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1. pA pA pA pA pA mbar mbar 4mbar mbar mbar Pa Pa Pa Pa Pa ppm ppm ppm ppm ppm mbar mbar mbar 4mbar mbar mbar mbar mbar mbar mbar Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 Buderus http buderus domestic co uk 65 Renuirementrelated maintenancetasks bae Ow 1 Clean heat exchanger and burner see chapter 4 1 on page 33 2 Check and adjust the gas air ratio Pa Pa CO content at full load at partial load see chapter 2 2 4 on page 28 3 Confirm servicing work confirmation of servicing carried out by a CORGI registered installer company stamp signature Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 66 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 P
2. fig 11 Condensate water outlet for longer exhaust flue systems made of aluminium fig 12 Remove sealing cap on condensate water bypass applies only to boiler connection pieces made of plastic Buderus http buderus domestic co uk 14 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 1 8 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 125 mm flue systems See subsection 1 3 3 for the maximum horizontal straight length of each type boiler Full instructions for fitting this flue are in Section 1 8 2 Installation of the horizontal flue on page 15 Buderus 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 1 8 1 Fitting the boiler s adaptor plate Place the boiler s adaptor plate onto the boiler fig 13 Secure with 6 screws 1 8 2 Installation of the horizontal flue The standard 125 mm diameter horizontal flue system is suitable for length upto 595 mm Flue length
3. Mains connection voltage V 230 230 230 230 230 230 Type of enclosure IP40 By IP40 B IP40 By IP40 B IP40 B4 IP40 By IPAX Cy IPAX C4 IPAX C4 IP4X C44 IP4X C4 IP4X C44 Power consumption full load W 120 120 130 130 180 200 partial load W 60 60 70 70 85 100 Boiler dimensions and weight V H V H Height mm 685 1250 685 685 1250 685 685 685 Width mm 560 560 900 560 560 900 900 900 Depth mm 431 431 431 431 431 431 431 431 Weight without casing kg 41 71 66 48 77 70 53 61 Weight casing kg 11 14 11 11 14 11 11 11 Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 60 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 6 2 Residual pump lift for wall hung gas boilers The residual pump lift graphics show the amount of pump lift that remains for the heating system 800 24 600 500 S3 gt _ maximum modulation 400 E T 20 minimum modulation in heating mode only v S S Residual pump lift mbar 8 8 de MM i 0 1 0 200 400 600 800 1000 1200 1400 1600 Flow Uh 800 29 600 500 F PN m maximum modulation 540 mall a euna krn j in heating mode only
4. fig 32 Hot water sensor FW for external storage type water heater type 800 24T25 H V and 800 29T25 H V Setting the hot water flow limiter Set the desired value on the flow volume limiter fig 33 e g for 60 C at 6 liters min for type 800 24T25 or 8 liters min for type 800 29T25 Turning to the right reducing the flow volume Turning to the left increasing the flow volume 2 2 3 Measuring the gas supply pressure flow pressure Open at least one radiator thermostat valve The gas boiler must not be turned on yet Move the chimney sweeper switch fig 34 to position 1 On type 800 60 the full capacity is achieved after approx one minute Therefore measurements should be carried within one minute of boiler operation Loosen the screw plug on the gas distribution pressure test nipple on Honeywell gas units fig 35 item 1 two turns fully unscrew the plug on SIT gas units fig 36 item 1 Fit the measuring hose of the pressure gauge to the test nipple fig 35 item 2 or fig 36 item 2 fig 34 Chimney sweeper switch Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 27 Insert the mains plug and move the mains switch to I Af
5. water heater fig 22 Connecting the control unit Key to fig 22 Item 1 ON OFF temperature controller non conducting bridge Item 2 Room temperature controller iRT digital Item 3 I O port communication port Item 4 Outdoor temperature sensor Item 5 Power supply 24 VAC max 6 VA switching voltage three way valve 94 11 Item 6 RTH converter Item 7 24 VAC connection Item 8 230 VAC connection Item 9 Volt free connection Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 19 1 9 8 Service tool The service tool allows you to determine the operating status of the boiler check components and carry out fast fault diagnosis Open the flap at the front of the boiler unit and insert the twin plug connector of the service tool into the sockets provided fig 23 item 1 fig 23 Service tool connection Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 20 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 1 9 9 System examples Buderus 800 with Buderus controls Key to abbreviations AV Air Vent BCT Buderus cylinder thermostat BDV Buderu
6. Close the gas shutoff valve Remove all plug in cables from the gas valve assembly Note order of cable terminals Loosen the screw in adapter on the tube connector Remove the valve assembly and replace with a new unit attaching it to the screw in connection adapter Connect all plug in cables in the correct order NOTE Carry out all initial start up tasks as indicated in fig 82 Gas valve assembly replacement HONEYWELL valve the installation and servicing instructions and assembly shown as example complete the corresponding report form With the system running check for leaks at all joints likely to have been affected by the fitting of replacement parts 5 3 21 Checking the wiring connection to the KIM Disconnect the system from the power supply Check plugs and wiring connections to KIM Connect system to mains power supply fig 83 Checking the wiring connection to the KIM Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 56 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 5 3 22 Checking the controller connections at the boiler Set the mains switch to 0 Remove loop non conductive from terminals 1 and 2 Loosen cable at terminals 3 and 4 Fit a link between terminals 1 and 2 3 and 4 NOTE
7. 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 18 Check all the wiring Check the UBA and replace if necessary see subsection 5 3 5 Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 45 Buderus http ouderus domestic co uk 5 3 Checking and replacing parts 5 3 1 Unblock the 800 Series Each time a fault has been rectified push the reset button fig 53 and keep it pressed for five seconds A letter r will appear on the display After five seconds the display returns to 0 This unblocks the UBA and returns it to standby mode NOTE The system cannot be unblocked by disconnecting at the master switch Buderus 5 3 2 Chimney sweep mode Certain troubleshooting tasks must be carried out with the 800 Serie in heating mode When doing so the chimney sweep switch should be set to 1 Remember to return the chimney sweep switch to 0 once work is compl
8. Y 8a m CH flow CH return Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 6 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 800 24T25H 800 29T25H 900 mm 35 385 mm 13 4115 mm 4 N 20 7 RI DHW warm out CH flow 4 CH return Y DHW warm DHW cold hot water outlet 15 mm dia R 152 mm 6 40 1 431 mm 17 DHW cold in cold water inlet 15 mm dia GAS gas connection R 800 24T25H 29T25H CH return boiler return line 28 mm dia CH flow boiler flow line 28 mm dia CWDO condensate water drain 32 mm dia Minimum side clearance required for all boilers is 100 mm 4 Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 Buderus http buderus domestic co uk 7 1 2 Boiler assembly exploded view Single unit type 800 24 800 29 390 Air inlet pipe incl gasket 400 Support mounting bracket fan anti vibration 410 Fan 420 Connection pipe gas valve burner 430 Connection nipple 3 4 x1 2 with O ring 440 Gas unit 460 Gas inlet pipe 1 2 470 Contro
9. benchmark Buderus http ouderus domestic co uk 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 Regulations and directives It is law that all gas appliances are installed and serviced by a CORGI registered installer in accordance with the regula tions Failure to install appliances correctly could lead to pros ecution It is in your own interest and that of safety to ensure the law is complied with The installation of the boiler MUST be in accordance with the latest I E E BS7671 Wiring Regulations local building regulations water regulations the building regulations and the Building Standard Scotland and any relevant requirements of the local authority 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 ins
10. oL E 300 T 20K a T 200 S gt 3 Paa 9 3 p e 100 P o i 0 200 400 600 800 1000 1200 1400 1600 Flow Vh 800 43 700 600 FE maximum modulation 500 minimum modulation F in heating mode only amp 400 g 2 300 3 200 T 20K B 1 100 i o 1 0 200 400 600 800 1000 1200 1400 1600 1800 Flow h Subject to modifications resulting from technical improvements 800 24T25 600 200 DEREN maximum modulation Fa T 20K minimum modulation E in heating mode only F9 e i 300 r a P 200 7 100 0 0 200 600 800 1000 1200 1400 1600 1800 Flow l h 800 29T25 600 590 maximum modulation 7 minimum modulation 400 i i 5 in heating mode only amp 300 T 20K a i 8 200 3 1 E i 100 1 1 0 i 0 200 600 800 1000 1200 1400 1600 1800 Flow l h 800 60 700 4 600 EL maximum modulation GOD SI i minimum modulation 3 in heating mode only g 400 a amp 300 T 20K T i 1 amp 200 1 100 1 fi o o 200 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 Flow h Buderus http ouderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800
11. Pull out the baffle plate fig 48 fig 48 Baffle plate Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 34 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 Clean the burner with a soft brush and compressed air fig 49 NOTE The perforated plate fig 49 item 1 is only provided on type 800 24 and 800 24T25 models Buderus Clean the heat exchanger with a rib comb and compressed air Putall components back in place in reversed order DANGER The hot surface ignitor fig 50 item 1 is made of fragile material Remove and clean the syphon fig 51 Take care that the syphon cap is screwed on correctly Fill with water before putting the syphon back in place Putall components back in place in reversed order When plastic boiler connectors are used check the operation of the condensate water bypass Inject water e g using a spray bottle into the left hand flue gas measuring point fig 51 and check that the condensate water bypass is not obstructed Subject to modifications resulting from technical improvements fig 49 Cleaning the burner E SS C fig 50 Cleaning the heat exchanger fig 51 Checking the operation
12. see chapter 2 1 5 on page 23 Remarks or measurement readings kWh m kWh m Check combustion air flue gas connection Check the boiler equipment change to another type of gas if necessary see chapter 2 2 1 on page 24 Carry out adjustment settings see chapter 2 2 2 on page 25 Measure the gas supply pressure flow pressure see chapter 2 2 3 on page 27 Check and set the gas air ratio CO gt content under full load under partial load see chapter 2 2 4 on page 28 mbar Pa 96 Check for leaks with system in operational condition see chapter 2 2 5 on page 30 Record readings Flow pressure Exhaust gas temperature gross tA Air temperature t Flue temperature net t4 tL Carbon dioxide CO3 or oxygen O2 content Exhaust gas losses qa Carbon monoxide content CO free from air see chapter 2 2 6 on page 30 Pa C C C ppm 10 Testing the operation Measure the ionisation current see chapter 2 2 7 on page 30 pA 11 Fit the boiler casing see chapter 2 2 8 on page 31 12 Instruct the user hand over the documentation see chapter 2 2 9 on page 31 13 Confirm commissioning see Benchmark Confirmation of professional commissioning Company stamp signature Subject to modifications resulting from technical improve
13. 24T25 29T25 H V e edition 02 2006 61 6 3 Shortlist 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 picture on page 8 distribution plate 800 29 only pos description article no 10 Casing complete 7098751 20 Door 7098756 30 Casing clamp 2x left and 2x right 73466 40 Casing seal 73454 50 Back panel 73030 60 Mounting bracket 75038 70 Seal lid for air vent 79090 80 Heat exchanger 800 29 only 73020 80 Heat exchanger 800 24 only 73031 90 Revision set for air vent 73116 100 Seal 73451 110 Sight glas complete with sealing rings 73412 120 Restriction plate 800 24 only 73033 120 Restriction plate 800 29 only 73019 Seal for condensate collector 130 800 24 only 73471 Seal for condensate collector 130 800 29 only 73458 Condensate collector incl seal 140 800 24 only 73127 Condensate collector incl seal 140 800 29 only 73125 150 Sensor complete with o ring 38323 160 Mounting clip 73459 Seal for hot surface ignitor ionisation 170 electrode Set of 5 pieces 61S 180 Hot surface ignitor 78105 190 lonisation electrode with
14. 9 Gas leak test in operational condition see chapter 2 2 7 on page 30 L 10 Measure the carbon monoxide content CO vacuum ppm ppm see chapter 2 2 6 on page 30 11 Pressure testing of heating system Inlet pressure of expansion vessel see chapter 2 1 1 on page 22 instructions supplied with the vessel filling pressure see chapter 2 1 1 on page 22 mbar mbar mbar mbar 12 Check combustion air flue gas pipes for correct functioning and safety see chapter 5 3 4 on page 47 13 Check requirement related adjustment settings of control device see documentation supplied with control unit 14 Final check of inspection tasks with record kept of measurement readings and test results 15 Confirm servicing work Confirmation of professional servicing work Company stamp signature Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 64 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 Inspection and service reports cont d Date Date Date Date Date
15. Move the hot water temperature controller to 10 Measure and record the CO content on the flue gas measuring point fig 40 Partial load Set the hot water temperature controller to 1 Measure and record the CO content The CO content under partial load must be 0 7 96 lower than the one under full load If the measured value is too high or too low use the setscrew of the gas burner unit fig 38 item 3 or fig 39 item 2 to set the gas air ratio under partial load Setthe hot water temperature controller to the original value Set the chimney sweeper switch to 0 Subject to modifications resulting from technical improvements fig 38 Checking and adjusting the gas air ratio Honeywell gas unit P2 Pit fig 39 Checking and adjusting the gas air ratio SIT gas unit fig 40 Flue gas measuring point Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 29 2 2 5 Checking for leaks in operational condition Check with the burner running all joints across the entire gas route of the burner using a foaming agent The agent must be certified as a gas leak test agent Do not apply the agent to electrical connection cables 2 2 6 Measuring the carbon monoxide content Measur
16. The system is delivered ready fitted with a non conductive link between terminals Buderus 1 and 2 Set the mains switch to I and press reset If the 800 Series goes into standby mode after start up display 0 H the room temperature control device is defective Move mains power switch to 0 If the room temperature control device is in order remove the bridging leads and attach the cable and non conducting link 5 3 23 Replacing the room temperature control device Loosen all cables Note order of cable terminals Attach cables in the right order to the new room tempera ture control device Carry out the corresponding adjustment settings on the room temperature control device 5 3 24 Checking the three way valve for correct activation Set the mains switch to 0 Push in catch on regulating motor and remove bayonet connector by twisting anticlockwise fig 85 Remove regulating motor Set the mains switch to I and press the reset button Once the 800 Series is in operation open one of the hot water taps If the regulating motor starts up check for movement of red adjusting lever the activation system of the three way valve is in order Shut the hot water tap Set the mains switch to 0 If the activation system of the three way valve is in order attach the regulating motor and lock into place by twisting the bayonet connector Subject to modifications resulting from technical
17. 0 flue gas system table 9 2 8 4 10 8 15 2 25 3 3 10 2 13 0 18 3 29 7 4 11 9 15 2 21 4 33 5 5 13 6 17 5 24 5 37 3 6 15 3 19 7 27 7 41 2 7 17 0 21 9 30 8 45 0 8 18 7 24 1 35 9 48 8 9 20 4 26 3 37 0 52 7 10 22 0 28 0 40 2 56 5 Table8 Heating capacity Setting the pump over run time Pressure loss of Available portion of Move the switch fig 31 item 4 to position 1 flue gas system maximum capacity Pump over run time 4 minutes in Pa in Move the switch to position 2 when the system is 800 24 29 43 800 60 controlled in accordance with the room temperature and if parts of the system outside the detection area of the room 20 98 5 98 5 temperature controller are at risk of freezing e g radiators in the garage 30 97 8 98 0 Pump over run time 24 hours constant operation 40 97 1 97 4 50 96 4 96 9 60 95 6 96 3 70 94 8 95 8 80 95 2 90 94 7 Table 9 Capacity losses Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 26 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 Connecting the hot water sensor FW Remove the bridge plug fig 32 item 1 Cable colours black white and lilac Connect 3 m long extension cable fig 32 item 2 for the hot water sensor to the plug and fit sensor in the reservoir
18. 840 30 030 102 020 30 030 102 020 44 015 146 375 80 865 204 720 Seasonal efficiency SEDBUK 90 0 90 4 90 1 90 5 90 3 90 2 Boiler efficiency Heating curve 75 60 C max capacity 97 3 97 3 97 5 97 5 97 8 97 6 Heating curve 40 30 C min capacity 107 0 107 0 107 1 107 1 107 0 107 1 Stand by heat losses 0 60 0 50 0 50 0 50 0 40 0 34 Central heating installation Min circulation water volume Mal 150 150 225 225 300 500 Heating water temperature C 40 80 40 80 40 80 40 80 40 80 40 80 AT at residual head of 200 mbar K approx 15 approx 18 approx 18 approx 18 approx 22 approx 20 Max operating overpressure boiler bar 3 3 3 3 3 3 Volume heat exchanger heating circuit I 2 5 2 5 3 0 3 0 3 6 4 7 Pump over run time Position 1 min 4 4 4 4 4 4 Position 2 h 24 24 24 24 24 24 Hot water circuit combination boilers Volume hot water reservoir t 25 25 Max operating overpressure bar 8 8 hot water reservoir Pump over run time following min 2 2 domestic hot water mode Domestic hot water flow rate at 60 C Lmin 7 6 0 8 0 Stand by heat losses in hot water mode in 24 hours at WW DHW temp 60 C kWh approx 1 6 approx 1 6 E Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 Buder
19. and the use and adjustment of all system controls should be fully explained to the house holder 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 Explain the function and the use of the boiler heating controls 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 Explain and demonstrate the function of time and temper ature controls radiator valves etc for the economic use of the system Subject to modifications resulting from technical improvements t e fig 42 Fitting the boiler casing Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 31 3 Inspection 3 1 Preparing the heating boiler for inspection Disconnect the system DANGER OF FATAL INJURY due to electric shock when system is opened Before opening the system disconnect the heating unit at the emer gency OFF switch or the corresponding circuit breaker of the house power supply Ensure that the heating system cannot be reconnected by accident Rem
20. from burner thermostat Allow burner thermostat to cool down activation tempera ture 107 C Check burner thermostat for throughput If no throughput is detected the burner thermostat is defective lf the burner thermostat is working correctly plug it in once more fig 74 Checking the burner thermostat 5 3 14 Replacing the burner thermostat Pull cable lugs off Unscrew burner thermostat and screw in new unit Reconnect cable lugs and plug in once more fig 75 Replacing the burner thermostat Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 53 5 3 15 Checking the hot surface ignitor Disconnect the system from the power supply Unplug the hot surface ignitor Measure the resistance of the hot surface ignitor at the plug If the resistance is less than 200 Q the hot surface ignitor is in order Disconnect measuring device If the hot surface ignitor is working correctly plug it in once more Connect system to mains power supply 5 3 16 Replacing the hot surface ignitor Disconnect the system from the power supply Disconnect the plug in cable Loosen fixing screws and remove hot surface ignitor Fit new hot surface ignitor and retighten fixing scr
21. improvements fig 84 Checking the controller connections at the boiler fig 85 Checking the three way valve for correct activation Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 57 5 3 25 Replacing the control valve Close maintenance isolating valves and drain the 800 Series Remove the control valve with a spanner and fit a new unit Fit regulating motor and lock into place by twisting the bayonet connector Plug cable in NOTE Open the maintenance isolating valves and then fill the 800 Series and purge the system of air 5 3 26 Replacing the three way valve Close maintenance isolating valves and drain the 800 Series Loosen all screw in tube connectors Remove three way valve and fit new unit Refit screw in tube connectors Fit regulating motor and lock into place by twisting the bayonet connector Plug cable in Open maintenance isolating valves NOTE i Fill the 800 Series and purge the system of air Buderus 5 3 27 Checking the condensation water bypass Check to ensure that the condensation water bypass is connected NOTE The device itself is fitted with an additional condensation water bypass located on the fume exhaust outlet Buderus S
22. 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 From a terminal facing a terminal 1200 mm 48 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 Table 1 Balanced flue terminal position 300 mm 12 Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 9 1 3 2 Air supply and flue gas exhaust in a closed installation To ensure optimal operation the 800 Series appliances must be connected to a Buderus wall mounted or roof mounted flue terminal These terminals have been developed specifically for the 800 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 80 125 pos 2 1 Horizontal flue terminal 80 125 pos 3 1 Flue finishing kit 1 3 3 Maximum Flue length The maximum pipe length of the air supply and flue gas exhaust pipes for the 800 Series condensing gas boilers
23. 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 Action cause 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 Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 39 Code Meaning MF Flow sensor exceeds 100 C Possible Action cause 1 Resistance in the installation is too high Check if thermostatic radiator valves are clogged with dirt 2 Boiler capacity is too large for the installation Adjust the boiler s 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 9 and subsection 5 3 10 4 Problem with the pump or pump cabling Check if the pump cabling is faulty or if the pump is stuck no circulation see subsection 5 3 7 5 Water pressure is too low in the installation Top up the system see subsection 2 1 1 Code Meaning 4L Short
24. level Setting the flow temperature Controller position Flow temperature in C Setthe controller fig 31 item 2 to the desired maximum 1 40 flow temperature in accordance with the system design and table 6 2 44 Factory setting 80 C controller poition 10 3 48 4 53 5 58 6 62 7 67 8 71 9 76 10 80 Table 6 Flow temperature Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 25 With external storage type water heater Controller Domestic hot water temperature of set the hot water temperature position external reservoir in C Use the controller fig 31 item 3 to set the desired i 1 27 domestic hot water temperature in accordance with table 7 31 34 38 41 45 49 52 9 56 o NIOJ ao BRB Ww 10 60 Table 7 Domestic hot water temperature Setting the heating capacity Gon Heating capacity in kW x5 96 Open the cover of second control level fig 31 item 7 troller pA 800 24 800 29 Set the heating capacity in accordance with the required position 24125 29T25 800 43 800 60 heat demand table 8 on the controller fig 31 item 6 Take into account the appropriate losses caused by the 1 6 6 8 4 12 1 22
25. water reservoir and lift it clear from the top holders This is only possible with the upper casing removed Attach the gas boiler to the wall bracket fig 6 Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 fig 4 Items supplied with unit Eu od eoe Pos s Key to fig 4 wall mounted condensing gas boiler wall bracket technical documents wall mounting template screw fittings for connecting the boiler heating system gas service valve 12 800 24 29 43 gas service valve 34 800 60 fig 6 Installation Buderus http buderus domestic co uk 11 1 06 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 1 7 1 Heating circuit connection On type 800 60 an automatic air release valve must be fitted in the return line A servicing valve has to be installed in the flow and return lines to allow the gas boiler to be serviced and repaired Make sure that the expansion vessel pressure relief valve and draining valve are installed between the gas service valve and the boiler In order to ensure an optimum and efficient operation of the heating system care must be taken that the hea
26. 1 37 mbar 800 60 Category GB Ip 20 mbar natural gas H Power rating 230 VAC 50 Hz IPAX Fuse rating 1 25 slow blow G C Aplliance No Buderus 800 24 41 110 19 Buderus 800 29 41 110 20 Buderus 800 24 T25 V Buderus 800 29 T25 V Buderus 800 24 T25 H Buderus 800 29 T25 H Buderus 800 43 41 110 14 Buderus 800 60 41 110 15 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 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 Pipework from the boiler is routed downwards as standard but may be routed upwards behind the boiler using the distance frame supplied in a seperate 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
27. 2 2006 13 1 7 5 Condensate water drain NOTE The condensate water collecting in the gas boiler and possibly in the flue gas line must be drained Local regulations must also be noted Buderus When shorter aluminium flue gas systems are used CAUTION If the flue gas adapter is made of aluminium the sealing cap fig 12 item 1 MUST NOT be Buderus removed There is no integrated condensate water outlet in the flue gas adapter of the aluminium exhaust flue The condensate water from the exhaust flue flows via the gas boiler and into the boiler s odour trap syphon see fig 10 When longer aluminium flue gas systems are used CAUTION If the flue gas adapter is made of aluminium the sealing cap fig 12 item 1 MUST NOT be Buderus removed There is no integrated condensate water outlet in the flue gas adapter of the aluminium exhaust flue The condensate water from the exhaust flue flows via the external condensate water outlet with odour trap syphon see fig 11 This additional component is required from 10 m expanded overall length of exhaust flue with 800 Series to boiler size of 24 kW or from 5 m expanded overall length of exhaust flue with type 800 29 800 43 and 800 60 Subject to modifications resulting from technical improvements fig 10 Condensate water outlet for exhaust flue systems made of aluminium
28. 360 Gas injector natural gas G20 incl O ring 370 Air restrictor natural gas G20 375 Connection tube fan burner 380 Connection tube fan burner Gasket for pump DN 44 x 2 5 Pump power cable complete with connector Ring Nut for heat exchanger 1 1 2 Nut for heat exchanger 1 1 2 Return pipe Filling draining valve RTH converter Buderus http buderus domestic co uk 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 Pluming will occur at the terminal so terminal positions where this could cause a nuisance should be avoided 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 The boiler MUST be installed so that the terminal is exposed to external air It is important that the position of the terminal allows the free passage of air at all times Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in table 1 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 whi
29. 5 3 7 4 Water pressure is too low in the installation Top up the system see subsection 2 1 1 Code Meaning cF Temperature difference between the safety sensor and flow sensor is greater than or equal to 15 K blocked for 30 sec Possible Action cause 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 temporarily with another one see subsection 5 3 9 and subsection 5 3 10 3 Flow sensor is dirty or faulty Check the sensor replace if necessary by temporarily connecting another one see subsection 5 3 9 and subsection 5 3 10 4 Problem with the pump or pump cabling Check if the pump cabling is faulty or if the pump is stuck no circulation Replace pump if necessary see subsection 5 3 7 and subsection 5 3 8 5 Water pressure is too low in the installation Top up the system see subsection 2 1 1 Subject to modifications resulting from technical improvements 38 Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 Code Meaning cP Safety sensor rises faster than 5 C sec blocked for 30 sec Possib
30. Air inlet pipe incl gasket 73439 400 Support mounting bracket fan anti 73016 vibration 410 Fan 73320 Connection pipe gas valve burner 420 800 24 only 73219 Connection pipe gas valve burner 420 800 29 only 73207 1 1 3 1 430 Connection nipple 34 x Ya 73209 with O ring 440 Gasunit 73264 460 Gas inlet pipe 1 2 76610 470 Control uba 7099845 480 Temp pressure gauge 79021 490 Bracket for uba 73432 500 Power switch 38340 510 230V cable 7099204 520 Cable harness complete 75958 530 Supply pipe heat exchanger 73600 540 O ring set of 10 pieces 79025s 550 Spring clip heat exchanger supply 734465 set of 5 pieces 560 Pressure relief valve 73197 570 Non return valve R 1 4 75823 580 Pump 38622 590 Gasket for pump DN 44 x 2 5 150225 set of 10 pieces 600 Pump power cable complete with 73319 connector 610 Ring set of 5 pieces 73480s 1 LLI 620 Nut for heat exchanger 11 73481s set of 5 pieces 630 Swivel nut for pump 15020s 640 Return pipe 73122 650 Filling draining valve 38452 660 RTH converter 78079 Buderus http buderus domestic co uk 7 7 1 Reports Start up report Please check off the start up tasks carried out and enter the corresponding readings while making sure that you carefully follow the instructions 1 Initial start up tasks Note down gas characteristics Wobbe index Operational heat value Has a leak test been carried out
31. Installation and servicing instructions Gas wall hung Boiler condensing Buderus 800 24 29 43 60 and Buderus 800 24T25 29T25 H V b enchmark 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 minor deviations in 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 Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 2 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 Contents 1 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 2 1 2 2 3 3 1 3 2 3 3 4 4 1 5 5 1 5 2 5 3 6 6 1 6 2 6 3 7 7 1 7 2 Installation 0 eee 6 Dimensions connections and assembly 6 Boiler assembly exploded view 8 Flue Installation 0 2 0 eee eee 9 Items supplied with unit 11 Gas boilers uil iu RE rm ER eR ae 11 Water circulation system 12 Pipe connections 00 eee ee eee 12 Flue install
32. The product must be certified as a gas leak testing agent DO NOT allow the product to come into contact with elec trical wiring 2 1 6 Purging air from the gas supply pipe Loosen the screw plug on the gas connection and air purging test nipple on Honeywell gas units two turns fig 29 item 1 fully unscrew the plug on SIT gas units fig 30 item 1 and fit the hose Purge system and appliance as per relevent procedures IGE UP 1b Ensuring all safety requirments are met Subject to modifications resulting from technical improvements fig 27 Automatic air release valve fig 28 Filling the syphon with water fig 29 Purging the gas supply pipe Honeywell gas units Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 23 2 2 Start up work 2 2 1 Checking the boiler equipment Li Buderus NOTE The burner must only be put into operation with the correct injectors table 5 Subject to modifications resulting from technical improvements fig 30 Purging the gas supply pipe SIT gas units Type of gas Factory setting of gas burners When delivered ready for operation and set to Wobbe index 14 1 kWh m referred to Natural 15 C 1013 mbar appli
33. a Pa Pa Pa Pa 926 96 96 96 96 96 96 96 Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 67 Buderus 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 754 620 721 239A 4612 02 2006 www buderus domestic co uk Buderus is a trading name of BBT Thermotechnology UK Ltd
34. above this will require extension duct assemblies See table 2 on page 10 for the maximum pipe length for each type boiler NOTE Use the wall mounting template to help you mark the position of the side flue opening Buderus Subject to modifications resulting from technical improvements fig 13 Adaptor plate fig 14 Elbow with flue gas testing point Flue Terminal Turret Maximum 595 mm assembly fig 15 Standard flue Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 15 1 8 3 Flue duct preparation and assembly Measure the flue length L Refer to figure 16 NOTE The flue must be inclined to the boiler Buderus 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 fig 16 Flue length rear at the terminal indicating the outer face of the wall Refer to figure 18 Extension air duct L 70 mm flue duct L 50 mm The measurement is from the formed end 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 th
35. ammable room thermostat see subsection 1 9 5 A room temperature control device at 230V connected to the RTH converter see subsection 1 9 6 ON OFF temperature controller volt free see subsection 1 9 7 If the boiler has to be temporarily put into operation without control unit place a conducting bridge in terminal 1 2 and set the feed temperature and the required heating capacity on the UBA 1 9 5 Buderus room temperature control device connection Remove the bridge in terminal 3 4 fig 22 item 2 and connect the control unit to the terminal strap Remove the wire in terminal 1 2 fig 22 item 1 NOTE RTH converter is no longer in use 1 9 6 230V room temperature control device connection Remove the cover of the RTH converter fig 22 item 6 Leadthe control device wire through the cable lead fig 22 item 8 Fixthe wire to terminal 1 and 2 of the 230 Volt connection fig 22 item 9 Secure the wire with the bracket and the two screws onto the RTH converter 1 9 7 Volt free external control device connection Remove the cover of the RTH converter fig 22 item 6 Lead the control device wire through the cable lead Fix the wire to terminal 1 and 2 of the volt free connection fig 22 item 10 Subject to modifications resulting from technical improvements fig 21 Connecting a three way valve of an external storage type
36. ation 00 0 eee eee 15 Electrical connections 04 17 Initial start up 00 00 eee eee 22 Preparing the boiler for operation 22 Start up work 0 2 eee 24 Inspection llle 32 Preparing the heating boiler for inspection 32 Checking for internal leaks 32 Visual inspection 02 0 eee eee 32 Maintenance lesen 33 Cleaning the heat exchanger burner and syphon 33 Servicing iler eI emcee wie Rc Rosa ous 37 Operating codes llle eee eee eee 37 Fa lt Codes reg hea eben 38 Checking and replacing parts 46 Appendix srice ru gru EE TIR 59 Technical data 0 0 eee eee eee 59 Residual pump lift for wall hung gas boilers 61 Short list of spare parts 0 000 62 Reports 1r x aer n aar f AR e RR 63 Start up report 2 2 eee eee ee 63 Inspection and service reports 64 Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 3 Preface These installation and servicing instructions apply to Buderus wall mounted condensing gas boilers 800 24 29 43 60 and 800 24T25 29T25 HN Model Bos B33 Cas Cas Cys C53 and C73 800 24 29 43 Category GB Iloy3p 20 mbar 37 mbar natural gas H and LPG In this document LPG 3P G3
37. cable and 38320 connector 200 Safety sensor ntc complete 73321 210 Flue gas collector 77450 220 Lip ring seal DN 80mm 38419s set of 10 pieces 230 Condensate by pass 75950 240 Syphon complete 7100825 260 Safety valve pipe 73555 270 Seal set for syphon 73124 280 Burner housing 800 24 only 73035 280 Burner housing 800 29 only 73011 290 Burner thermostat 107 C 36318 300 Burner seal 800 24 only 73475 300 Burner seal 800 29 only 73441 310 Gas air distribution plate 800 24 only 73217 310 Gas air distribution plate 800 29 only 73208 320 Secundairy gas air distribution plate 73046 Burner plaque assembly incl gas air 930 distribution plate 800 24 only 13018 330 Burner plaque assembly incl gas air 73010 Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 62 pos description article no 340 Gas air manifold 73215 350 O ring gas air manifold to burner 73440s set of 5 pieces Gas injector natural gas G20 20 incl O ring 800 24 only fee Gas injector natural gas G20 360 incl O ring 800 29 only 9206 Air restrictor natural gas G20 370 800 24 only 73448 Air restrictor natural gas G20 370 800 29 only 73267 Connection tube fan burner 375 800 24 only 73477 Connection tube fan burner 380 800 29 only 73438 390
38. cable for Wobbe in gas E dex range 11 3 to 15 2 KWh m includes Inscription on type of gas label natural Category setting G 20 2E 20 mbar gas H Formerly set to Wobbe index 15 0 kWh m referred to 0 C 1013 mbar applicable for Wobbe index range 12 0 to 15 7 kWh m After change over see Installation Instruc tions Changing to another type of gas LPG suitable for LPG Inscription on type of gas label Category setting 3P G 31 30 50 mbar Table 4 Gas burner factory settings Gas injec Air injec Gas boiler Type of gas tordiame tor diame ter mm ter mm 800 24 Natural gas H 4 65 21 55 24T25 H V LPG 3 45 20 10 800 29 Natural gas H 5 00 23 30 29T25 HV LPG 3 90 23 00 Natural gas H 6 40 29 30 800 43 LPG 4 85 27 40 800 60 Natural gas H 8 00 36 40 Table5 Gas and air injector diameters Buderus http buderus domestic co uk 24 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 2 2 2 Settings fig 31 Controls Key to fig 31 Item 1 Main switch Item 2 Flow temperature controller Item 3 Domestic hot water temperature controller Item 4 Jumper 11 50 kW to limit capacity Item 5 Pump over run time switch Item 6 Heating capacity controller Item 7 Cover for second control
39. ch 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 i Buderus 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 fig 1 Flue terminal position Terminal Position eae A Directly below or alongside an opening 300 mm 12 window air vent or other ventilation opening 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
40. circuit in safety sensor Possible Action cause 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 9 and subsection 5 3 10 A short or bad connection in the cable harness Check the cable harness and or connector of the sensor UBA might be faulty Check the UBA by temporarily connecting a different UBA see subsection 5 3 5 Code Meaning 4P Safety sensor has a loose connection or is defective Possible Action cause 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 9 and subsection 5 3 10 2 A short or bad connection in the cable harness Check the cable harness and or connector of the sensor see subsection 5 3 12 3 UBA might be faulty Check the UBA by temporarily connecting a different UBA see subsection 5 3 5 Code Meaning dU Short circuit in flow sensor Possible Action cause 1 Flow sensor is dirty or faulty Check the sensor replace if necessary see subsection 5 3 9 and subsection 5 3 10 2 A short or bad connection in the cable harness Check the cable harness and or connector of the sensor see subsection 5 3 12 Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 40 _ Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e editio
41. e 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 Compartment Installations 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 porpose 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 i
42. e male end of the ducts NOTE An inner wall sealing plate is provided which should be fitted to the ducts before assembly Buderus fig 17 Flue length side Push the assembly through the wall and slide the turret onto the flue connector Refer to figure 14 Outer Flue Terminal 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 Raised Ring locating the terminal relative to the outside wall face fig 18 Flue terminal position Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 16 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 1 9 Electrical connections 1 9 1 Mains connection NOTE All Buderus boilers require a permanent live 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 E E BS 7671 Wiring Regulations and any local regu
43. ecking the wiring connections on the gas valve assembly HONEYWELL assembly illustrated to provide example 5 3 19 Checking the gas burner assembly for correct HER activation pr Set the mains switch to 0 Remove a plug in cable at the main gas valve and connect a current measuring device at the same point with a measuring range of up to 1000 mA AC fig 81 item 1 Set the mains switch to T Unblock the 800 Series by pressing reset button and take current reading during start up procedure Carry out the same measuring procedure at the ignition gas valve fig 81 item 2 f the current reading at pos 1 is approximately 210 mA and the reading at pos 2 is about 450 mA the gas valve activation system is in order Set the mains switch to 0 fig 81 Checking the gas valve assembly activation system If the gas valve assembly activation system is in order HONEYWELL valve assembly shown as example plug the cable in once more Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 55 5 3 20 Replacing the gas valve assembly CAUTION Work on gas pipes and fittings must only be carried out by a registered service provider Disconnect the system from the power supply
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45. erature on the hot water temperature controller to the desired value Move the mains switch to I When the display shows 7 and the service button is pressed the display turns to c Press the reset button until r is shown on the display Close the cover Subject to modifications resulting from technical improvements fig 41 Measuring the ionisation current Buderus http buderus domestic co uk 30 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 2 2 8 Fitting the boiler casing Put the casing in place fig 42 item 1 Close fig 42 item 2 and lock the clasps fig 42 item 3 with the radiator key fig 42 item 4 Turn in the screw fig 42 item 5 Close the cover of the control panel fig 42 item 6 Do not carry the casing by the clasps 2 2 9 Handing over After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions Fill out the form at the end of this manual This confirms that the system is properly set up installed and commis sioned and that it has been handed over in good working order Hand the User Manual to the householder and explain his her responsibilities under the relevant national regula tions Explain and demonstrate the lighting and shutting down procedures The operation of the boiler
46. et button until r appears in the display FF F3 fuse defect or burner control unit error 1 Short circuit in the 24V circuit three way valve or Check for a short circuit and replace the F3 fuse connector see subsection 5 3 3 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 Voltage peaks in the UBA 1 Regulating device may have to cope with interference Check if for example induction fields interfere with the regulating device Check if the are any peaks in the electrical network caused by maybe windmills or a power generator Internal UBA error 1 Regulating device may have to cope with interference Check if for example induction fields interfere with the regulating device Check if the are any peaks in the electrical network caused by maybe windmills or a power generator Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 43 Code Meaning BY Gas fault Possible Action cause 1 External swi
47. ete NOTE The system cannot be used for heating water while it is in chimney sweep mode Buderus Remove cover of control level 2 Set chimney sweep switch fig 54 to 1 5 3 3 Checking the fuses Disconnect the system from the power supply Swivel the UBA to one side Check fuse for throughput or carry out visual inspection fig 55 items 1 2 and 3 If defective fit new fuse 1 25 AT Connect system to mains power supply Subject to modifications resulting from technical improvements fig 53 Reset button fig 54 Chimney sweep switch fig 55 Checking the fuses Buderus http buderus domestic co uk 46 X Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 5 3 4 Check combustion air flue gas system and hose connections Check combustion air flue gas system for blockages 5 3 5 Replacing the UBA Disconnect system from power supply by removing main fuse or power connection plug Swivel the UBA to one side and pull the four pin plug of the mains power switch out at the back of the UBA Disconnect all plug in cables Note the position of each plug in cable Loosen the three screws on the UBA and remove it Remove mains power switch and fit to new UBA Screw the rep
48. ews Plug in cable connection Connect system to mains power supply 5 3 17 Checking the hose connection between the gas air injector and gas valve assembly Check hose connection for tightness and for signs of possible blockages or damage Check that the hoses are correctly fitted to P1 Hose connection P1 to T piece gas valve assembly Subject to modifications resulting from technical improvements fig 76 Checking the hot surface ignitor fig 77 Replacing the hot surface ignitor fig 78 Checking the hose connection between the gas air injector and gas valve assembly Honeywell gas units Buderus http buderus domestic co uk 54 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 f P2 h fig 79 Checking the hose connection between the gas air injector and gas valve assembly SIT gas units 5 3 18 Check wiring connections on gas valve assembly Check that the plug in cables are correctly attached to the gas valve assembly The plug in cables should be connected as follows Blue plug in lead fig 80 item 1 White plug in lead fig 80 item 2 fig 80 Ch
49. he CH flow and the CH return service valve Place hose on the draining tule Turn to drain the system Subject to modifications resulting from technical improvements fig 24 Mechanical switch on the three way valve double check valve temporary DHW hose CH cold return fig 25 Connecting temporary hose fig 26 Pressure display Buderus http buderus domestic co uk 22 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 2 1 2 Preparing the automatic air release valve Openthe protective cap on the automatic air release valve one full turn fig 27 Should the air purging operation cause the pressure to drop below minimum top up water 2 1 3 Filling the hot water reservoir Open the cold water inlet on the service valve Open the hot water valve until a full jet of water is flowing 2 1 4 Filling the syphon with water Pull the hose from the condensate plate fig 28 item1 Fill the syphon with water Fit the hose to the condensate plate 2 1 5 Checking for leaks Disconnect the system from power supply 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
50. he 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 Buderus A 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 1 5 Gas boiler Remove the packing and discard to ensure proper recycling Do not remove the polystyrene foam bottom slab protecting the connection nozzles During installation the gas boiler and the flue gas adapter must be protected to prevent site dirt from entering e g using aluminum foil NOTE Note the clearance required to install the flue system see chapter 1 8 Flue installation Note the side wall minimum clearance of 100 mm If a storage type water heater is installed underneath take care that the minimum clearances according to the installa tion instructions are adhered to Fit the wall bracket Removing the casing Open the cover of the control panel fig 5 item 1 Remove the screw fig 5 item 2 Open the locks fig 5 item 3 with the radiator key fig 5 item 4 Release the clasps fig 5 item 5 Remove the boiler casing forwards fig 5 item 6 Do not carry the casing by the clasps Combination unit type 800 24T25V 29T25V Vertical boilers Pull forward the casing of the hot
51. he gas supply in accordance with the relevant standards Fit the supplied service valve in the gas feed line Connect the pipe free of tension fig 7 Fit a gas service valve with a size of R34 on type 800 60 1 7 4 Hot water connection On type 800 24 29 43 60 Connect the external storage type water heater in accordance with the appropriate installation instructions using the connec tion kit On type 800 24T25 H V and 800 29T25 H V When using plastic pipes note the information provided by the pipe manufacturer This particularly applies to the mode of connection recommended by manufacturer CAUTION Do not use galvanised pipes or fittings The hot water heat exchanger is made of copper and risks electrolytic corrosion In certain situations to prevent hammering within the system when closing taps controls can be installed to counter act this action For further information please contact Buderus Forthe size of pipe connections please refer to the wall mounting template Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 fig 8 Hot water connection vertical boilers type 800 24T25V 800 29T25V fig 9 Hot water connection horizontal boilers type 800 24T25H 800 29T25H Buderus http buderus domestic co uk 24 29 43 60 and 800 24T25 29T25 H V e edition 0
52. ing 3 There is no flame ionisation electrode and fan Check and adjust the gas air ratio see subsection 2 2 4 are working Check for 24 V on the gas valve during start up Check the gas supply pressure see subsection 2 2 3 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 Check the gas supply pressure see subsection 2 2 3 this when the fan starts up should be higher than 20 mbar for natural gas Check and adjust the gas air ratio see subsection 2 2 4 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 5 Subject to modifications resulting from technical improvements Buderus http ouderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 41 Subject to modifications resulting from technical improvements Code Meaning RC lonisation message but no flame Possible Action cause 1 There is no flame ionisation electrode doesn t Check wiring of the hot surface ignitor measure the resistance glow fan is turning of the hot s
53. ing point see fig 40 on page 29 The carbon monoxide values under vacuum must be smaller than 400 ppm and 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 Find and eliminate the cause 2 2 Checking the operation During commissioning and the annual inspection and servicing routine the working order of all control regulating and safety devices must be checked to see if they are correctly set provided these devices can be adjusted Measuring the ionisation current Move the mains switch to 0 Loosen the plug and socket connector of the monitoring cable and connect the measuring device in series fig 41 Select on the measuring device the pA direct current range The measuring device must have a resolution of at least 1 pA Move the mains switch to I and the chimney sweeper switch to 1 After the burner has fired press the service button fig 37 until Y is shown on the display Move the hot water temperature controller to 1 Measure the ionisation current The ionisation current must be gt 2 pA direct current under partial load Enter the measurement in the certificate Move the mains switch to 0 Remove the measuring device and restore the original condition of the plug and socket connection Move the chimney sweeper switch to 0 Close the cover of the 2nd control level Set the temp
54. l uba 480 Temperature pressure gauge 490 500 510 520 530 540 550 560 570 580 Bracket for uba Power switch 230V cable Cable harness complete Supply pipe heat exchanger O ring Spring clip heat exchanger supply Pressure relief valve Non return valve R 1 4 Pump Subject to modifications resulting from technical improvements 8 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 590 600 610 620 630 640 650 660 Legend 10 Casing complete 20 Door 30 Casing clamp 40 Casing seal 50 Back panel 60 Mounting bracket 70 Seallid for air vent 80 Heat exchanger 90 Revision set for air vent 100 Seal 110 Sight glas complete with sealing rings 120 Restriction plate 130 Seal for condensate collector 140 Condensate collector incl seal 150 Sensor complete with O ring 160 Mounting clip 170 Seal for hot surface ignitor ionisation electrode 180 Hot surface ignitor 190 lonisation electrode with cable and connector 200 Safety sensor ntc complete 210 Flue gas collector 220 Lip ring seal DN 80mm 230 Condensate by pass 240 Syphon complete 260 Safety valve pipe 270 Seal set for syphon 280 Burner housing 290 Burner thermostat 107 C 300 Burner seal 310 Gas air distribution plate 320 Secondary gas air distribution plate 330 Burner plaque assembly 340 Gas air manifold 350 O ring gas air manifold to burner
55. lacement UBA into position Reconnect all plug in cables to their correct sockets Fit the casing Connect system to mains power supply Move mains power switch to I Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 47 fig 56 Checking combustion air flue gas system and hose connections P2 Pit fig 57 Replacing the UBA Buderus http buderus domestic co uk 5 3 6 Replacing the fan unit NOTE Please refer to fitting instructions for 230 V fan unit Buderus Loosen the screw couplings of the gas injector fig 58 item 1 and safety valve fig 58 item 2 Pull off the hoses leading to the fan fig 58 item 3 Pull off the hoses at the differential pressure measuring point fig 58 item 4 Pull out the plug of the burner thermostat fig 58 item 5 Pull out the plug of the fan fig 59 item 1 Turn and pull out the safety retainer of the fan fig 59 item 2 Push up the fan fig 60 item 1 Pivot the lower end of the fan forward fig 60 item 2 and take it out downwards and forwards fig 60 item 3 Replace the fan Reassemble in reverse order Subject to modifications re
56. lations Wiring should be a 3 core PVC insulated cable not less than 0 75 mm 24 x 0 2 mm and to table 16 of BS 6500 Connection must be made in a way that allows complete isola tion of the electrical supply such as a double pole switch having 3 mm 1 8 contact separation in both poles or by a three pin connector serving only the boiler and system controls This boiler is equipped with a double pole switch see fig 19 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 If the supply cord is damaged it must be replaced by a regis tered Corgi installer to avoid a hazard and must be an original spare part The electrical supply for both the boiler and the system must be taken from the same fused spur outlet WARNING Do not connect 230V to the connection block on the UBA Subject to modifications resulting from technical improvements fig 19 UBA Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 17 1 9 2 Wiring Diagram WARNING Do not connect 230V to the connection block on the UBA ueioujeje peyrjenb e 3jnsuoo 1qnop Aue ur ale no ji j2e1100 pejoeuuoo si eouer dde noA yeu eunsu3 qaHagva as LSNW 39NVITddV SIHL SNINHVM YOR p
57. le Action cause 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 by temporarily with another one see subsection 5 3 9 and subsection 5 3 10 3 External domestic hot water tank is too small for the Top up the system see subsection 2 1 1 boiler s capacity Code Meaning cu Temperature difference between the flow and return sensors is too high blocked for 30 sec Possible Action cause 1 Resistance in the installation is too high Check if not all thermostatic radiator valves are closed or clogged with dirt 2 Problem with the pump or pump cabling Check if the pump cabling is faulty or if the pump is stuck no circulation see subsection 5 3 7 3 Water pressure is too low in the system Top up the system see subsection 2 1 1 Return sensor is defective or the cabling is faulty Measure the resistance of the sensor see subsection 5 3 12 Code Meaning 4A Flow sensor exceeds 100 C Possible Action cause 1 Flow sensor is dirty or faulty Check the sensor replace if necessary see subsection 5 3 9 and subsection 5 3 10 2 There is a problem with the pump or pump cabling Check if the pump cabling is faulty or if the pump is stuck no circulation Replace pump if necessary see subsection 5 3 7 and subsection 5 3 8 3 Water pressure
58. ments Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 Buderus http buderus domestic co uk 63 7 2 Inspection and service reports The inspection and maintenance reports provide an overview of all the tasks and operations carried out See section 3 Inspection page 32 and section 4 Maintenance page 33 Please check off the inspection and or requirement related maintenance tasks carried out and enter the corresponding readings Sign details of inspection and maintenance tasks indicating date carried out Use only original replacement parts Inspection work Date Date 1 Check the general condition of the installation 2 Visual and functional inspection of the installation 3 Check the gas and water transporting parts for internal leaks see chapter 3 2 on page 32 visible corrosion see chapter 3 3 on page 32 ageing 4 Check pollution of the burner heat exchanger and siphon see chapter 4 1 on page 33 L E 5 Check the ionization electrode and incandesent firing electrode see chapter 4 1 on page 33 6 Measure the ionization current yA yA see chapter 2 2 7 on page 30 7 Measure the gas distribution pressure mbar mbar see chapter 2 2 3 on page 27 8 Check the gas air ratio Pa Pa see chapter 2 2 4 on page 28
59. mer PRV Pressure relief valve HT Room Thermostat TRV M TRV Thermostatic radiator valve a fse WC Wiring Centre DLL ZV Two port Zone Valve LSV H reference room main living area H other rooms Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 21 Condensing gas boiler Buderus 800 ll l LUIT radiator AII 2 initial start up 2 1 Preparing the boiler for operation 2 1 4 Filling the heating system WARNING The wall mounted condensing gas boiler must not be activated at this stage When using oxygen permeable pipes e g for floor heating heat exchangers must be used to separate the system Move the mechanical switch on the three way valve to centre position fig 24 applicable for 800 24T25 and 800 29T25 only and systems with an external storage type water heater f necessary open the CH flow and CH return maintenance valves Connect temporary hose of the filling loop for pipe locations see page 6 and 7 Open both stop valves Fill the system to a pressure of 1 0 to 1 2 bar fig 26 item 1 Max water pressure is 2 0 bar Shut both stop valves and disconnect the filling loop To drain the system take the following steps Close t
60. n 02 2006 Code Meaning 4y Flow sensor interrupted Possible Action cause 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 9 and subsection 5 3 10 2 A short or bad connection in the cable harness Check the cable harness and or connector of the sensor see subsection 5 3 12 Code Meaning EN Boiler shut down after connection with Service Tool Possible Action cause 1 Service tool connection Press reset If fault code remains than try to temporarily connect a different UBA see subsection 5 3 5 2 A short or bad connection in the cable harness Check the cable harness and or connector of the sensor see subsection 5 3 12 3 UBA might be faulty Check the UBA by temporarily connecting an other UBA see subsection 5 3 5 Code Meaning BA F1 fuse defective or no ionisation message after ignition Possible Action cause 1 There is no flame ionisation electrode doesn t Check wiring of the hot surface ignitor measure the resistance glow fan is turning of the hot surface ignitor should be between 50 and 300 Ohm Replace hot surface ignitor if necessary see subsection 5 3 15 and subsection 5 3 16 Check the UBA s F1 fuse replace if necessary 2 There is no flame ionisation electrode does Check the fan and KIM connectors and the UBA fuses glow fan isn t turn
61. nerator Code Meaning gu KIM defective Possible Action cause 1 Kim connected incorrectly or KIM defective Check the KIM connector and fan connector see subsection 5 3 21 If the connectors are fine then contact Buderus Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 44 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 Code Meaning E with UBA defective any character but P Possible Action cause 1 Regulating device may have to cope with interference Check if for example induction fields interfere with the regulating device Check if the are any peaks in the electrical network caused by maybe windmills or a power generator 2 UBA may be defective Press reset If fault code remains then try to temporarily connect a different UBA see subsection 5 3 5 Code Meaning EP Non compatible UBA fitted Possible Action cause 1 Regulating device may have to cope with interference Check if for example induction fields interfere with the regulating device Check if the are any peaks in the electrical network caused by maybe windmills or a power generator 2 Kim connected incorrectly or KIM defective Check the KIM connector and fan connector see subsection 5 3 21 If the connectors are fine then contact Buderus
62. nstallation MUST allow adequate space for servicing in front of the boiler Buderus http buderus domestic co uk 4 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 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 Observe the relevant standards regulations and legislation of the country of final use CAUTION Use this device for its intended purpose only 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 Sentinal X100 to fill and top up the system When using water treatment only products suitable for use with Buderus heat exchangers are permitted eg 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 watertreatment product is maintained in accordance with the manufacturer s instructions If the boiler is used in an exis
63. of the condensate water bypass Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 35 When aluminium boiler connectors are used check the sealing cap of the condensate water bypass Visual inspection to see if there is a white sealing cap on the condensate water bypass fig 52 fig 52 Condensate water bypass sealing cap Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 36 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 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 Buderus malfunctioning warnings the burner control unit itself is Display after Display pressing the Meaning service button 800 Series is ready for operation H Burner interval circuit 10 minutes from start of burner C Waiting for the three way valve and or pump to switch H Ready for operation L First safety period P U Safety period y Flow water temperature setting reached switching difference 2 K 800 Series runs in heating mode H Chimney sweep mode H Normal heating mode y Service mode 800 Series runs in hot water mode H Normal hot wa
64. ose Drain Unplu Open NOTE Fill the 800 Series and purge the system of air eplacing the flow return and safety sensors maintenance isolating valves the 800 Series g Unscrew sensor and replace with new unit Plug in cable connection maintenance isolating valves Buderus Temperature Resistance Temperature Resistanc in C inQ in C e in Q 0 29 490 5 23 462 55 3 271 10 18 787 60 2 760 15 15 136 65 2 339 20 12 268 70 1 990 25 10 000 75 1 700 30 8 197 80 1 458 35 6 754 85 1 255 40 5 594 90 1 084 45 4 656 95 940 50 3 893 100 817 Table 10 Resistance values indicative values of the sensors fig 67 Replacing the flow return sensors C 90 80 70 60 50 40 30 20 10 0 0 5 000 Boiler temperature sensor 10 000 15 000 fig 68 Boiler temperature sensor diagram 25 20 20 10 000 Outside temperature sensor 20 000 30 000 40 000 50 000 60 000 70 000 80 000 fig 69 Outside temperature sensor diagram Subject to m odifications resulting from technical improvements Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 51 5 3 11 Replacing the mains water sensor Unplug cable connection from mains water sensor Pull mains water sensor ou
65. ove the burner housing or cover from the heating boiler fig 5 on page 11 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 Buderus 3 2 Checking for internal leaks Check all internal pipework and controls for leaks using the appropriate methods as in IGE UP 1b using the correct leak detection fluid Please ensure that any leak detector fluid DO NOT come into contact with any electrical components 3 3 Visual inspection Check all gas bearing and water bearing pipes for signs of corrosion fig 43 Replace corroded pipes if necessary fig 43 Visual inspection for signs of corrosion For further information please refer to subsection 7 2 Inspec tion and service reports on page 64 and fill out the Benchmark Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 32 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 4 Maintenance For further information please refer to subsection 7 2 Inspec tion and service reports on page 64 and fill out the Benchmark Preparations Disconnect the system from the power supply Close the gas service valve Remove the boiler casing fig 5 on page 11 4 4 Cleaning the heat exchanger burne
66. pi 131109 WIS Bunoeuuoo ueym arowa 77 J reuiu p eu pue d lH Bugonpuoo uou s doo L 1 E uoneiedo oy Ajayes 10sues ainyesoduiay Ajayes S4 JeyeM SUJEUJ JO uinjoi JoSuas eunje1eduiogj uinjod ud ZHOS A0 c Ajddns sosuas aunyesaduua 19 eM 110g 3 9onos Jamod sure Josuas eJnjeJeduie j9 ew surejA 84 s eowep Duniuj enjereduua se6 an 4 aiv uonjoeuuoo yno Buiueo ueuM eBpuq e oueH epoujoeje Buy 3ueosepueou ve xew Ha duind uoneino11g apoujoaja Buuoyuour eure J F 60000600000000900000 3960600000660 0000 0 O OO OO OO O diis uogoeuuoo uid gt duis uonoeuuoo uid oz a zi j MOJq MOJS G2 9sn4j j i H van xun joguoo jeuing ju Uu I RM i fig 20 Wiring diagram Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 Subject to modifications resulting from technical improvements 18 1 9 3 Connecting a three way valve of an external storage type water heater Three way valve with plug Connect the plug and socket connector to the plug of the external storage type water heater fig 21 Three way valve without plug Connect the three way valve to terminals 9 and 11 of the terminal strap fig 22 item 5 1 9 4 External controls The wall mounted condensing gas boiler can be fitted with the following control devices Buderus progr
67. r and syphon The heat exchanger can be cleaned with a brush and compressed air Loosen the screw couplings of the gas injector fig 44 item 1 Pull off the hose leading to the fan fig 44 item 2 Pull off the hoses at the differential pressure measuring point fig 44 item 3 Pull off the wiring of the burner thermostat fig 44 item 4 Pull off the plug of the fan fig 45 item 1 Turn and pull out the safety retainer of the fan fig 45 item 2 Subject to modifications resulting from technical improvements fig 45 Removing the fan Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 33 Push up the fan fig 46 item 1 Pivot the lower end of the fan forward fig 46 item 2 and take it out downwards and forwards fig 46 item 3 Loosen both retaining clamps fig 47 item 2 of the burner cover and remove the burner cover and burner fig 47 item 3 Cleaning by using a brush and compressed air Pull the syphon away from the condensate plate fig 47 item 1 Loosen the connection to the condensate water bypass fig 47 item 6 Loosen the retaining clamps fig 47 item 4 of the condensate plate and remove the condensate plate fig 47 item 5
68. reducing device is fitted into the boiler cold supply with the requirements of the local water company CAUTION Provision must be made to accomodate the expansion of DHW contained within the appliance if a non return valve is fitted to the DHW inlet as detailed in BS 6798 5 4 3 Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 5 Installation 1 1 Dimensions connections and assembly 800 24T25V 800 29T25V 800 24 800 29 560 mm 22 560 mm 22 335 mm 13 335 mm 13 152 mm 55 mm 2 6 55 mm 2 O S E E o a T 55 150 o 46 175 2 6 3 ated 3 1p 431 mm 17 A lg d 8g z IT o OO x To vo 55 50 46 1 DHW warm out hot water outlet 15 mm dia 2 4 x 75 3 6 h FI s 431 mm 17 DHW cold in cold water inlet 15 mm dia e E E E Q S E i GAS gas connection R 800 24 29 43 and zzz 5 x 800 24T25V 29T25V o Bu o gas connection R34 800 60 CH return boiler return line 28 mm dia 800 43 800 60 CH flow boiler flow line 28 mm dia 900 mm 35 CWDO condensate water drain 32 mm dia 335 mm 4115 mm 152 mm 13 44 6 46 1 431 mm 17 55 75 323 209 254 3 12 8
69. s diverter valve Sonde Bi CB Connection Block ondensing gas boiler Buderus 800 CHF Central Heating Flow CHR Central Heating Return EV expansion vessel JB Junction Box RTH Relay PO Mkd A c LSV Lockshield Valve L Beie Daere PL Permanent Live E Bandai PRV Pressure relief valve CHF TRV Thermostatic radiator valve TRV M E ae P 4 ug radiator radiator EV BHL PHU LSV d reference room main living area L other rooms Buderus 800 with external 230V connection Key to abbreviations AV Air Vent CB Connection Block CHF Central Heating Flow CHR Central Heating Return CT Cylinder thermostat DV Diverter valve EV expansion vessel Condensing gas boiler Buderus 800 JB Junction Box RTH Relay LSV Lockshield Valve PL Permanent Live Prog Programmer PRV Pressure relief valve TRV M RT Room Thermostat Es eter TRV Thermostatic radiator valve P WC Wiring Centre a itr LSV H reference room main living area H other rooms Buderus 800 with external 230V connection and two port zone valves WELLE radiator Key to abbreviations AV Air Vent CB Connection Block CHF Central Heating Flow CHR Central Heating Return CT Cylinder thermostat EV expansion vessel JB Junction Box RTH Relay LSV Lockshield Valve PL Permanent Live Prog Program
70. see table 2 is determined by the total pressure loss of all components in the flue gas exhaust air supply system Maximum wall thickness without extensions is 550 mm Maintain a minimum side wall clearance of 50 mm see fig 3 1 3 4 Additional flue parts Additional flue parts See table 3 can be ordered from your supplier Subject to modifications resulting from technical improvements fig 2 Horizontal flue pack Uu 550 mm 50mm fig 3 Side flue and rear flue installation For every 90 bend the Boiler Mox maximum pipe length has Bipellengu to be reduced by 800 24 24T25 H V L 14m Om 800 29 29125 H V L 14m Om 800 43 L 14m 1 5m 800 60 L 9m 1 5m Table2 Pipe length Flue parts Order No Concentric pipe 500 mm long adjustable NE 83713 Concentric pipe 1000 mm long adjustable NE 83714 Concentric bend 90 NE 83715 Concentric bend 45 NE 83716 24 43 kW adaptor plate NE 79061 60 kW adaptor plate NE 79064 Table 3 Additional flue parts Buderus http buderus domestic co uk 10 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 1 4 Items supplied with unit Check t
71. serted correctly Connect cables in correct order inside terminal box close terminal box and screw shut Connect system to mains power supply Open maintenance isolating valves NOTE Fill the 800 Series and purge the system of air Buderus Subject to modifications resulting from technical improvements fig 61 Checking the modulating pump fig 63 Cable modulating pump Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 49 5 3 9 Checking the flow return safety and mains water sensors Unplug cable connection from sensor Measure resistance of sensor Use a second reading thermometer to measure the temperature around the sensor Check readings against values shown in table 10 see page 51 If there is any mismatch the sensor is defective lf the sensor is working correctly plug it in once more fig 66 Checking the mains water sensor Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 50 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 5 3 10 R Cl
72. subsection 2 2 3 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 lonisation electrode may be faulty Check the cabling on the ionisation electrode Code Meaning BL Flame goes out during warm up phase Possible Action cause 1 Gas air ratio not in order Check and adjust the gas air ratio see subsection 2 2 4 2 Gas supply pressure may need adjusting Check the gas supply pressure see subsection 2 2 3 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 lonisation electrode may be faulty Check the cabling on the ionisation electrode Buderus http buderus domestic co uk 42 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 Regulating device may have to cope with interference Voltage in burner control unit too low lower than 187 V or too high higher than 246 V Servicing 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 cm NNNM supply interrupted A problem with the mains supply Check the mains supply during operation 230V 2 Reset button pressed too briefly Press the Res
73. sulting from technical improvements 48 fig 58 Disconnecting fig 60 Removing the fan Buderus http buderus domestic co uk Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 5 3 7 Checking the modulating pump Unscrew the plug on the modulating pump CAUTION Water will flow out Set the mains switch to P Check to ensure that the modulating pump is running The modulating pump s running mechanism may become blocked if the heating system has been out of use for an extended period If the modulating pump fails to run Set the mains switch to 0 Use a spanner to rotate the modulating pump in its normal running direction If this fails to unblock the mechanism the modulating pump is defective If the modulating pump is working correctly screw the plug in 5 3 8 Replacing the modulating pump Disconnect the system from the power supply fig 62 item 1 Close maintenance isolating valves Drain the 800 Series Loosen screws on modulating pump terminal box and open terminal box fig 62 item 2 Loosen cable fig 63 item 1 Note order of cable terminals Loosen modulating pump screw in adapters and remove pump fig 62 item 3 Fit new pump and connect to system fig 62 item 4 Ensure when doing so that the heat exchanger spacer washer is in
74. t and push new unit in Plug in cable connection 5 3 12 Checking the cables to the flow return and safety sensors and to the burner thermostat Check to ensure that all plug in connections to the sensors burner thermostat and in the UBA are in order Note that an incorrectly inserted plug can lead to the generation of error messages Start up the boiler by pressing the reset button Set the mains switch to 0 Disconnect the system from the power supply Unplug the cable connection from the sensor burner thermostat Check the cable between the plug in connection and the 24 pin plug in the UBA with a continuity tester If the cables are in order plug them in Connect system to mains power supply Set the mains switch to P Subject to modifications resulting from technical improvements HANI I Flow senso I 4 Red wire sleeve LX fig 72 Checking the cable to the safety sensor Buderus http buderus domestic co uk 52 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 5 3 13 Checking the burner thermostat Unplug cable connection
75. tallation pipes IGE UP Ab Tightness testing and purging domestic sized gas installations Health and amp Safety Document No 635 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 boilers 800 24 29 43 60 and 800 24T25 29T25 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 Subject to modifications resulting from technical improvements REMEMBER Please hand the log book back to the user NOTE i 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 IP4X The boiler may b
76. tching contact e g temperature Check gas pressure detector is defective or the wires have monitoring device for underfloor heating has been not been properly connected to the back of the UBA tripped or gas pressure too low see subsection 5 3 18 Code Meaning OF System error Possible Action cause 1 Regulating device may have to cope with interference Check if for example induction fields interfere with the regulating device Check if the are any peaks in the electrical network caused by maybe windmills or a power generator 2 UBA may be defective Press reset If fault code remains then try to temporarily connect a different UBA see subsection 5 3 5 Code Meaning gc KIM error Possible Action cause 1 Kim connected incorrectly or KIM defective Check the KIM connector and fan connector see subsection 5 3 21 If the connectors are fine then contact Buderus Code Meaning gL Gas valve assembly error Possible Action cause 1 Wiring to the gas valve incorrect or loose wiring Check the electrical connections of the gas valve connections in UBA 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 5 3 Peaks in the electrical network Check if the are any peaks in the electrical network caused by maybe windmills or a power ge
77. ter about 30 seconds the burner will fire Slowly open the gas service valve Measure the gas distribution pressure and enter into the certificate The gas distribution pressure must be min 17 mbar max 25 mbar rated distribution pressure 20 mbar for natural gas H and min 30 mbar max 50 mbar rated distribution pressure 37 mbar for LPG Pull off the measuring hose and tighten up the screw plug on the test nipple fig 35 Measuring the gas distribution pressure Honeywell gas units NOTE If the required connection pressure is not available or too high contact your gas supplier Sues or TRANSCO e EN e DDA Ensure all disturbed joints and connections are checked for T N gas tightness on completion of tasks A ed C 2 2 4 Checking and setting the gas air ratio The gas air ratio can be checked and set in two different ways using a pressure gauge in accordance with the CO content fig 37 Service button Subject to modifications resulting from technical improvements Buderus http buderus domestic co uk 28 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 Setting the gas ratio using a pressure gauge Move the mains switch and chimney sweeper switch to 0 Pull off the bottom hose a
78. ter mode Reset after reset button has been pressed for 5 sec UBA is reset to the switch on condition Subject to modifications resulting from technical improvements Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 Buderus http buderus domestic co uk 37 5 2 Fault codes Code Meaning it Flue gas thermostat STB has been tripped Possible Action cause 1 Water pressure is too low in the installation Top up the system see subsection 2 1 1 2 Connection in cable harness defective or is getting too Check cable harness and press reset until r appears in hot the display 3 Flue gas thermostat if present is defective or is getting Check the cable connections and press reset until r too warm appears in the display Replace if necessary Code Meaning et Safety sensor exceeds 95 C blocked for 30 sec Possible Action cause 1 Resistance in the installation is too high Check if not all thermostatic radiator valves are clogged with dirt Bypass is installed incorrectly 2 Safety sensor is faulty Measure if resistance over the sensor is correct If not replace safety sensor temporarily with another one see subsection 5 3 9 and subsection 5 3 10 3 Problem with the pump or pump cabling Check if the pump cabling is faulty or if the pump is stuck no circulation see subsection
79. ting boiler always has the required minimum amount of circulation water In single circuit systems the required minimum amount of circulation water can be provided e g by means of an bypass valve A bypass valve is not needed when a hydraulic shunt is installed Thoroughly flush pipes and radiators For sizes of pipe connections please refer to the wall mounting template Fit expansion vessel in compliance with the separate installation instructions or install the expansion vessel in the boiler return line Fitthe service valve in the flow and return lines see subsection 1 1 on pages 6 and 7 Connect pipes free of tension 1 7 2 Gas Supply The gas installation must be installed in accordance with BS6891 CAUTION A Pipework from the meter to the boiler MUST be of adequate size The complete installation MUST be tested for gas tightness and purged as described in IGE UP 1b Subject to modifications resulting from technical improvements fig 7 Gas connection Buderus http buderus domestic co uk 12 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V edition 02 2006 1 7 3 Gas connection For the size of the pipe connection please refer to the wall mounting template CAUTION Work on gas bearing components may only be carried out by a CORGI registered installer Connect the boiler to t
80. ting 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 Under no circumstances should the boiler be fired before the system has been thoroughly flushed Donotuse water softened in a salt bedding exchanger Do notuse 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 NOTE Notes relating to domestic hot water The domestic hot water service must be in accordance with BS 5546 and BS 6700 The boilers are suitable for connection to most types of washing machine and dishwasher appliances 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 Where the water hardness exceeds 150 mgllitre it is recommended that a proprietary scale
81. ttached P1 fig 38 item 1 and fit a hose with Tee in between Connect the Tee to the negative port of the pressure gauge Loosen the screw in the burner pressure measuring nipple on Honeywell gas units fig 38 item 2 two turns comple tely unscrew the screw on SIT gas units fig 39 item 1 Connect the positive port of the pressure gauge with a hose to the burner pressure measuring nipple fig 38 item 2 or fig 39 item 1 Move the mains switch to I and the chimney sweeper switch to 1 When the burner has fired after approx 30 seconds press the service button fig 37 until Y is shown on the display Move the hot water temperature controller to 1 Read the differential pressure The differential pressure paas Pair must be 5 Pa 5 Pa display on the meter 10 to 0 Pa Incase of gas air ratio deviations adjust by using the setscrew fig 38 item 3 or fig 39 item 2 Set mains switch and chimney sweeper switch to 0 Remove the measuring equipment tighten up the screw in the burner pressure measuring nipple put the hose back on P1 Setthe hot water temperature controller back to the original value Move the mains switch to I Adjustment according to the CO content natural gas The mains switch must be set to I and the chimney sweeper switch to 1 Press the service button fig 37 until Y is shown on the display Full load
82. ubject to modifications resulting from technical improvements fig 86 Replacing the valve core on the 800 24 24T25 29 43 60 fig 87 Replacing the three way valve Key to three way valve A hot water B heating AB boiler feed line fig 88 Function diagram of condensation water bypass Buderus http buderus domestic co uk 58 Installation and servicing instructions condensing gas boiler 800 24 29 43 60 and 800 24T25 29T25 H V e edition 02 2006 6 Appendix 6 1 Technical data Size Unit 800 24 800 24T25 800 29 800 29T25 800 43 800 60 H V H V Type of gas category as per EN 437 GB Iloy3p 20 mbar natural gas H 37 mbar LPG GB la 20 mbar Great Brittain natural gas H Rated thermal load G20 KW 6 6 22 0 6 6 22 0 8 4 28 0 8 4 28 0 12 1 40 2 22 0 56 5 Btu h 22 520 75 060 22 520 75 060 28 660 95 540 28 660 95 540 41 285 137 162 75 064 192 778 Rated heating capacity Heating curve 75 60 C kW 6 4 21 4 6 4 21 4 8 2 27 8 8 2 27 8 11 8 39 3 21 4 55 1 Btu h 21 840 73 020 21 840 73 020 27 980 93 150 27 980 93 150 40 260 134 090 73 016 188 000 Heating curve 40 30 C kW 7 0 23 4 7 0 23 4 8 8 29 9 8 8 29 9 12 9 42 9 23 7 60 0 Btu h 23 880 79 840 23 880 79
83. urface ignitor should be between 50 and 300 Ohm Replace hot surface ignitor if necessary see subsection 5 3 15 and subsection 5 3 16 Check the UBA s F1 fuse replace if necessary 2 There is no flame ionisation electrode does Check the fan and KIM connectors and the UBA fuses glow fan isn t turning 3 There is no flame ionisation electrode and fan Check and adjust the gas air ratio see subsection 2 2 4 are working Check for 24V on the gas valve during start up Check the gas supply pressure see subsection 2 2 3 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 The gas valve doesn t close properly If there is still more than when the fan starts up 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 2 7 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 5 Code Meaning BH Flame dies out after gas valve is opened Possible Action cause 1 Gas air ratio not in order Check and adjust the gas air ratio see subsection 2 2 4 2 Gas supply pressure may need adjusting Check the gas supply pressure see
84. us http ouderus domestic co uk 59 Technical data cont d Size Unit 800 24 800 24T25 800 29 800 29T25 800 43 800 60 H V H V Pipe connections Gas inch R 2 R R R R R6 Flow amp return mm 28 28 28 28 28 28 Condensate water drain mm 32 32 32 32 32 32 Flue gas values Condensate water volume natural gas H 40 30 C Asi 2 6 2 6 3 3 3 3 4 7 T pH value condensate water approx 4 1 approx 4 1 approx 4 1 approx 4 1 approx 4 1 approx 4 1 Flue gas mass flow full load YJ 10 03 10 03 12 64 12 64 18 33 25 9 Flue gas temperature Heating curve 40 30 C C 45 45 45 45 45 45 Heating curve 75 60 C C 65 65 65 65 65 65 CO full load natural gas G20 96 9 2 9 2 9 2 9 2 9 2 9 3 Standard emission factor CO 9 ew 15 15 15 15 15 15 Standard emission factor NO Moh wal lt 20 lt 20 lt 20 lt 20 lt 20 lt 20 Free feed pressure of fan Pa up to 140 up to 140 up to 140 up to 140 up to 140 up to 140 Gasrate G20 m h 2 33 2 33 2 96 2 96 4 25 5 98 Flue gas system Type of flue gas system Bos B33 C13 C33 C43 C53 C73 depending on room air and independent of room air Diameter of flue gas system dependent on room air mm 80 80 80 80 80 80 independent of room air mm 80 125 80 125 80 125 80 125 80 125 80 125 concentric concentric concentric concentric concentric concentric Electrical data

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