screw-threaded gas shutoff valve (accessory)
to the gas supply system.
1.7.3
Hot-water temperature for 600 - 24C
CAUTION
DO NOT use galvanised pipes or fittings.
The hot water heat exchanger is made of
copper and is liable to suffer the effects of
electrolytic corrosion.
NOTE
When using plastic pipes, observe the
supplier’s instructions ­ especially those
referring to recommended jointing techniques
and the notes relating to the heating system
water on page 5.
z Fit a non-shutting diaphragm safety valve (max. 8 bar)
upstream of the cold-water inlet. This is not required if the
building is equipped with a pressure regulator configured to
guarantee that the maximum supply pressure of 10 bar
cannot be exceeded.
z Connect pipes free of tension (fig. 6).
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12
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Installation
1.7.4
1
Condensate drain
A condensate drain is integrated in the boiler. The drain outlet
is a standard G1" outside connection. This drain needs to be
connected to a drainage point. All pipework and fittings in the
condensate drainage system MUST be made of plastic - no
other materials may be used.
The routing of the drain must be made to allow a minimum fall
of 1 in 20 away from the boiler, throughout its length.
Excessive external pipe runs should be avoided in order to
prevent possible freezing.
Any external pipework should be a minimum of 32 mm internal
diameter.
WARNING!
Any external run must be insulated.
Ensure that the 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 and vent stack or waste pipe. Alternatively, the
condensate can be discharged into the rainwater system, or
into a purpose-made soak away (condensate absorption
point).
All connecting drainage pipework should have a fall of at least
2.5° to the horizontal, or approximately 50 mm per metre of
pipe run.
If the drainage pipe has to be run externally, it is recommended
that the pipe be insulated to protect against frost.
It should be noted that the connection of a condensate pipe to
a drain may be subject to local building controls.
Material for condensate
The condensate drainage pipe should be run in a standard
drain pipe material, e.g. PVC (polyvinyl chloride), PVC-U
(unplasticized polyvinyl chloride), BS (acrylonitrilebutadienestyrene), PP (polypropylene polyprolene) or PVC-C
(cross-linked polyvinyl chloride).
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
13
1
Installation
Any internal pipework should be of a diameter to match the
requirements of the condensate exit pipe on the appliance.
A 32 mm (1¼") waste pipe solvent weld fitting can be used,
fitted externally over the condensate exit pipe on the
appliance.
All external pipework should be kept to a minimum to avoid
freezing and should have a diameter of not less than 22 mm.
Boiler
internal soil
and vent stack
Ø22 mm min.
Internal termination to internal stack
No length restriction
75 mm min. trap
450 mm min.
The condensate drainage pipe should have a minimum
diameter of 1" with no length restriction. It should incorporate
a trap with a 75 mm condensate seal and be connected to the
stack at a point at least 450 mm above the invert of the stack.
The trap built into 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 boiler (see fig. 7).
invert
Fig. 7
Internal termination of condensate drainage pipe to
internal stack
External termination via internal branch (e.g. sink waste)
The condensate drainage pipe should have a minimum
diameter of 1" with no length restriction and should incorporate
a trap with a 75 mm seal. The connection should preferably be
made downstream of the sink waste trap. If the connection is
only possible upstream, then the air break is needed between
the two traps. This is normally provided by the sink waste pipe
(see fig. 8 and fig. 9).
Boiler
No length restriction
Sink
75 mm min. trap
Ø22 mm min.
Fig. 8
Open end of pipe
direct into gully,
below ground but
above water level
External termination of condensate drainage pipe
via internal discharge branch (e.g. sink waste) and
condensate syphon
Boiler
Ø22 mm min.
Sink
No length
restriction
Fig. 9
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14
Open end of pipe
direct into gully,
below ground but
above water level
75 mm min. trap
External termination of condensate drainage pipe
via internal discharge branch (e.g. sink waste –
proprietary fitting) and condensate syphon
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Installation
Condensate absorption point
1
External length of
pipe 3m max.
The condensate drainage pipe should have a minimum
diameter of 1" and the external pipe length should not be more
than 3 m. The condensate absorption point should be sited in
a convenient position as close as possible to the boiler but not
in the vicinity of other services.
See fig. 10 for information.
Ø22 mm min.
1000 mm min.
Ø100 mm min.
plastic tube
bottom of
tube sealed
limestone
cladding
300 mm min.
NOTE
When discharging condensate to an outside
drain caution must be taken to ensure
blockage cannot occur during freezing
conditions. If this is likely to occur, the use of a
syphon trap is recommended.
25 mm min.
Ground
(either/or)
hole depth
400 mm min.
Two rows of three
12 mm holes at 25 mm centres
50 mm from bottom of tube and
facing away from house
Fig. 10
1.8
External termination of condensate drainage pipe to
absorption point
Flue installation
The only flue systems that may be used are those supplied by
Buderus. The flue system must be installed in accordance with
the requirements of BS5440:1. 2000.
Standard 100 mm flue systems
The standard concentric flue system provides for a max.
horizontal straight length of upto 7.5 m (see subsection 1.3.3).
Full instructions for fitting this flue are in subsection 1.8.2:
"Installation of the horizontal flue" on page 16.
IMPORTANT
Any horizontal flue system fitted to a
condensing boiler must be incline towards the
appliance at an angle of 3% (30 mm per metre
length) to prevent condensate dripping from
the flue terminal.
This means that the clearance above the
appliance must be increased to match the duct
length. See figure on page 6.
NOTE
When using a stand-off frame, don’t forget to
take its measurements into account when
designing a flue system.
1.8.1
Flue gas
testing point
Fig. 11
Vertical flue connection
Flue gas
testing point
Connecting the vertical flue gas duct
z Fit the vertical flue gas duct (fig. 11) onto the appliance flue
connector.
z For remaining installation of the vertical flue assembly,
refer to the relevant installation instructions.
Fig. 12
Subject to modifications resulting from technical improvements!
Elbow with flue gas testing point
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
15
1
1.8.2
Installation
Installation of the horizontal flue
The standard 100 mm diameter horizontal flue system is
suitable for lengths upto 560 mm (see fig. 13).
For longer flue runs upto 7.5 m, extension air/flue ducts are
available (see page 10, table 3).
NOTE
Use the wall-mounting template to help you
mark the position of the side flue opening
1.8.3
Flue
Turret
Terminal
assembly
Maximum 560 mm
Outer
Wall
No Clamp
Fig. 13
Standard flue
Flue duct preparation and assembly
L
z Measure the flue length L. Refer to figures 14 and 15.
NOTE
The flue must be inclined to the boiler.
z Mark of the lengths shown onto the ducts and cut the
length. The cuts must be square and free from burrs.
Terminal assembly outer (air) duct - L-70 mm, inner (flue)
duct - L-50 mm. The measurement is made from the ridge
at the terminal indicating the outer face of the wall.
Refer to figure 16.
Extension air duct - L-70 mm, flue duct - L-50 mm.
The measurement is from the formed end.
185
Fig. 14
Flue length - rear
z Assemble flue system completely. Push the ducts fully
together. The slope of the terminal outlet must be face
downwards.
The assembly will be made easier if a solvent free grease
is lightly applied to the male end of the ducts.
L
NOTE
An inner wall sealing plate is provided which
should be fitted to the ducts before assembly.
Fig. 15
z Push the assembly through the wall and slide the turret
onto the flue connector. Refer to figure 12.
Flue length - side
Flue Finishing Kit
z Ensure that the turret is fully entered into the socket on the
boiler. From the outside fix the flue finishing kit to the
terminal and, after ensuring the duct is properly inclined
towards the boiler, fix the finishing kit to the wall.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm around
the terminal and be fixed with corrosion resistant screws.
Flue Terminal
Outer
Wall
Face
Fig. 16
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16
Raised Ring
locating the
terminal relative
to the outside
wall face
Flue terminal position
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Installation
1.9
Electrical connections
1.9.1
Mains connection
1
A mains supply of 230 V - 50Hz is required.
External controls are suitable for volt free or 230 V installation.
Wiring to the boiler MUST be in accordance with the current
I.E.E. (BS.7671) Wiring Regulations and any local regulations.
Wiring should be a 3 core PVC insulated cable, not less than
0.75 mm2 (24 x 0.2 mm), and to BS.6500 Table 16.
1
Connection must be made in a way that allows complete
isolation of the electrical supply such as a double pole switch
having 3 mm (1/8'') contact separation in both poles, or a plug
and socket, serving only the boiler and system controls. This
boiler is equipped with a double pole switch see fig. 17, item 1.
The means of isolation must be accessible to the user after
installation.
The electrical connection to the mains supply should be readily
accessible and adjacent to the boiler.
Fig. 17
UBA
If the supply cord is damaged, it must be replaced by a
registered Corgi installer to avoid a hazard.
The electrical supply for both the boiler and the system must
be taken from the same sparred fused spur outlet.
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
17
2
~
M
2
N
Flue gas monitor
Domestic hot water temperature sensor
Return-temperature sensor (return)
Safety-temperature sensor (safety)
Boiler water-temperature sensor (supply)
Boiler identification module
Solenoid valve
Plug socket for additional equipment
Hand-held terminal
STB
FW
FR
FS
FK
KIM
MV
STK
HT
M
N
2
3
HT2
24Vdc
1
3
4
5
6
FK
KIM
7
8
STK
9
1
2
2
1
*) remove wirebridge
when used
Volt free room
thermostat
when used with
230V timer *)
external
230V controls
Connection box
(RTH converter)
FW
remove bridge when
carrying out connection
2
Only one room-temperature regulating
device may be connected.
Ventilator
L
1
10
13
14
15
external three-way
reversing valve for
mains water
(AC operation)
MV
12
2
1
1
2
Volt free external
control device
11
16
1
17
2
18
1)
19
20
3
4
6
UBA terminal box
I/O
communication port
5
7
8
9
1
2
3
FR
10 11
PA
4
5
FS
6
7
8
9
10
18-pin connection strip
11
STB
12
13
14
15
17
STK
18
1
2
Bridge is conductive
(remove when connecting)
Loop is non-conducting
(remove when connecting)
hot surface
ignitor
HT1
16
3
safety measures to comply with local regulations and standards
Fuse, main switch, emergency OFF switches and
turn-on voltage for external,
customer-supplied three-way
reversing valve (AC operation)
24V output (AC)
external sensor
Burner-control unit (UBA)
flame-monitoring electrode
4
For location of individual components, see service section and the exploded views in this manual.
IMPORTANT
The wires in this mains lead are coloured in accordance with the following code:
GREEN AND YELLOW - EARTH ; BLUE - NEUTRAL ; BROWN - LIVE
As the colours of the wires in the mains lead of of the appliance may not correspond with the coloured markings identifying the terminals in your connector proceed as follows:
The wire coloured green and yellow must be connected to the terminal on the connector marked with the letter E or by the earth symbol
or coloured green or green-and-yellow. The wire coloured brown must be connected to the terminal marked
with the letter L or coloured red. The wire coloured blue must be connected to the terminal marked with the letter N or coloured black.
WARNING
THIS APPLIANCE MUST BE EARTHED
Ensure that your appliance is connected correctly - if you are in any doubt consult a qualified electrician.
Volt-free connection (bridge connector)
1)
Note:
PA
fuse rating
10A
230V
50 Hz
Max. permitted
L
1
circulation pump (PH)
(max. 2A)
Mains power source
1
20-pin connection strip
0
1.25 Ampere slow blow
max. 6 VA
18
24 VAC
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0 VAC
1
Installation
1.10 Wiring Diagram
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Installation
1
1.10.1 External controls
The wall-mounted condensing gas boiler can be fitted with the
following control devices:
–
ON/OFF temperature controller, volt free;
–
A room-temperature control device at 230V connected to
the connection plate (fig. 20, item 1).
–
A modulating room-temperature control device at 24 Volt
connected to the connection plate (fig. 22, item 1) such as
the 250 RF ModuLink and the iRT controllers.
1
Fig. 18
Swivel the housing of the burner-control unit
downwards
Fig. 19
Open back of the burner-control unit
1.10.2 External 230V controls
z Loosen crosshead screw (fig. 18, item 1) on burner-control
unit (UBA).
z Swivel burner-control unit downwards.
z Open the back of the burner-control unit to the right
(fig. 19).
z Connect the black pre-wired lead to a permanent live
supply (from the same fused isolator as all other controls
on the heating system), L N E.
1
z Feed the 230V switch live and neutral (from external
controls) through the cable lead.
z Identify the 230V terminal block by the shaded area and
230V label.
z Connect the switch live to terminal "1" and a neutral to
terminal "2" (fig. 20, item 1).
z Replace covers.
NOTE
Terminal 3 (fig. 20, item 2) is not used.
2
Fig. 20
Subject to modifications resulting from technical improvements!
Connection box in burner-control unit 230V connection
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
19
1
Installation
1.10.3 Volt free external control device connection
1
z Connect the black pre-wired lead to a permanent live
supply (from the same fused isolator as all other controls
on the heating system), L N E.
z Loosen crosshead screw (fig. 18, item 1) on burner-control
unit (UBA).
z Swivel burner-control unit downwards.
z Open the back of the burner-control unit to the right
(fig. 19).
z Lead the control device wire through the cable lead.
z Fix the wire to terminal 1 and 2 of the volt free connection
(fig. 21, item 1).
Fig. 21
Connection box in burner-control unit volt free connection
1.10.4 24 Volt modulating room-temperature control
device connection
z Loosen crosshead screw (fig. 18, item 1) on burner-control
unit (UBA).
z Swivel burner-control unit downwards.
z Open the back of the burner-control unit to the right
(fig. 19).
1
z Connect the 24 Volt modulating room-temperature control
device at fig. 22, item 1 on pin 3 and 4.
Fig. 22
Connection box in burner-control unit 24 Volt connection
1.10.5 Other connections
1
Connection of an external water tank for single devices
600 - 11S/19S/24S:
z Remove bridge (fig. 23, item 1).
z Connect sensor for external water tank.
Connection for a second LPG solenoid valve:
2
z Connect switch unit for a second solenoid valve
(accessory) at green plug (fig. 23, item 2).
3
Connection of a modulating pump:
z Connect modulating pump (accessory) at plug (fig. 23,
item 3).
Connection of an external switch contact for underfloor
heating system:
4
z Open plug (fig. 23, item 4) connection.
z Connect underfloor heating header thermostat (volt free)
and in series.
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20
Fig. 23
Other connections
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Installation
1
1.10.6 System example
NOTE
Example systems are to be regarded as
schematic representations only.
Fig. 24
System example
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
21
2
Initial start-up
2
Initial start-up
2.1
Preparing the boiler for operation
CAUTION
DO NOT operate the condensing gas boiler if
large amounts of dust are present, e.g. due to
building work in and around the place of
installation.
2.1.1
Fill the heating system
WARNING
The wall-mounted condensing gas boiler must
not be activated at this stage.
z Set three-way valve to the middle setting (applicable for
24C only). This is done by pushing the lever on the threeway valve (fig. 25) with a screwdriver to the middle setting.
Fig. 25
Three-way valve
z If necessary open the CH flow and CH return maintenance
valves (fig. 26, item 1 and 2).
1
Fig. 26
CH Return
DHW Cold
(combi only)
Gas
DHW Hot
(combi only)
CH Flow
2
Maintenance shutoff valves
z Connect temporary hose (fig. 27).
z Open both stop valves.
stop
valve
stop
valve
double
check
valve
DHW
cold
Fig. 27
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22
temporary
hose
CH
return
Connecting temporary hose
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Initial start-up
2
z Fill the system to a pressure of 1.0 to 1.2 bar (fig. 28,
item 1). Max. water pressure is 1.5 bar.
z Shut both stop valves and disconnect the filling loop.
1
60
120
3
2
°C
4
bar
1
20
0
I
0
1
Fig. 28
11
KW
10
1
10
1
0
1
1
2
10
Pressure display
In the case of the 600 - 24C:
Purge the hot-water circuit of air
z Bleed the hot-water heat exchanger via the vent screw on
the heating-circuit side (fig. 29, item 1).
z Open the maintenance valve for the cold-water inlet.
z Leave the hot water taps open until water begins to flow
freely.
1
Fig. 29
Purge the hot-water heat exchanger of air (applies
to type 600 - 24C only)
To drain the system take the following steps:
z Close the DHW cold and the CH return valve.
z Connect temporary hose (fig. 30).
z Open the CH return stop valve to drain the system.
Stop
valve
Stop
valve
temporary
hose
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 detected during tightness testing, use an
approved leak detector to check all connections 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.
Subject to modifications resulting from technical improvements!
DHW Cold
(combi only)
z Disconnect the system from the power supply.
Fig. 30
CH Return
Drain
Checking for leaks
CH Flow
2.1.2
Draining the system
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
23
2
2.1.3
Initial start-up
Purging air from the gas supply system
z Close the gas service valve.
z Unscrew the sealing closure of the gas connectionpressure testing nipple by two turns (fig. 31).
z Purge system and appliance as per relevant procedures,
IGE/UP/1b. Ensuring all safety requirements are met.
z Open the gas service valve.
z Close the gas shutoff valve once more.
z Shut the sealing closure of the test nipple once more.
z Open cover for 2nd operating level (fig. 32, item 1).
z Start boiler up and move chimney sweep switch (fig. 32,
item 3) to position “1”.
The display shows (fig. 32, item 2) “ -.” or “ =.” to indicate that
the gas supply system is purged of air. Return chimney sweep
switch to normal running position, that is position “0”.
Fig. 31
Purging air from the gas supply system
2
3
11
KW
1
10
1
0
1
1
2
10
1
Fig. 32
2.1.4
Display and chimney-sweep switch
Check combustion air/flue gas connection
Check to ensure that the correct combustion air/flue gas
system has been fitted.
Type of gas
Factory settings of gas burners
Natural gas H
When delivered ready for operation
and set to Wobbe index
14.1 kWh/m3 (referred to 15 °C,
1013 mbar), applicable for Wobbe
index range 11.3 to 15.2 kWh/m3.
Check that the instructions included in the appropriate flue gas
system installation manual have been followed.
Inscription on gas-type indicating
label: Category setting:
2H G 20_20 mbar
LPG
After adaptation by a CORGI
registered installer, the unit can be
run on LPG. Inscription on gas-type
indicating label: Category setting:
3P G 31_37 mbar
Table 4 Gas-supply types
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24
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Initial start-up
2.1.5
Checking the type of gas and supply
Type of gas supply
CAUTION
The burner must only be put into operation with
the correct nozzles (table 5).
NOTE
Observe stickers attached to Venturi tubes.
Gas nozzles ∅ [mm]
2
Venturi
tubes
11S
19S/24(C)
Natural gas H (G20)
5.55
6.5
Standard
Venturi
tubes
LPG
3.40
4.15
Standard
Venturi
tubes
Table 5 Gas-nozzle diameter
Controller
setting
Flow temperature
[°C]
Heat-retaining
temperature (only 24 C)
[°C]
Outlet temperature
(only 24 C)
[°C]
Hot-water temperature
of external tanks
[°C]
1
40
-
60
27
2
44
3
48
40
40
34
4
53
43
43
38
5
58
46
46
41
6
62
49
49
45
7
67
52
52
49
8
71
55
55
52
9
76
58
58
56
10
80
60
60
60
DO NOT use setting no. 2
31
Table 6 Temperature settings
2.1.6
Adjusting the flow temperature
3
z Open the cover to the 2nd operating level (fig. 33, item 1).
2
z Adjust the knob (fig. 33, item 2) to the desired flow
temperature (table 6) for your particular installation.
11
KW
NOTE
Factory setting of the controller is "10"
(around 83 °C).
1
2.1.7
10
1
0
1
1
2
10
Adjusting the hot-water temperature for 24C only
z Adjust the heat-retaining and outlet temperature (table 6)
using the hot-water temperature regulator (fig. 33, item 5).
NOTE
Factory setting of the controller is "10".
To avoid energy losses set the controller to
setting "1" (fig. 33, item 5). Remove the green
blocking plate before making the adjustment.
6
5
4
1
Fig. 33
Control box
Key to Fig. 33:
1: Cover for second operating level
2: Flow temperature knob
3: Heat-capacity jumper
4: Heating capacity knob
5: Hot-water temperature knob
6: Green blocking plate
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
25
2
2.1.8
Initial start-up
Adjusting the hot-water temperature for external
tanks
z Use the hot-water temperature regulator to adjust the
temperature (fig. 33, item 5) to the desired setting table 6.
2.1.9
Adjust the hot-water flow controller (applies to
combi-unit 600 - 24C only)
Adjust the hot-water flow controller (fig. 34) to the desired
setting:
–
To increase the flow of hot water:
turn valve towards “+”.
–
To reduce the flow of hot water:
turn valve towards “ ”.
+
NOTE
The unit is factory-adjusted to an output of
22 kW and a flow of 7 l/min
2.1.10 Setting the heating capacity
Fig. 34
Hot-water flow controller
Set the heating capacity (table 7), according to the amount of
heat required, at the controller (fig. 33, item 4).
NOTE
The controller is factory-adjusted to position “6”
Heating capacity [kW] (±5 %)
Controller setting
600 - 11 S
600 - 19 S
600 - 24 S
600 - 24 C
1
4.9
9.7
9.7
9.7
2
5.6
10.7
11.3
11.3
3
6.3
11.8
12.9
12.9
4
6.9
12.8
14.5
14.5
5
7.6
13.8
16.0
16.0
6
8.3
14.9
17.6
17.6
7
9.0
15.9
19.2
19.2
8
9.6
16.9
20.8
20.8
9
10.3
18.0
22.4
22.4
10
11.0
19.0
24.0
24.0
Table 7 Heating capacity
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26
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Initial start-up
2
2.1.11 Measure gas-supply pressure (flow pressure)
3
z Open at least one radiator thermostat valve.
CAUTION
The condensing gas boiler must not be
activated at this stage.
z Turn the chimney-sweep switch (fig. 35, item 4) to
position “1”.
2
1
z Loosen the screw plug on the gas test nipple (fig. 36) by
two turns.
z Attach the pressure-gauge connection hose to the gas test
nipple (fig. 37).
z Slowly open the gas shutoff valve.
4
11
KW
10
0
1
1
2
1
10
1
Fig. 35
Mains switch, service button and chimney-sweep
switch
Fig. 36
Measure the gas connection pressure
Fig. 37
Check the gas/air ratio
z Turn the power switch (fig. 35, item 2) to position “I”.
The burner should ignite after about 30 seconds.
z Measure the gas connection pressure and note it down on
the report form.
The gas-connection pressure must be:
for natural gas H min. 17 mbar, max. 25 mbar, nominal
connection pressure 20 mbar
for LPG min. 30 mbar, max. 50 mbar, nominal connection
pressure 37 mbar.
z Detach the gauge-connection tube once more and close
the test nipple at the screw plug.
z Ensure that switch is returned to "0" after this task has been
carried out.
.
NOTE
If the required connection pressure is not
available or too high, contact your gas supplier
or TRANSCO.
Ensure all disturbed joints and connections are checked for
gas tightness on completion of tasks.
2.1.12 Check the gas/air ratio and adjust as required
z Turn mains power switch (fig. 35, item 2) and chimneysweep switch (fig. 35, item 4) to “0”.
z Unscrew the sealing closure of the burner-pressure testing
nipple by one turn (fig. 36).
z Connect the positive port of the pressure gauge with a
hose to the burner pressure measuring nipple (fig. 37).
z Turn mains power switch to “I” and chimney-sweep switch
to “1”.
z If the burner has fired after approx. 30 seconds, keep the
service button (fig. 35, item 3) pressed until “Y” appears on
the display.
z Turn the hot-water temperature controller (fig. 35, item 1)
to “1”.
z Read the differential pressure.
The differential pressure (pGAS – pAIR) should total -5 Pa
(±5 Pa) (display on measuring gauge: -10 Pa to 0 Pa).
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
27
2
Initial start-up
z If the gas/air ratio does not conform to specifications,
readjust at the setscrew (fig. 37, item 1).
z Turn mains power switch and chimney-sweep switch to “0”.
z Remove the measuring equipment and retighten the screw
in the burner-pressure measuring nipple.
z Readjust the hot-water temperature controller to its original
setting.
z Turn the mains power switch to “I”.
2.1.13 Gas rating test
z Isolate all other appliances.
z Set the boiler to maximum firing rate.
z Ensure that there is no modulating of the fan gas valve.
z Carry out the Gas Rating procedure as described in
"Essential Gas Safety' 3rd edition on pages 169-176.
2.1.14 Record readings
z Unscrew the corresponding sealing closure (fig. 38) on the
connection adapter for the combustion-air/flue-gas system
and replace it once the measuring operation in question
has been carried out.
Carbon monoxide content
1
CAUTION
2
The carbon monoxide values under vacuum
must be smaller than 400 ppm or 0.04 Vol%.
Values around or exceeding 400 ppm indicate
a faulty burner adjustment, a dirty gas burner
or heat exchanger, or a defective burner.
Ensure that the cause of the fault is remedied
immediately.
2.1.15 Function testing
NOTE
During initial start-up and annual servicing,
make sure that all control, regulating and
safety devices are in full working order and, if
applicable, check for correct adjustment.
Fig. 38
Measuring points on exhaust conduit
Key to Fig. 38:
1: Exhaust-fume temperature, CO2, CO, NOx
2: Combustion-air temperature
Measuring the ionisation current (fig. 39)
z Disconnect the system from the power supply.
z Loosen the plug-and-socket connector of the ionisation
electrode and connect the multimeter in series.
On the measuring device, select the µ-direct current range.
The measuring device must have a resolution of at
least 1 µA.
z Reconnect the system to the power supply and turn the
chimney-sweep switch to “1”.
z Measuring the ionisation current. The ionisation current
being checked must measure >2 µA direct current.
z Enter the reading on the report form.
z Disconnect the system from the power supply.
Fig. 39
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28
Measuring the ionisation current
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Initial start-up
2
z Remove multimeter and restore the plug-and-socket
connection to its original state.
z Turn the chimney sweep switch to position “0”.
z Reconnect the system to the power supply.
When the display shows “7” and the service button is
pressed, the display turns to “c”. Press the Reset button.
The display shows “r”.
2.1.16 Handing over
After completing the installation and commissioning of the
system the installer should hand over to the householder by
the following actions:
z Hand the User Manual to the householder and explain
his/her responsibilities under the relevant national
regulations.
z Explain and demonstrate the lighting and shutting down
procedures.
z The operation of the boiler and the use and adjustment of
all system controls should be fully explained to the
householder, to ensure the greatest possible fuel economy
consistent with the household requirements 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 inoperative during frosty conditions.
z Explain the function and the use of the boiler heating
controls.
z Explain the function of the boiler fault mode. Emphasise
that if a fault is indicated, the boiler should be turned off and
a registered local heating installer consulted.
z Explain and demonstrate the function of time and
temperature controls, radiator valves etc., for the economic
use of the system.
Loss of system water pressure
z Explain that the dial on the control panel indicates the
central heating system pressure and that if the normal
COLD pressure of the system is seen to decrease over a
period of time then the systems needs to be topped up.
If the pressure decreases frequently than a registered local
heating installer should be consulted.
WARNING
Do not fire the boiler if the pressure has
reduced to zero from the original setting.
z After installation, commissioning and customer handover
instructions please complete the BENCHMARK appliance
log book and leave this with the customer.
z IMPORTANT
A comprehensive service should be carried out annually.
Stress the importance of regular servicing by a Corgi
registered installer.
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
29
3
Inspection
3
Inspection
3.1
Preparing the heating boiler for
inspection
z Disconnect the system.
DANGER OF FATAL INJURY
due to electric shock when system is
opened.
z Before opening the system:
disconnect the heating unit at the
emergency OFF switch or the
corresponding circuit breaker of the house
power supply.
z Ensure that the heating system cannot be
reconnected by accident.
z Remove the burner housing or cover from the heating
boiler.
NOTE
If the gas supply pipes are to be disconnected
from the burner, the housing MUST ONLY be
removed by a qualified service technician and
checked for tightness on reassembly.
For further information, please refer to subsection 8.2
"Inspection and maintenance reports" on page 66 and fill out
the Benchmark.
Buderus • http://www.buderus-domestic.co.uk
30
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Maintenance
4
4
Maintenance
For further information, please refer to subsection 8.2
"Inspection and maintenance reports" on page 66 and fill out
the Benchmark.
4.1
Clean the heat exchanger, burner and
condensate trap
NOTE
The cleaning of the burner and heat exchanger
described here should be carried out whenever
there are signs of heavy soiling on the wallmounted condensing gas boiler. It is sufficient,
during annual servicing, to clean the burner
and heat exchanger with the help of an
appropriate cleaning product and a soft brush
and compressed-air hose (see following
section).
The heat exchanger can be dismantled
completely for thorough cleaning if required
(see “Cleaning the heat exchanger after
dismantling” on page 33)
4.1.1
Fig. 40
Loosen the union nut and remove the cable
Cleaning the heat exchanger without dismantling
z Disconnect the system from the power supply.
2
z Close the gas shutoff valve.
1
z Loosen the fixing screw, remove casing and combustionchamber cover.
z Release plug-in connection of fan power lead (fig. 40,
item 1), burner-control unit fan control lead (fig. 40, item 2)
and gas-burner assembly (fig. 40, item 3).
z Loosen union nut on gas valve assembly (fig. 40, item 4).
z Push safety plate out of way.
z Turn air suction tube and pull off from below.
z Swivel forward the air combination unit (fig. 41, item 1).
z Pull the air combination unit up and out of bayonet
connector (fig. 41, item 2) and remove via front of unit.
Fig. 41
Remove the air combination unit
Fig. 42
Remove burner gasket and rubber seal
z Remove burner gasket (fig. 42, item 1).
z Remove rubber seal in combustion chamber by pushing
upwards from inside (fig. 42, item 2).
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
31
4
Maintenance
z Remove burner by pulling upwards through the opening
(fig. 43).
NOTE
Maintain the specified clearance of approx.
25 cm between the ceiling and the combustion
chamber cover.
z Remove the front casing shell of the combustion chamber.
This is done by releasing the four snap catches at the
sides.
Fig. 43
z Remove the hot surface ignitor (fig. 44, item 1) and
ionisation electrode (fig. 44, item 2).
In the case of the hot surface ignitor: loosen the fixing
screw of the hot surface ignitor, detach both earth (ground)
leads and remove the retaining plate of the hot surface
ignitor by pulling it upwards, withdraw the hot surface
ignitor by pulling it upwards.
In the case of the ionisation electrode: Swivel the
retaining plate to one side and carefully remove the
ionisation electrode by pulling it upwards.
Remove burner
1
2
z Clean the burner and both parts of the combustion
chamber with a compressed-air line or brush.
z Refit the heat exchanger by following the above procedure
in reverse order.
CAUTION
The gasket between the two halves of the
casing shell should normally be replaced.
Fit the new gasket by pressing in from the top
on both sides, and without stretching.
DO NOT attempt to cut the gasket to size.
Fig. 44
Remove the hot surface ignitor and ionisation
electrode
CAUTION
The burner gasket must match the shape of
the groove in the housing.
CAUTION
Check the heat-exchanger for leaks BEFORE
reassembling the casing shells.
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32
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Maintenance
4.1.2
4
Cleaning the heat exchanger after dismantling
z Disconnect the system from the power supply.
z Close the gas shutoff valve.
z Loosen the retaining screw and remove the casing.
z Close the heating shutoff valves and drain the system.
Stop
valve
Stop
valve
temporary
hose
CAUTION
Cut hot water on supply side by closing the
heating shutoff valve.
Fig. 45
CH Return
DHW Cold
(combi only)
CH Flow
CAUTION
Drain the system via the temporary filling loop
(fig. 45) or the screw-in drain plug (fig. 46,
item 1) located under the pump.
Drain
Draining the system
z Open snap closures and remove combustion-chamber
cover.
z Release plug-in connection of fan power lead (fig. 40,
item 1), burner-control unit fan control lead (fig. 40, item 2)
and gas-burner assembly (fig. 40, item 3).
z Loosen union nut on gas valve assembly (fig. 40, item 4).
z Push safety plate out of way.
z Turn air suction tube and pull off from below.
z Swivel the air combination unit forward (fig. 41, item 1).
z Pull the air combination unit up and out of bayonet
connector (fig. 41, item 2) and remove via front of unit.
z Remove burner gasket (fig. 42, item 1) and rubber seal in
combustion chamber from top (fig. 42, item 2).
1
Fig. 46
Screw-in drain plug
z Remove burner by pulling upwards through the opening
(fig. 47, item 1) and release the four retaining clips (fig. 47,
item 2).
1
z Remove the front casing shell of the combustion chamber.
z Remove the hot surface ignitor (fig. 44, item 1) and
ionisation electrode (fig. 44, item 2).
In the case of the hot surface ignitor:
Loosen the fixing screw of the hot surface ignitor, detach
both earth (ground) leads and remove the retaining plate of
the hot surface ignitor by pulling it upwards, withdraw the
hot surface ignitor by pulling it upwards.
In the case of the ionisation electrode:
Swivel the retaining plate to one side and carefully remove
the ionisation electrode by pulling it upwards.
2
Fig. 47
Subject to modifications resulting from technical improvements!
Remove burner and release retaining clips
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
33
4
Maintenance
z Remove securing pin on flow and return flow conduit
(fig. 48) of heat exchanger.
z Remove spiral heat exchanger by pulling towards front
(fig. 48). Drain any water remaining in the heat exchanger
into the condensate trap.
Fig. 48
Securing pin on spiral heat exchanger
z Remove the diffusion head (fig. 49, item 2) on the
underside of the heat exchanger by withdrawing the
securing pin (fig. 49, item 1) and unscrewing the diffusion
head.
z Clean the two casing shells of the combustion chamber,
heat exchanger and burner with water or compressed air.
Take care not to damage the fins of the heat exchanger.
2
1
Fig. 49
Removing the diffusion head
Fig. 50
Refitting the heat exchanger
Refitting (fig. 50) :
NOTE
Excessive exhaust temperatures may be an
indication of an incorrectly-fitted diffusion
head.
z Screw the diffusion head in as far as it will go on the
underside of the heat exchanger (the final turn of the heat
exchanger increases the clearance between the pipes) and
insert securing pin.
CAUTION
Take care not to damage the insulation on the
diffusion head.
z Check to ensure that the heat exchanger has been fitted
the right way round. The upper securing-pin groove must
be horizontal.
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34
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Maintenance
4
Refit the heat exchanger by following the above procedure in
reverse. Note the following:
–
The gasket between the two halves of the casing shell
should normally be replaced. Fit the new gasket by
pressing in from the top on both sides, and without
stretching. DO NOT attempt to cut the gasket to size.
–
Check the heat-exchanger for leaks BEFORE
reassembling the casing shells.
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
z Remove the trap from the sleeve with the lip seal facing
downwards (fig. 51, item 1) and withdraw it from the outlet
(fig. 51, item 2).
z Remove the safety cover and clean the trap.
2
z Fill the syphon with water and then reassemble in reverse
order.
z Measuring the gas input pressure (flow pressure).
z Check the gas/air ratio.
z Leak test in operational condition.
z Measuring the carbon monoxide content.
z Carry out function testing.
4.2
1
Fig. 51
Removing the condensate trap
Fig. 52
Flushing out the hot-water heat exchanger
Flushing out the hot-water heat
exchanger
z Turn mains power switch to “0”.
z Shut cold-water tap (accessory).
z Open a hot-water tap (e.g. at the washbasin) and then
close it again in order to check the pressure of the water
being supplied.
z Loosen the cable on the stand-by sensor.
z Release the plastic clip from the bottom insulation of the
hot-water heat exchanger and remove the insulation.
z Connect the system to a power flusher unit and flush it out.
z Remove temperature sensor for DWH warm out and standby sensor, and replace with flushing hoses (fig. 52).
z Reassemble.
z Open cold-water tap (accessory).
z Open hot-water tap (e.g. at washbasin) and thoroughly
flush out system.
z Turn mains power switch to “I”.
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
35
5
Servicing
5
Servicing
5.1
Operating codes
NOTE
If the code displayed on the burner-control unit
is not listed under the operating codes or fault
warnings, the burner-control unit itself is
malfunctioning.
Display
Display after
pressing the
service button
0
Buderus 600 - 11S/19S/24S/24C is ready for operation
A
Burner interval circuit, 10 min. from burner start-up
C
Waiting for activation of the three-way valve (if fitted) or pump
H
Stand-by activated, Buderus 600 - 11S/19S/24S/24C ready to provide heat or hot water
L
Initial safety period: self-testing of burner-control unit during burner start-up
U
Post- or pre-purging period of fan unit
Y
Flow temperature at adjustment setting
-.
Buderus 600 - 11S/19S/24S/24C running in heating mode
A
“Chimney-sweep” mode, flow-temperature controller bypassed,
Buderus 600 - 11S/19S/24S/24C heating to previously-entered flow temperature.
H
Normal heating mode
Y
Service mode
=.
Buderus 600 - 11S/19S/24S/24C running in hot-water mode
H
r
Meaning
Normal hot water mode
Reset
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36
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
5.2
5
Fault codes
Code
Meaning
2C
Safety sensor exceeds 100 °C
Possible
cause
Action
1
Resistance in the installation is too high
Check if not all (thermostatic) radiator valves are clogged
with dirt.
2
Heating capacity is too large for the installation
Adjust the heating capacity (see subsection 2.1.10)
3
Safety sensor is faulty
Measure if resistance over the sensor is correct.
If not replace safety sensor (see subsection 5.3.11,
subsection 5.3.12, subsection 5.3.13)
4
Problem with the pump or pump cabling
(no circulation)
Check if the pump cabling is faulty or if the pump is stuck
(see subsection 5.3.9)
5
Water pressure is too low in the installation
Top up the system (see subsection 2.1.1)
Code
Meaning
2F
Temperature difference between the safety sensor and flow sensor is greater than or equal to 15 °K
Possible
cause
Action
1
Resistance in the installation is too high
Check if not all (thermostatic) radiator valves are closed or
clogged with dirt
2
Safety sensor is dirty or faulty
Check the safety sensor for dirt. Measure if resistance over
the sensor is correct. If not replace safety sensor (see
subsection 5.3.11, subsection 5.3.12, subsection 5.3.13)
3
Flow sensor is dirty or faulty
Check the sensor, replace if necessary (see subsection
5.3.14, subsection 5.3.15, subsection 5.3.16)
4
Problem with the pump or pump cabling
(no circulation)
Check if the pump cabling is faulty or if the pump is stuck.
Replace pump if necessary (see subsection 5.3.9 and
subsection 5.3.10)
5
Water pressure is too low in the installation
Top up the system (see subsection 2.1.1)
Code
Meaning
2P
Safety sensor rises faster than 5 °C/sec.
Possible
cause
Action
1
Heating capacity is too large for the installation
Adjust the heating capacity (see subsection 2.1.10)
2
Resistance in the installation is too high
Check if not all (thermostatic) radiator valves are closed or
clogged with dirt
3
Safety sensor is dirty or faulty
Check the safety sensor for dirt. Measure if resistance over
the sensor is correct. If not replace safety sensor (see
subsection 5.3.11, subsection 5.3.12, subsection 5.3.13)
4
External domestic hot water tank is too small for the
heating capacity
Top up the system (see subsection 2.1.1)
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
37
5
Servicing
Code
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 UBA are loose or faulty
Check the connectors at the back of the UBA
3
UBA might be faulty
Check the UBA by temporarily connecting an other UBA
(see subsection 5.3.3)
Code
Meaning
4A
Flow sensor exceeds 100 °C
Possible
cause
Action
1
Flow sensor is dirty or faulty
Check the sensor, replace if necessary (see subsection
5.3.14, subsection 5.3.15, subsection 5.3.16)
2
There is a problem with the pump or pump cabling
(no circulation)
Check if the pump cabling is faulty or if the pump is stuck.
Replace pump if necessary (see subsection 5.3.9 and
subsection 5.3.10)
3
Water pressure is too low in the installation
Top up the system (see subsection 2.1.1)
Code
Meaning
4C
F2 fuse malfunction, or flue gas thermostat active
Possible
cause
Action
1
Water pressure is too low in the installation
Top up the system (see subsection 2.1.1)
2
Heat exchanger is dirty
Check for a dirty heat exchanger and clean if necessary.
(see subsection 4.1)
3
Flue gas retarder faulty or missing
Check if the flue gas retarder is installed in the heat
exchanger
4
Heat exchanger has a problem
Purge heat exchanger
Code
Meaning
4F
Flow sensor exceeds 100 °C
Possible
cause
Action
1
Resistance in the installation is too high
Check if not all (thermostatic) radiator valves are clogged
with dirt
2
Heating capacity is too large for the installation
Adjust the heating capacity
3
Safety sensor is faulty
Check the sensor and measure if resistance over the
sensor is correct. If not replace safety sensor (see
subsection 5.3.11, subsection 5.3.12, subsection 5.3.13)
4
Problem with the pump or pump cabling (no circulation)
Check if the pump cabling is faulty or if the pump is stuck
(see subsection 5.3.9)
5
Water pressure is too low in the installation
Top up the system (see subsection 2.1.1)
Code
Meaning
4H
System error
Possible
cause
1
Action
Boiler is in operation for DHW due to a dripping faucet
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38
Check for dripping faucets
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
Code
Meaning
4L
Short circuit in safety sensor
Possible
cause
5
Action
1
Safety sensor is faulty
Check the sensor and measure if resistance over the
sensor is correct. If not replace safety sensor (see
subsection 5.3.11, subsection 5.3.12, subsection 5.3.13)
2
A short or bad connection in the cable harness
Check the cable harness and/or connector of the sensor
3
UBA might be faulty
Check the UBA by temporarily connecting a different UBA
(see subsection 5.3.3)
Code
Meaning
4P
Safety sensor has a loose connection or is defective
Possible
cause
Action
1
Safety sensor faulty or disconnected
Check the sensor and measure if resistance over the
sensor is correct. If not replace safety sensor (see
subsection 5.3.11, subsection 5.3.12, subsection 5.3.13)
2
A short or bad connection in the cable harness
Check the cable harness and/or connector of the sensor
3
UBA might be faulty
Check the UBA by temporarily connecting a different UBA
(see subsection 5.3.3)
Code
Meaning
4U
Short circuit in flow sensor
Possible
cause
Action
1
Flow sensor is dirty or faulty
Check the sensor, replace if necessary (see subsection
5.3.14, subsection 5.3.15, subsection 5.3.16)
2
A short or bad connection in the cable harness
Check the cable harness and/or connector of the sensor
3
UBA might be faulty
Check the UBA by temporarily connecting a different UBA
(see subsection 5.3.3)
Code
Meaning
4Y
Flow sensor interrupted
Possible
cause
Action
1
Flow sensor faulty or disconnected
Check the sensor and measure if resistance over the
sensor is correct. If not replace safety sensor (see
subsection 5.3.14, subsection 5.3.15, subsection 5.3.16)
2
A short or bad connection in the cable harness
Check the cable harness and/or connector of the sensor
3
UBA might be faulty
Check the UBA by temporarily connecting a different UBA
(see subsection 5.3.3)
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
39
5
Servicing
Code
Meaning
5C
Boiler shut down after connection with Service Tool
Possible
cause
Action
1
Service tool connection
Press reset. If fault code remains than try to temporarily
connect a different UBA (see subsection 5.3.3)
2
A short or bad connection in the cable harness
Check the cable harness and/or connector of the sensor
3
UBA might be faulty
Check the UBA by temporarily connecting an other UBA
(see subsection 5.3.3)
Code
Meaning
6A
F1 fuse defective, or no ionisation 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 ignitor (should be between 50 and 300 Ohm).
Replace hot surface ignitor if necessary (see subsection 5.3.19
and subsection 5.3.20)
2
There is no flame, ionisation electrode does
glow, fan isn’t turning
– Check the fan and KIM connectors and the UBA fuses
3
There is no flame, ionisation electrode and fan
are working
– Check and adjust the gas/air ratio (see subsection 2.1.12)
– Check the UBA’s F1 fuse, replace if necessary
– Check for 24 V~ on the gas valve during start up
– Check the gas-supply pressure (see subsection 2.1.11), this
should be higher than 20 mbar for natural gas.
– Check the earthing cable connections
(yellow/green wire).
– Check the cabling on the ionisation electrode
4
There is a flame, but the flame disappears
when the fan starts up
– Check the gas-supply pressure (see subsection 2.1.11), this
should be higher than 20 mbar for natural gas.
– Check and adjust the gas/air ratio (see subsection 2.1.12)
– Check the earthing cable connections (yellow/green wire)
– Check the cabling on the ionisation electrode
– Press reset. If fault code remains than try to temporarily connect
a different UBA (see subsection 5.3.3)
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40
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
Code
Meaning
6C
Ionisation message, but no flame
Possible
cause
5
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 ignitor (should be between 50 and 300 Ohm).
Replace hot surface ignitor if necessary (see subsection 5.3.19
and subsection 5.3.20)
2
There is no flame, ionisation electrode does
glow, fan isn’t turning
– Check the fan and KIM connectors and the UBA fuses
3
There is no flame, ionisation electrode and fan
are working
– Check and adjust the gas/air ratio (see subsection 2.1.12)
– Check the UBA’s F1 fuse, replace if necessary
– Check for 24V – on the gas valve during start up
– Check the gas-supply pressure (see subsection 2.1.11), this
should be higher than 20 mbar for natural gas.
– Check the earthing cable connections (yellow/green wire).
– Check the cabling on the ionisation electrode
4
There is a flame, but the flame disappears
when the fan starts 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 electrode/circuit (see subsection 2.1.15 and
subsection 5.3.22)
– When both the UBA and the ionisation electrode/circuit are OK,
then replace the gas valve
– Press reset. If fault code remains than try to temporarily connect
a different UBA (see subsection 5.3.3)
Code
Meaning
6H
Flame dies out after gas valve is opened
Possible
cause
Action
1
Gas/air ratio not in order
Check and adjust the gas/air ratio (see subsection 2.1.12)
2
Gas supply pressure may need adjusting
Check the gas-supply pressure (see subsection 2.1.11),
this should be higher than 20 mbar for natural gas
3
Earthing cable may be faulty
Check the earthing cable connections (yellow/green wire)
4
Ionisation electrode may be faulty
Check the cabling on the ionisation electrode
Code
Meaning
6L
Flame goes out during warm-up phase
Possible
cause
1
Action
Gas/air ratio not in order
Check and adjust the gas/air ratio (see subsection 2.1.12)
Gas supply pressure may need adjusting
Check the gas-supply pressure (see subsection 2.1.11),
this should be higher than 20 mbar for natural gas
3
Earthing cable may be faulty
Check the earthing cable connections (yellow/green wire)
4
Ionisation electrode may be faulty
Check the cabling on the ionisation electrode
2
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
41
5
Servicing
Code
Meaning
7A
Voltage in burner-control unit too low (lower than 187 V~) or too high (higher than 246 V~)
Possible
cause
1
Action
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 electrical network
caused by maybe windmills or a power generator
Code
Meaning
7C
Mains supply interrupted
Possible
cause
Action
1
A problem with the mains supply
Carry out a power test procedure for safe testing of the
mains electrical supply
2
Reset button pressed too briefly
Press 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)
Check for a short circuit and replace the F3 fuse
2
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 electrical network
caused by maybe windmills or a power generator
Code
Meaning
7H
Voltage peaks in the UBA
Possible
cause
1
Action
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 electrical network
caused by maybe windmills or a power generator
Code
Meaning
7L
Internal UBA error
Possible
cause
1
Action
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 electrical network
caused by maybe windmills or a power generator
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42
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
Code
Meaning
8Y
Gas fault
Possible
cause
Action
1
External switching contact (e.g. temperaturemonitoring device for underfloor heating has been
tripped or gas pressure too low
Code
Meaning
9A
System error
Possible
cause
1
5
Check gas pressure detector is defective or the wires have
not been properly connected to the back of the UBA (see
subsection 5.3.6)
Action
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 electrical network
caused by maybe windmills or a power generator
– Check for dripping hot water taps on the combination
boiler only
2
UBA may be defective
Code
Meaning
9C
KIM error
Possible
cause
Action
1
KIM connected incorrectly or KIM defective
Code
Meaning
9F/H
System error
Possible
cause
1
Press reset. If fault code remains then try to temporarily
connect a different UBA
Check the KIM connector and fan connector.
If the connectors are fine then contact Buderus
Action
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 electrical network
caused by maybe windmills or a power generator
2
UBA may be defective
Code
Meaning
9L
Gas valve assembly error
Possible
cause
1
Press reset. If fault code remains then try to temporarily
connect a different UBA (see subsection 5.3.3)
Action
Wiring to the gas valve incorrect, or loose wiring
connections in UBA
– Check the electrical connections of the gas valve.
– Measure the resistance of the gas valve (18-55 Ohm)
– Check if for example induction fields interfere with the
regulating device
2
UBA may be defective
– Press reset. If fault code remains then try to temporarily
connect a different UBA (see subsection 5.3.3)
3
Peaks in the electrical network
– Check if the are any peaks in the electrical network
caused by maybe windmills or a power generator
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
43
5
Servicing
Code
Meaning
9U
KIM defective
Possible
cause
Action
1
KIM connected incorrectly or KIM defective
Code
Meaning
E with
any
character
but P
UBA defective
Possible
cause
1
Check the KIM connector and fan connector.
If the connectors are fine then contact Buderus
Action
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 electrical network
caused by maybe windmills or a power generator
2
UBA may be defective
Code
Meaning
EP
Non compatible UBA fitted
Possible
cause
1
– Press reset. If fault code remains then try to temporarily
connect a different UBA (see subsection 5.3.3)
Action
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 electrical network
caused by maybe windmills or a power generator
2
KIM connected incorrectly or KIM defective
– Check the KIM connector and fan connector. If the
connectors are fine then contact Buderus
Problem: No DHW, despite the system being operational
– Set chimney sweep switch to "0"
– Check three-way valve replace if necessary
– Check DHW sensor and replace if necessary
Problem: No heating, despite that there is a demand for heat and the boiler is operational
– Check regulating device configuration and/ or the wiring
– Check the wiring between the regulating device and the UBA (see subsection 5.3.6)
– Check all the wiring
– Check the UBA and replace if necessary (see subsection 5.3.3)
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44
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
5.3
Checking and replacing parts
5.3.1
Checking the flue gas sensor
5
z Detach plug-and-socket connection on cable to flue gas
sensor. Ensure that no cable is earthed (grounded) at any
point.
z Allow the flue gas sensor to cool down.
Activation temperature:
600 - 11S / 19S / 24S / 24C: 105 °C
z Check flue gas sensor for free throughput. If throughput is
not free, the flue gas sensor is defective.
z Replace any flue gas sensor found to be defective.
Ensure you use only genuine Buderus spare parts.
z If the flue gas sensor is working correctly, plug it in once
more.
5.3.2
Replacing the flue gas sensor
z Unscrew the flow-backup mounting.
z Detach the cable plug at the flue gas sensor.
z Loosen both retaining screws on the flue gas sensor.
z Remove the flue gas sensor and replace with a new unit
(fig. 53).
z Retighten the retaining screws.
z Reconnect the cable plug.
z Screw the mounting into place.
Fig. 53
5.3.3
600 - 11S / 19S / 24S / 24C:
replacing the flue gas sensor
Replacing the UBA
z Disconnect the system from the power supply.
1
z Loosen crosshead screw (fig. 54, item 1) on UBA housing.
z Swivel UBA housing downwards.
Fig. 54
Subject to modifications resulting from technical improvements!
Swivel UBA housing downwards
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
45
5
Servicing
z Open the UBA housing (fig. 55).
z Note the position of the cable plugs, disconnect all cable
plugs.
z Open the mains connection box by loosening the screw.
z Loosen the four screws and remove the strain-relief clamp.
Fig. 55
Opening the UBA housing
Fig. 56
Carefully lift the UBA to remove
Fig. 57
Checking the fan
z Carefully lift the UBA and remove by pulling forwards (snap
lock) (fig. 56).
z Fit new UBA.
z Reconnect all plug-in cables to their correct sockets.
z Feed the mains lead in through the strain-relief clamp in the
connection box and connect to the terminals as per the
wiring diagram.
z Retighten the strain-relief clamp and shut the connection
box.
z Shut the mains connection box.
z Shut the UBA housing.
z Swivel the UBA housing upwards and screw into place.
z Fit the casing.
z Connect system to mains power supply.
5.3.4
Checking the fan
z Set the mains switch to “0”.
z Disconnect the fan's plug and socket connection.
z Connect a multimeter (230 V AC).
z Turn the mains power switch to “I”.
z Take voltage reading at measuring device.
If the voltage reading is 230 V, the power supply is in order.
z Set the mains switch to “0”.
z If the power supply is in order, plug the unit in once more.
z Turn the mains power switch to “I”.
z If the fan now fails to run, it must be replaced.
z If the fan runs at only partial load (i.e. effective operation of
the boiler is not possible), troubleshooting should start at
the connection cable to the UBA or UBA.
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46
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
5.3.5
5
Replacing the fan
z Shut the gas valve.
z Disconnect the system from the power supply.
1
z Disconnect the fan, using the plug and socket from the
power supply (fig. 58, item 1), loosen the UBA control line
at the fan (fig. 58, item 2) and the gas burner fitting (fig. 58,
item 3).
2
3
z Loosen the union nut (fig. 58, item 4) on the gas burner
fitting.
4
Fig. 58
Replacing the fan on the 600 Series:
loosen plug and union nut
z Push the safety plate out of the way (fig. 59, item 1).
z Turn air suction tube and pull off from below.
1
Fig. 59
Replacing the fan on the 600 Series:
remove the air suction tube
z Swivel the gas combination unit forward (fig. 60, item 1)
z Remove the gas combination unit from its bayonet
connector and pull upwards to detach (fig. 60, item 2).
1
2
Fig. 60
Subject to modifications resulting from technical improvements!
Replacing the fan on the 600 Series:
remove the gas connection unit
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
47
5
Servicing
z Detach the fan by loosening the 2 x 2 screws on the
connection unit.
z Replace the fan.
z Refit by following the above procedure in reverse.
NOTE
Once installation has been completed
successfully, carry out leak testing as per
subsection 2.1.2.
5.3.6
Fig. 61
Replacing the fan on the 600 Series:
replace the fan
Fig. 62
Checking the wiring connections of the UBA
Checking the wiring connections of the UBA
z Disconnect the system from the power supply.
z Loosen crosshead screw on UBA housing.
z Swivel UBA housing downwards.
z Open the UBA housing.
z Check all cable terminals for tightness and
resecure/retighten as required.
z Shut the UBA housing.
z Swivel the UBA housing upwards and screw into place.
z Connect system to mains power supply.
5.3.7
Checking the mains supply
1
If the mains supply is interrupted or seems faulty, carry out a
power test procedure for safe testing of the mains electrical
supply.
z Loosen crosshead screw on UBA housing.
z Swivel UBA housing downwards.
z Open the UBA housing.
z Carry out the power test procedure (see fig. 63, item 1).
z Shut the UBA housing.
z Swivel the UBA housing upwards and screw into place.
z Connect system to mains power supply.
Fig. 63
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48
Checking the mains supply
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
5.3.8
Checking the miniature fuses
5
2
z Disconnect the system from the power supply.
3
z Loosen crosshead screw on UBA housing.
z Swivel UBA housing downwards.
z Open the UBA housing.
z Check miniature fuses (fig. 64) for correct functioning,
or carry out visual inspection. If defective, fit new fuse.
All fuses a rated 230 Vac - 1.25 AT.
Fuse
Function
1
Hot surface ignitor
2
UBA, sensors, thermostat valve
3
UBA, three-way valve
z Shut the UBA housing.
z Swivel the UBA housing upwards and screw into place.
1
Fig. 64
Checking the miniature fuse
Fig. 65
600 - 11S / 19S / 24S / 24C:
checking the pump
z Connect system to mains power supply.
5.3.9
Checking the pump
z Remove screw plug on the pump (fig. 65).
z Turn the UBA mains power switch to “I”.
z Check to ensure that the pump is running. The pump’s
running mechanism may become blocked if the heating
system has been out 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 is working correctly, screw the plug back in.
5.3.10 Replacing the pump
z Disconnect the system from the power supply.
2
z Shut the servicing valve.
z Drain the 600 - 11S / 19S / 24S / 24C as per the
"Installation and Servicing Instructions".
3
z Loosen the screw on the terminal box (fig. 66, item 2) of the
pump and open the terminal box. Note the wiring layout,
and loosen the cables (fig. 66, item 1).
1
z Loosen the screw-in connections on the pump (fig. 66,
item 3) and remove the pump.
z Fit new pump and connect to system.
z Connect cables in previously-noted order inside terminal
box, close terminal box and screw shut.
z Connect system to mains power supply.
z Open servicing valves.
Fig. 66
600 - 11S / 19S / 24S / 24C:
replacing the pump
NOTE
Fill the 600 - 11S / 19S / 24S / 24C and purge
the system of air.
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
49
5
Servicing
5.3.11 Checking the safety sensor
z Unplug cable connection from sensor.
z Measure resistance of sensor (fig. 67, item 1).
z Use a second-reading thermometer to measure the
temperature around the sensor.
z Compare readings with values shown intable 8 on
page 52. If there is any mismatch (i.e. > 5%), the sensor is
defective.
z If the sensor is working correctly, plug it in once more.
Fig. 67
600 - 11S / 19S / 24S / 24C:
checking the safety sensor
Fig. 68
600 - 11S / 19S / 24S / 24C:
replacing the safety sensor
Fig. 69
600 - 11S / 19S / 24S / 24C:
checking the safety sensor connection lead
5.3.12 Replacing the safety sensor
z Shut the servicing valve.
z Drain the 600 - 11S / 19S / 24S / 24C as per the
"Installation and Servicing Instructions".
z Loosen the plug-in connection (fig. 68, item 1).
z Unscrew the sensor (fig. 68, item 2) and replace with a new
unit.
z Plug in cable connection.
z Open servicing valves.
NOTE
Fill the 600 - 11S / 19S / 24S / 24C and purge
the system of air.
5.3.13 Checking the safety sensor connection lead
Check to ensure that all plug-in connections on the sensor and
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 mains switch to “0”.
z Disconnect the system from the power supply.
z Unplug cable connection from flow sensor.
z Disconnect 18-pin plug from UBA.
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 06-18 and
08-18 (fig. 69).
z If the cables are in order, plug them in.
z Connect system to mains power supply.
z Turn the mains power switch to “I”.
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50
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
5
5.3.14 Checking the flow sensor
z Unplug cable connection from sensor.
z Measure resistance of sensor (fig. 70, item 1).
z Use a second-reading thermometer to measure the
temperature around the sensor.
1
z Compare readings with values shown in table 8 on
page 52. If there is any mismatch (i.e. > 5%), the sensor is
defective.
z If the sensor is working correctly, plug it in once more.
Fig. 70
600 - 11S / 19S / 24S / 24C:
checking the flow sensor
5.3.15 Replacing the flow sensor
1
z Shut the servicing valve.
z Drain the 600 - 11S / 19S / 24S / 24C as per the
"Installation and Servicing Instructions".
1
z Loosen the plug-in connection (fig. 71, item 1).
z Unscrew the sensor (fig. 71, item 2) and replace with a new
unit.
2
z Plug in cable connection.
z Open servicing valves.
NOTE
Fill the 600 - 11S / 19S / 24S / 24C and purge
the system of air.
Fig. 71
600 - 11S / 19S / 24S / 24C:
replacing the flow sensor
5.3.16 Checking the flow sensor connection lead
UBA
Check to ensure that all plug-in connections on the sensor and
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.
1
10
11
20
z Set the mains 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 cable between the
plug-in connection and the 20-pin plug in the UBA.
The test should be carried out on connections 05-20 and
18-20 (fig. 72).
z If the cables are in order, plug them in.
z Connect system to mains power supply.
z Turn the mains power switch to “I”.
Subject to modifications resulting from technical improvements!
Fig. 72
600 - 11S / 19S / 24S / 24C:
checking the flow sensor connection lead
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
51
5
Servicing
5.3.17 Checking the hot water / boiler sensor
z Disconnect the plug-and-socket connection on the hot
water sensor cable (fig. 73, item 1) and/or the boilersensor
(fig. 73, item 2).
z Measure resistance, take a temperature reading at the
thermal pressure gauge (tolerance ± 5 K) and compare
with the values listed in table 8. If there is any marked
mismatch, the hot-water sensor is defective.
z If the hot water / boiler sensor is in order, plug it back in.
Temperature [°C]
Resistance [Ω]
0
29,490.0
5
23,462.0
10
18,787.0
15
15,136.0
20
12,268.0
25
10,000.0
30
8,197.0
35
6,754.0
40
5,594.0
45
4,656.0
50
3,893.0
55
3,271.0
60
2,760.0
65
2,339.0
70
1,990.0
75
1,700.0
80
1,458.0
85
1,255.0
90
1,084.0
95
1,939.6
100
1,817.2
2
1
Table 8 Resistance values for hot water / boiler sensor
(approximate values)
Fig. 73
Checking the hot water / boiler sensor
Fig. 74
Boiler temperature sensor diagram
Outside temperature sensor
(°C)
25
20
15
10
5
0
-5
-10
-15
-20
10,000
Fig. 75
R (Ω)
20,000
30,000
40,000
60,000
70,000
80,000
Outside temperature sensor diagram
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52
50,000
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
5
5.3.18 Changing the hot water / boiler sensor
z Shut the servicing valve.
z Drain the 600 - 11S / 19S / 24S / 24C as per the
"Installation and Servicing Instructions".
z Disconnection plug-and-socket connection on cable to
hot water / boiler sensor.
z Remove insulation mounting (fig. 76, item 1) and detach
insulation.
1
Fig. 76
Changing the hot water / boiler sensor
z Pull out the sensor fuses (fig. 77).
z Unscrew hot water / boiler sensor and replace with new
unit.
1
z Refit insulation and corresponding mounting elements.
2
z Plug cable connection in once more.
z Open servicing valves.
z Fill the 600 - 11S / 19S / 24S / 24C and purge the system
of air as indicated in the installation and servicing
instructions.
Fig. 77
Changing the hot water / boiler sensor
Fig. 78
Checking the hot surface ignitor
5.3.19 Checking the hot surface ignitor
z Disconnect the system from the power supply.
z Loosen crosshead screw on UBA housing.
z Swivel UBA housing downwards.
z Open the UBA housing.
z Unplug and remove hot surface ignitor from UBA housing
(fig. 78).
z Check hot surface ignitor for free throughput.
If throughput is free, the hot surface ignitor is in order.
z If the hot surface ignitor is in order, plug the cable into the
UBA housing.
z Shut the UBA housing.
z Swivel the UBA housing upwards and screw into place.
z Connect system to mains power supply.
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
53
5
Servicing
5.3.20 Replacing the hot surface ignitor
z Disconnect the system from the power supply.
z Remove combustion-chamber cover.
1
z Remove the earth (ground) lead from the hot surface
ignitor (fig. 79, item 1).
3
2
Fig. 79
Replacing the hot surface ignitor
Fig. 80
Disconnect the plug-in cable from the UBA housing
z Loosen crosshead screw on UBA housing.
z Swivel UBA housing downwards.
z Open the UBA housing.
z Unplug hot surface ignitor connection cable from UBA
housing (fig. 80).
z Loosen nut on clamp used to secure earth (ground) lead
(fig. 79, item 2).
z Detach retaining plate of hot surface ignitor (fig. 79, item 3)
and remove hot surface ignitor.
5.3.21 Measuring the ionisation current
z Disconnect the system from the power supply.
z Loosen the plug-and-socket connector of the monitoring
cable and connect the measuring device in series.
Select the µA direct current range on the multimeter.
The multimeter must have a resolution of at least 1 µA.
z Reconnect the system to the power supply and turn the
chimney-sweep switch to “1”.
z Measure the ionisation current.
The ionisation current must be > 2 µA DC.
z Enter the reading on the report form.
z Disconnect the system from the power supply.
z Remove the measuring device and restore the
plug-and-socket connection to its original state.
z Turn the chimney-sweep switch to position “0”.
z Refit the cover for 2nd operating level.
z Reconnect the system to the power supply. When the
display shows “7”, press the service button to display “c”.
Press the "reset" button. The display shows “r”.
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54
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
5
5.3.22 Replacing the ionisation electrode
z Remove the CombiVENT air combination unit.
z Loosen the plug-and-socket connection of the ionization
electrode.
z Loosen screw (fig. 81, item 1) by a half-turn and slide bar
to remove.
1
z Pull electrode to remove, and fit new unit.
z Reassemble by following the above procedure in reverse.
Fig. 81
Replacing the ionisation electrode
Fig. 82
600 - 11S / 19S / 24S / 24C:
checking the motorised head for correct operation
5.3.23 Checking the three-way motorised valve for
correct operation
z Disconnect the system from the power supply, set mains
switch to "0".
z Dismantle condensate trap.
z Remove protective cap from three-way valve.
z Remove bottom insulation from internal hot-water reservoir
(applies to 600 - 24C only).
z Push in catch on regulating motor and
z Remove bayonet connector by twisting anticlockwise.
z Remove regulating motor.
z Set the mains switch to “I” and press the “reset” button.
z Once the 600 - 11S / 19S / 24S / 24C is in operation, open
one of the hot-water taps.
The UBA displays " =. " for hot water. If the regulating
motor starts up (check for movement of adjusting lever),
the motorised head is working.
z Shut the hot-water tap.
z Set the mains switch to “0”.
z If the motorised head is working, attach the regulating
motor and lock into place by twisting the bayonet
connector.
z Connect the system to the power supply, set the mains
switch to “I” and press the “reset” button.
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
55
5
Servicing
5.3.24 Replacing the motorised valve body control valve
z Shut the servicing valve and drain the
600 - 11S / 19S / 24S / 24C as per the "Installation and
Servicing Instructions".
z Dismantle condensate trap.
z Remove protective cap from three-way valve.
z Remove bottom insulation from internal hot-water reservoir
(applies to 600 - 24 C only).
z Push in catch on regulating motor and remove bayonet
connector by twisting anticlockwise.
z Remove regulating motor.
z Remove the control valve with a spanner and fit a new unit
(fig. 83).
z Fit regulating motor and lock into place by twisting the
bayonet connector.
z Reconnect the cable plug.
Fig. 83
600 - 11S / 19S / 24S / 24C:
replacing the control valve
NOTE
Open servicing valves, fill the 600 - 11S / 19S
/ 24S / 24C and purge the system of air.
z Set the mains switch to “I” and press the “reset” button.
5.3.25 Replacing the three-way valve
NOTE
Replace the three-way valve only if leaking
occurs on the screw-in pipe connectors.
A: Mains water, B: Heating,
AB: Boiler flow line
z Shut the servicing valve and drain the
600 - 11S / 19S / 24S / 24C as per the "Installation and
Servicing Instructions".
A
z Dismantle condensate trap.
B
AB
z Remove protective cap from three-way valve.
z Remove bottom insulation from internal hot-water reservoir
(applies to 600 - 24 C only).
z Push in catch on motorised valve head and remove
bayonet connector by twisting anticlockwise.
z Remove motorised head.
Fig. 84
600 - 11S / 19S / 24S / 24C:
replacing the three-way valve
z Loosen the 3 compression nuts (fig. 84).
z Remove three-way valve and fit new unit.
z Tighten the 3 compression nuts.
z Fit motorised valve head and lock into place by twisting the
bayonet connector.
z Reconnect the cable plug.
NOTE
Open servicing valves, fill the 600 - 11S / 19S
/ 24S / 24C and purge the system of air.
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56
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Servicing
5
z Connect the system to the power supply, set the mains
switch to “I” and press the “reset” button.
5.3.26 Checking the ERC/RC connections to the UBA
z Disconnect the system from the power supply.
z Loosen crosshead screw on UBA housing.
z Swivel the UBA housing downwards (fig. 85).
z Push in UBA housing on left-hand side and open to the
right (fig. 86).
z Check to ensure that ERC or RC are correctly connected
to 3 and 4.
z Terminals 1 and 2 should not be wired in any way.
The unit is supplied with a dummy connector between
terminals 1 and 2 (fig. 87). The DC voltage at terminals 3
and 4 should be approx. 11.5 V. If this is not so, the UBA
or the cable harness is defective.
Fig. 85
Swivel UBA housing downwards
Fig. 86
Opening the UBA housing
z Shut the UBA housing once more.
z Swivel the UBA housing upwards and screw into place.
z Connect system to mains power supply.
z Set the mains switch to “I” and press the “reset” button.
5.3.27 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.
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
57
5
Servicing
5.3.28 Checking connections at the ModuLink or iRT
z Check contact link between cable and ModuLink or iRT.
1
z There should be a DC voltage of approx. 11.5 V at the
ModuLink or iRT.
2
3
NOTE
It is possible, in order to limit the source of
errors, to disconnect the ModuLink or iRT from
the boiler (bridge required at 3 and 4) and to
install a conductor bridge at 1 and 2 (fig. 87).
The heating and hot-water requirement is then
passed via the potentiometer setting of the
UBA.
4
5
6
Fig. 87
Checking the controller-device connections at the
boiler
Key to control-device connections:
Item 1:
ON/OFF temperature controller
Item 2:
ModuLink or iRT room temperature controller (digital)
Item 3:
I/O port / communication port
Item 4:
Outdoor-temperature sensor
Item 5:
Power supply 24 VAC/max. 6 VA
Item 6:
Turn-on voltage for three-way valve (9+11)
5.3.29 Checking KIM connections
z Locate KIM on boiler frame under UBA housing.
z Check 4 pin connector (fig. 88, item 1) is fitted and secure.
NOTE
This is not a serviceable part and any fault
identified with this component, contact
Buderus.
1
Fig. 88
Buderus • http://www.buderus-domestic.co.uk
58
KIM connections
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Changing to another type of gas
6
6
Changing to another type of gas
WARNING!
Work on components in contact with gas must
only be carried out by a registered CORGI
engineer.
1
Switch off the heating boiler
z Disconnect the system from the power supply.
z Close the gas shutoff valve.
z Loosen the fixing screw and remove cover.
1
z Open snap locks (fig. 89, item 1) and remove combustion
chamber cover.
Fig. 89
Open snap locks
Fig. 90
Loosen the union nut and remove the cable
Fig. 91
Remove safety plate
z Loosen union nut on gas valve assembly (fig. 90, item 4).
z Release plug-in connection of fan power lead (fig. 90,
item 1), burner-control unit fan control lead (fig. 90, item 2)
and gas-burner assembly (fig. 90, item 3).
z Push safety plate out of way (fig. 91, item 1).
z Turn air suction tube and pull off from below.
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
59
6
Changing to another type of gas
z Swivel the air combination unit forwards (fig. 92, item 1).
s
z Pull the air combination unit up and out of the bayonet
connector (fig. 92, item 2) and remove via the front of the
unit.
1
2
Fig. 92
Remove the air combination unit
Type of gas supply
Gas nozzles ∅ [mm]
Venturi
tubes
11S
19S/24(C)
Natural gas H (G20)
5.55
6.5
Standard
Venturi
tubes
LPG
3.40
4.15
Standard
Venturi
tubes
Table 9 Gas-nozzle diameter
Replacing a gas nozzle
WARNING!
Conversion to another gas type is
implemented by installing/removing a gas
nozzle (fig. 93, item 3) of the appropriate gas
nozzle diameter (table 9).
z Undo the three screws (fig. 93, item 2) on the long side of
the gas fitting.
z Remove the gas nozzle and insert the correct gas nozzle
for the new gas type.
z Insert new seal (fig. 93, item 4).
z Remount all components in the reverse sequence.
z Cover stickers (fig. 94, item 1) with the new stickers
(2 pieces, included in conversion kit).
Starting up
z Start up the appliance following the procedure described in
the mounting and maintenance instructions.
z Include all seal areas concerned during mounting in the
gas-tightness check when in operation.
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60
Fig. 93
Replacing a gaz nozzle
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Changing to another type of gas
6
z Refit all covers.
1
Fig. 94
Subject to modifications resulting from technical improvements!
1
Place new stickers
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
61
7
Appendix
7
Appendix
7.1
Technical specifications
600 Series wall-mounted condensing gas boiler
Dimensions
Unit
11S
19S
24S
24C
GB II2H3P 20 mbar, 37 mbar
(natural gas H and LPG)
Type of gas supply as established in
EN 437 (GB)
Rated thermal load
for hot water tank
kW
kW
4.5 - 10.5
4.5 - 13.0
9.0 - 18.2
9.0 - 23.0
9.0 - 23.0
Rated heating capacity for system
temperature (modulating from 30° to 100°)
Heating curve 75/60 °C
Heating curve 40/30 °C
kW
kW
4.3 - 10.0
4.9 - 11.0
8.6 - 17.4
9.7 - 19.0
8.6 - 22.0
9.7 - 24.0
8.6 - 22.0
9.7 - 24.0
Seasonal efficiency (SEDBUK)
%
90.3
90.3
90.2
90.1
0.95
Central heating installation
Heating water temperature
°C
40 - 80
ΔT at residual head of 200 mbar
K
<20
Max. operating overpressure of boiler
bar
3.0
Volume heat exchanger heating circuit
l
1.0
Position 1
min
4
Position 2
h
24
l
12
bar
0.75
Pump stopping time heating circuit
Expansion vessel
Capacity of expansion vessel
Admission pressure of expansion vessel
Hot water tank (type 24C)
Hot water capacity of heat exchanger
l
-
-
-
Outlet flow at 60 °C (ΔT = 50 °C)
l/min
-
-
-
Adjustable hot water temperature
°C
40 - 60
Minimum connection pressure
bar
0.75
Maximum connection pressure
bar
10
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62
6.5
(type 24C)
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Appendix
7
600 Series wall-mounted condensing gas boiler
Dimensions
Unit
11S
19S
24S
24C
Pipe connections
Gas
inch / mm
Ø22 mm
compression
fitting
G1"
Heating water
mm
Ø22 mm compression fitting
Domestic water
mm
Ø15 mm compression fitting
Condensate-water outlet
inch
G1"
Flue gas values
Condensate water quantity, natural gas,
40/30 °C
l/h
0.7
1.3
pH value of condensate water
1.6
1.6
approx. 4.1
Exhaust-fume mass-flow rate
Full load
Part-load
g/s
g/s
4.9
2.2
8.4
4.3
10.6
4.3
10.6
4.3
Exhaust-fume temperature, full load
Heating curve 75/60 °C
Heating curve 40/30 °C
°C
°C
75
50
85
55
95
55
95
55
Exhaust-fume temperature, part-load
Heating curve 75/60 °C
Heating curve 40/30 °C
°C
°C
65
40
70
45
70
45
70
45
CO2 full load, natural gas
standard test gas G20
%
9.2
CO2 full load, natural gas
standard test gas LPG
%
10.3
Standard emission factor CO
mg/kWh
<22
Standard emission factor NOx
mg/kWh
<30
Flow pressure available for use
Pa
100
100
35
60
Flue-gas system
Type of exhaust-fume connection
Diameter of flue gas system
C13, C33, C53
mm
60/100
Mains connection voltage
V
230
Electrical power consumption
Full/Part load
W
Electrical data
105/100
110/105
Electrical protection rating
115/105
115/105
IPX4D
Boiler dimensions and weight
Height x Width x Depth
mm
Weight (without casing)
kg
39
40
40
45
Casing
kg
7
7
7
7
Subject to modifications resulting from technical improvements!
850 x 480 x 370
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
63
7
7.2
Appendix
Short list of spare parts
The following are parts commonly required due to damage or
expendability. Their failure or absence is likely to affect safety
or performance of this appliance. For a pictorial representation
of the part see the respective position number on the exploded
view pictures on pages 7 and 8.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Flow connection piece
Automated air vent
Hairpin heat exchanger
Flow sensor
Clip
Flow pipe
Clip flow pipe
Back part heat exchanger
Seal heat exchanger
Sealing ring burner
Burner 11S / 19S and 24(C)
Heat exchanger
Front panel heat exchanger
Sight glass
Fastener
Ventilation cover
Casing
Condensate trap
Syphon cap with seal
Drain pipe condensate trap
Syphon
Sealing ring
Flue gas sensor
Sealing ring
Flue gas pipe
Flue gas pipe seal
Condensate collector
Lipring
Combustion divider
Insulation divider
Fan
Gas/air supply pipe
Fan seal
Venturi 11S / 19S and 24(C)
Gas valve
Rectifier
Suction pipe
Gas pipe
Concentric adapter
Lip ring
Adapter clip
Bracket
Cable duct
Ventilation cover seal
Pipe duct
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64
Product No.
73581
38618
73582s
38323
73056s
73613
38602s
73611
73578
73571s
73593 / 73594
73612
73610
73576
75132s
75135
38091
73589
73124
75988
75986
73561
73376
73736
73743
73579
73630
73563
73587
73515
73366
73570
73565
73567 / 73568
73278
38355
73573
73279
77463
77464
38496
38092
38463s
38456
38462s
Description
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
Sealing ring
Cable harness
UBA
Power switch
Temp-pressure gauge
UBA panel
230V cable
O-ring
O-ring
Return pump connection pipe
1-speed pump / 3-speed pump
Expansion vessel
Expansion vessel pipe
Manifold assembly
Pressure relief valve
Spring set
Connection house by-pass
Clip by-pass
Connection house three-way valve
Spring set
Connection housing pump
Connection housing
Clip
By-pass pipe
DHW pipe (hot)
Clip
DHW supply pipe
Hot water sensor
Boiler sensor
Insulation hot water tank
DHW pipe (cold)
Flow regulator
Three-way valve body
Three-way valve cartridge
Three-way valve cover
Three-way valve head
Ionisation electrode
Hot surface ignitor
Hot water tank
–
RTH converter 230V
Product No.
73561
73371
38324
38340
75300
38488
75301
73580s
73584s
73616
75302 / 75303
38461
38621
20378
73199
73531
38611
38483
38614
73531
73617
38611
38475s
38610
38601
38474s
73614
38352
38353
38493
38605
38604
73118
73499
73520
73317
38320
78105
38600
78091
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Reports
8
Reports
8.1
Start-up report
8
z Please check off the start-up tasks carried out and enter
the corresponding readings.
Initial start-up tasks
1.
Remarks or measurement readings
Note down gas characteristics:
Wobbe-index
Operating heat value
_____________________ kWh/m3
_____________________ kWh/m3
2.
Inspect to check for leaks
(See section 2.1.2 on page 23)
3.
Check combustion air/flue gas connection
(See section 2.1.4 on page 24)
4.
Checking the boiler equipment (change to another type of gas if
necessary) (See section 2.1.5 on page 25)
5.
Carry out adjustment settings
(See section 2.1.8 on page 26)
6.
Measure the gas connection pressure (flow pressure)
(See section 2.1.11 on page 27)
_____________________ mbar
7.
Checking and adjusting the gas/air -ratio
_____________________ Pa
CO2-content:
_____________________ %
_____________________ %
at full load
at part load
(See section 2.1.12 on page 27)
8.
Leak test in operational condition
9.
Measure carbon monoxide content (CO), vacuum
(See section 2.1.14 on page 28)
_____________________ ppm
10. Function testing
Measuring the ionisation current
(See section 2.1.15 on page 28)
_____________________ µA
11. Fit the boiler casing
12. Instruct the user. Fill in Benchmark log book.
Hand over documentation.
(See section 2.1.16 on page 29)
13. Confirm initial start-up
Confirmation of initial start-up by qualified service technician
(Company stamp, signature)
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
65
8
8.2
Reports
Inspection and maintenance reports
The inspection and maintenance reports provide an overview
of all the tasks and operations carried out.
Please check off the inspection and/or requirement-related
maintenance tasks carried out and enter the corresponding
readings.
See also Section 3: "Inspection“ on page 30 or Section 4:
"Maintenance“ on page 31.
z Sign details of inspection and maintenance tasks,
indicating date carried out.
Use only original replacement parts.
Inspection tasks
Date: _____________
Date: _____________
1.
Check general state of system
2.
Visual inspection and function check of system
3.
Check gas- and water-bearing components for
- leaks
- signs of corrosion
- signs of ageing
4.
Take system out of service and check the burner, heat exchanger
and syphon for signs of dirt and soiling.
(See section 4.1.1 on page 31)
5.
Check the burner, hot surface ignitor and ionisation electrode,
after disconnecting the system.
(See section 4.1.1 on page 31)
6.
Measuring the ionisation current
(See section 2.1.15 on page 28)
_________________ µA
_________________ µA
Measure the gas connection pressure (flow pressure)
(See section 2.1.11 on page 27)
________________ mbar
________________ mbar
Check the gas-air ratio
(See section 2.1.12 on page 27)
_________________ Pa
_________________ Pa
________________ ppm
________________ ppm
________________ mbar
________________ mbar
________________ mbar
________________ mbar
7.
8.
9.
Gas leak test in operational condition
(See section 2.1.2 on page 23)
10. Measure the carbon monoxide content (CO), vacuum
(See section 2.1.14 on page 28)
11. Pressure-testing of heating system:
- admission pressure of expansion tank
(see installation instructions supplied with expansion tank)
- Filling pressure
12. Check ventilation and exhaust conduits for correct functioning and
safety
13. Check requirement-related adjustment settings of control device
(see documentation supplied with control device)
14. Final check of inspection tasks,
with record kept of measurement readings and test results
15. Confirm inspection carried out by qualified service engineer
and fill out the Benchmark
Company stamp / Date / Signature)
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Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Reports
8
Date: _________
Date: ___________
Date: ___________
Date: ___________
Date: ___________
_______________ µA
_______________ µA
_______________ µA
_______________ µA
_______________ µA
_____________ mbar
_____________ mbar
_____________ mbar
_____________ mbar
_____________ mbar
_______________ Pa
_______________ Pa
_______________ Pa
_______________ Pa
_______________ Pa
______________ ppm
______________ ppm
______________ ppm
______________ ppm
______________ ppm
_____________ mbar
_____________ mbar
_____________ mbar
_____________ mbar
_____________ mbar
_____________ mbar
_____________ mbar
_____________ mbar
_____________ mbar
_____________ mbar
Subject to modifications resulting from technical improvements!
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Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
67
8
Reports
Requirement-related maintenance tasks
1.
Clean heat exchanger, burner and condensate trap
(See section 4.1 on page 31)
2.
Check and adjust the gas-air ratio
at full load
CO2-content:
at part load
(See section 2.1.12 on page 27)
3.
Date: _____________
Date: _____________
______________________ Pa
______________________ Pa
______________________
______________________
%
______________________ %
______________________
%
%
Confirm servicing work
Confirmation of servicing carried out by qualified technician
Company stamp, signature)
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68
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Reports
8
Date: ___________
Date: ___________
Date: ___________
Date: ___________
Date: ___________
___________________ Pa
___________________ Pa
___________________ Pa
___________________ Pa
___________________ Pa
____________________ %
____________________ %
____________________ %
____________________ %
____________________ %
____________________ %
____________________ %
____________________ %
Subject to modifications resulting from technical improvements!
____________________ %
____________________ %
Buderus • http://www.buderus-domestic.co.uk
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
69
Notes
Buderus • http://www.buderus-domestic.co.uk
70
Subject to modifications resulting from technical improvements!
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
Notes
Subject to modifications resulting from technical improvements!
Buderus • http://www.buderus-domestic.co.uk
Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 11S/19S/24S/24C • 02/2006
71
Buderus
Cotswold Way
Warndon
Worcester
WR4 9SW
Telephone: 01905 - 752 936
Fax: 01905 - 753 130
Customer Services:
Tel: 0870 - 421 5933
Technical Product Support:
Tel: 0870 - 421 5944
Sales:
Tel: 01905 - 752 640
Fax: 01905 - 456 445 / 455 394
Returns:
Tel: 01905 - 752 531
Fax: 01905 - 455 392
Spares:
Tel: 01905 - 752 576
Fax: 01905 - 754 620
www.buderus-domestic.co.uk
Buderus is a trading name of BBT Thermotechnology UK Ltd.
720.967A - 4612 - 02/2006
Heating system specialist:
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