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1. 7215 3100 63 1TD NOTE Always keep the user manual and installation and servicing instructions with the boiler for future reference 7215 3100 64 1TD Fig 64 Refit casing Buderus 500 24C 28C Subject to modifications resulting from technical improvements Buderus 45 Le Inspection 3 Inspection 3 1 General directions Do a visual and functional test of the installation 3 2 Preparing the boiler for inspection e Disconnect the boiler from the mains power supply DANGER OF FATAL INJURY due to electric shock when system is opened e Before opening the system Isolate the boiler at the dedicated electri cal spur e Ensure that the heating system cannot be reconnected by accident Remove the burner housing or cover from the heating boiler NOTE i If the gas supply pipes are to be disconnect ed from the burner the housing MUST ONLY be removed by a qualified service technician and checked for tightness on reassembly Replace the following seals two yearly Flat seal between the gas pipe and gas air unit Seal ignition unit Seal ionisation electrode Seal heat exchanger Burner seal Fill out the Benchmark 3 2 1 Internal leak test e Disconnect the boiler from the mains power supply e Do not allow the product to come into contact with the electrical wiring 3 2 2 Check the2. e Measure the working gas supply pressure The working gas supply pressure should be between a minimum of 17 mbar and a maximum of 25 mbar nominal connection pressure of 20 mbar for Natu i ral gas a minimum of 30 mbar and a maximum 50 mbar 1 2 nominal connection pressure 37 mbar for LPG 7215 3100 57 1TD e Pull off the tube from the gas testing nipple e Tighten the gas testing nipple screw Fig 57 Gas valve item 1 Gas valve closed ATTENTION item 2 Gas valve open If the required connection pressure is incor rect contact your gas supplier Ensure that all disturbed joints and connections are checked for gas tightness on completion of tasks 7215 3100 58 1TD Fig 58 Measuring the gas supply pressure Buderus 42 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 2 1 7 Checking the gas air ratio and adjust as required Turn mains power switch to 0 gt fig 56 item 1 Shut the gas shut off valve underneath the boiler gt fig 57 item 1 e Ensure at least two radiators are open to hot water flow e Open the top measuring nipple gt fig 59 item 1 two turns e Set the pressure gauge to 0 e Connect a tube from the side of the pressure gauge to burner pressure testing nippl
3. oA TA y i 7215 3100 10 1TD Fig 10 Pipe connections Key to fig 6 CH flow DHW outlet Gas MCW inlet CH return TEON T A 7215 3100 11 1TD Fig 11 Insert pipe 14 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 1 8 4 Hot water temperature CAUTION DO NOT use galvanised pipes or fittings The hot water heat exchanger contains cop per and can suffer from electrolytic corro sion Installation a Note When using plastic pipes observe the sup plier s instructions especially those referring to recommended jointing techniques and the notes relating to the heating system water on page 3 1 8 5 Condensate removal Positioning and termination of the condensate drain pipe Warning Any external run must be insulated with water proof insulation The condensate pipe should be run and terminate inter nally to the house soil and vent stack or waste pipe Alter natively the condensate can be discharged into the rainwater system if connected to a foul water draining sys tem or into a purpose made soak away condensate absorption point All connecting drainage pipework should generally have a fall of at least 2 5 to the horizontal or approximately 50 mm per metre of pipe run If this is can not be achieved consider the use of a conden
4. 7215 3100 68 1TD Fig 70 Remove restrictor baffle 48 Buderus 500 24C 28C Subject to modifications resulting from technical improvements e Replace the seal of the heat exchanger gt fig 71 item 1 The seal must be placed without tension and cut at the proper length at the end of it e Replace the 4 o rings gt fig 71 item 2 2 pieces at each side e Remove the old burner seal gt fig 72 Place a new burner seal Place anew flat seal between the gas pipe and the gas valve gt fig 73 2e NN e Reassemble in reverse order aoe Te 7215 3100 085 1TD Fig 73 Place a new flat seal Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 49 4 Maintenance 4 2 Cleaning the condensate trap and syphon e Remove the condensate trap gt fig 74 and fig 75 7215 3100 69 1TD Fig 74 Disconnect hose from condensate trap e Clean the condensate trap with tap water and a brush If required place a new lip seal e Fill the condensate trap with water and reassemble e Undo the condensate drain connection gt fig 74 item 1 and remove the syphon e Rinse and refit the syphon 7215 3100 70 1TD Fig 75 Remove the condensate trap
5. 7215 3100 18 1TD Terminal position Maximum Spacing A Directly below above or alongside an 300 mm opening window air vent or other venti lation opening B Below guttering drain pipes or soil 200 mm pipes C Below eaves 200 mm D Below balconies or a car port roof 200 mm Not recommended From vertical drain pipes or soil pipes 150 mm F From internal or external corners 300 mm Above adjacent ground roof or balcony 300 mm level H From a surface facing the terminal 600 mm From a terminal facing a terminal 1200 mm J From an opening in a car port e g 1200 mm door or window into dwelling Not recommended K Vertically from a terminal on the same 1500 mm wall L Horizontally from a terminal on the wall 300 mm M Adjacent to opening 300 mm N Above intersection with roof 300 mm O From a vertical structure on the roof 500 mm Fig 18 Flue terminal position 1 under carport Danger N Only use Buderus flue gas systems As other flue gas systems are not tested with this appliance The flue must be installed in accordance with the recom mendations 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 instruc tions provided with the flue terminal kits prior to installa tio
6. Tab 6 Gas injector diameter Buderus 40 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 2 1 5 Adjusting the DHW flow regulator Caution It is important to adjust the flow of hot water due to the resistance of the pipes in the in stallation and the differences in water pres sure The DHW flow regulator is located on the bottom frame of the boiler gt fig 55 e Adjust the DHW flow regulator fig 55 to the desired setting To increase the flow of hot water turn valve clockwise To reduce the flow of hot water turn valve counterclockwise Factory setting 10 I min of 48 C assuming that the DHW cold is 10 C and there is a pre pressure of 2 5 bar 2 1 6 Measuring the gas supply pressure flow pressure There are two ways to measure the gas supply pressure measuring the standing gas supply pressure boiler not in operation measuring the working gas supply pressure boiler operating at full power NOTE The difference between the standing and working pressure may never be greater than 5 mbar If the difference between the two is greater than 5 mbar then the pressure loss in the gas pipe is too great Measuring the standing gas supply pressure Take the boiler out of service by pressing the mains switch gt fig 56 item 1 to 0 Close the gas shut off valve gt fig 57 item 1 e
7. 7215 3100 066 2TD Fig 67 Remove connectors of the gas air unit Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 47 4 Maintenance e Remove the glow ignitor gt fig 55 item 1 and ionisa tion electrode gt fig 55 item 2 Mount a new glow ignitor with mounting plate and nut e Mount the old ionisation electrode with a new seal mounting plate and nut e By turning the unit a quarter turn gt fig 69 step 1 the unit can be removed by lifting it out of the boiler gt fig 69 step 2 e Clean the burner when necessary The burner may only be cleaned with a soft brush or compressed air Caution N Replace the burner seal after removing the burner from the gas air unit e Now the front cover of the heat exchanger can be removed by opening the latches gt fig 65 item 1 e Remove the restrictor baffle from the heat exchanger gt fig 70 item 1 Inspect the heat exchanger When required clean the heat exchanger with a soft brush or compressed air NOTE x Only when a heat exchanger is heavily soiled is it recommended to drain the system to re move the heat exchanger for cleaning e Check the seal for damage Always replace the seal if in doubt Buderus 1 7215 3100 082 1TD Fig 68 Remove the glow ignitor and ionisation elec Fig 69 Remove gas air unit
8. 9 onto the upper wall spacing frame bracket 1 7 Water circulation system The central heating system should be installed in accord ance with BS 6798 and in addition for smallbore and microbore systems BS 5449 or EN 12823 7215 3100 08 1TD Fig 8 Mounting the manifold 1 7215 3100 09 1TD Fig 9 Hanging the boiler Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 13 EE Installation 1 8 Pipe connections Connect pipes as shown in fig 10 Ensure that all pipe work is routed so as to minimise any strain on the boiler fittings The first 600 mm of pipework must be in copper then another approved material type can be used CAUTION N Do not use galvanised radiators or pipes 1 8 1 Gas supply The gas installation must be installed in accordance with BS 6891 CAUTION N Pipework from the meter to the boiler MUST be of adequate size generally 22 mm The complete installation MUST be tested for gas tight ness and purged as described in IGE UP 1b 1 8 2 Gas connection e Connect to gas supply according to relevant stand ards 1 8 3 Compression fitting pressure relief valve outlet e Insert the small piece of pipe gt fig 11 e Attach the compression fitting gt fig 12 Buderus N DA E
9. Subject to modifications resulting from technical improvements 9 EE Installation 1 4 Items supplied with unit Check the contents against the packing list to ensure that nothing is missing 7215 3100 03 1TD Fig 3 Items supplied with unit Key to fig 3 Wall mounted condensing gas boiler Wall bracket Manifold Assembly Wall spacing frame Bracket for ModuLink 250 RF Technical documents 1 x Installation and maintenance manual 1 x User manual 1 x Wall mounting template 1 x Benchmark Logbook 1 x Warranty card 1 x Envelope for Warranty card 7 Plastic bag containing the following accessories 4 x wall fixing screws 4 x wall plugs 4 x washers 4 x push fit rivet for wall spacing frame 2 x rubber stops for wall spacing frame 3 x cable clamp top part 6 x cable clamp fixing screw Seals 1 x G2 1 2 x 34 22 mm 2 x Yo 15 mm 1 x MCW inlet filter Initial start up sticker Second identification plate Pressure Relief Valve compression fitting brass insert Radiator key Se oN Buderus 10 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 1 5 Hanging the boiler Note i Pipework from the boiler is routed down wards as standard but may be routed up wards behind the boiler using the wall spacing frame supplied with the boiler If using the supplied wall spacing frame fol low the procedure i
10. button service button display menu button adjusting arrow up adjusting arrow down No oh OD 7215 3100 50 1TD Fig 50 DBA with open ended spanner 7215 3100 51 1TD Fig 51 DBA display Lo Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 37 E Commissioning The boiler operates at full load when the Service button is pressed again An open end spanner D appears in the top left hand corner of the display Press the A button if you want to make sure that the boiler is actually operating at full load Hi appears in the display gt fig 52 The boiler returns to regular operation when the Service button is pressed once again or after the boiler has operated at partial or full load for 30 minutes 4 Display gt fig 49 Setting adjustments and fault codes are displayed on the DBA see fig 53 5 Menu button gt fig 49 The menu button allows you to scroll through the menu items Press the button once to display the current warm start function setting Press the button twice to display the current DHW temperature setting Press the button three times to display the current setting of summer operation Press the button four times to display the current CH flow temperature setting 6 and 7 Up and Down keys gt fig 49 These keys can be used for adjusting temperatures and activating or
11. gt fig 32 e Using a screwdriver remove the grey 230V cover gt fig 38 item 1 The grey 230V cover houses one fused circuit board The board has four terminals gt fig 39 Lout LR N Nour SPARE Lour amp Nour are optional LIVE amp NEUTRAL supplies from the boiler which are isolated via the on off power switch on the front of the DBA If required these can be used to power a third party 230V thermostat programmer etc Alternatively 230V controls can be powered from a sepa rate mains supply external to the boiler i e Loyt amp Noyt terminals are not used Installation a 7215 3100 37 1TD Fig 37 Room thermostat connection on DBA 1 2 Room Thermostat 3 HW Tank Sensor 5 24VAC 6 7 3 Way Valve 7215 3100 38 1TD Fig 38 Room thermostat connection on DBA Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 29 ai Installation Using a separate supply is not recommended as the third party controls will not be isolated by the power switch on the front of the DBA although in some replacement instal lations this may be unavoidable 230V controls must be from the same fused spur that supplies the boiler described in subsection 1 10 a The direct external mains supply to third party Lptn must be connected with the live return switched live signal from the third party 230V controls
12. set of 10 pc 78152s Screw 4 x 20 Hydroframe 78179s 80 O ring 73 x5 78177 set of 5 pe 81 O ring 48 9 x 2 62 78178 Screw M5 x 30 Pump 78180s F set of 5 pc 82 O ring set of 10 pc 78157s 83 Screw screwcase 78181s set of 2 pc 84 Drain plug 78139 85 CH return pipe 7746900067 86 O ring set of 10 pc 38472s 87 34 Seal set of 10 pc 15002s 88 O ring set of 10 pc 38478s 89 Cover seal 78174 90 Seal 73561 91 O ring set of 2x2 pc 73642s 92 Seal set of 10 pc 8718600045 93 1 Seal set of 5 pc 73527s 94 Casing lock 73901 95 Cut off cock with pressure 78150 gauge 96 Valve Sanitary Hot 75962 97 Gas valve 78201 98 Valve Sanitary Cold 75963 99 Valve CH return 75964 100 Spring set of 5 pc 73490s 101 Spring Hydroframe 78164s set of 5 pc 102 1 2 Seal set of 10 pc 15033s 103 1 Seal set of 5 pc 73527s 104 Connection set combi 73784 105 Buderus 56 Buderus 500 24C 28C Subject to modifications resulting from technical improvements Appendix 5 Exploded view Combi unit Buderus 500 24C 500 28C agar gt 101 Ss 100 7215 3100 075 3TD Buderus Buderus 500
13. 24C 28C Subject to modifications resulting from technical improvements 57 Notes Buderus 58 Buderus 500 24C 28C Subject to modifications resulting from technical improvements Notes Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 59 Buderus Cotswold Way Warndon Worcester WR4 9SW Customer Services 0870 421 5933 Technical Product Support 0870 421 5944 Fax 01905 753 130 www buderus co uk In the UK and IE Buderus is a brand name of Bosch Thermotechnology Ltd 721 531A 0010 Buderus
14. CHR Central Heating Return DHW Domestic Hot Water JB Junction Box RTh Relay LSV Lock Shield Valve MCW Mains Cold Water PL Permanent Live PRT Programmable Room Thermostat Volt Free Contacts T Timer TRV Thermostatic Radiator Valve Buderus 33 Buderus 500 24C 28C Subject to modifications resulting from technical improvements E Commissioning 2 Commissioning When a boiler starts up there are a couple of things that happen Below is a short process description When there is a heat demand The fan starts up and the glow ignitor turns on When there is a DHW request then the three way valve switches from CH operation to DHW operation The pump starts up as soon as the three way valve is in the right position Once all the requirements are met glow ignitor is hot enough fan is operating at the correct speed and the pump is on then the gas valve will open A flame may or may not develop but regardless of that fact the glow ignitor extinguishes The operating controls are released once a flame is sensed After a possible check the boiler will deliver the requested output Should the flow check fail the boiler will shut down for a short while and then try to start up again If no flame develops then the gas valve closes and the fan continues to run for a while to purge the appliance The boiler will try to start up three times If no flame develops after three attempts the boiler will lock
15. Heating curve 40 30 C kW 6 0 24 0 6 0 24 0 Seasonal efficiency SEDBUkK for natural gas 90 0 90 0 for LPG 92 3 92 3 Max gas rate for heating m h 2 43 2 43 Max gas rate preparing hot water m3 h 2 43 3 02 Central heating installation Heating water temperature C 30 80 30 80 AT at residual head of 200 mbar C lt 20 lt 20 Max operating pressure of boiler bar 3 0 3 0 Pump over run time min 5 5 Expansion vessel Capacity of expansion vessel 7 5 7 5 Admission pressure of expansion vessel bar 1 0 1 0 Plate heat exchanger DHW flow rate at 35 C rise l min 9 4 11 7 Adjustable hot water temperature C 40 60 40 60 Minimum connection pressure bar 0 8 0 9 Maximum connection pressure bar 10 0 10 0 Pipe connections Maximum connection pressure mm 22 CH flow return compression fitting mm 22 MOW inlet DHW outlet compression fitting mm 15 Condensate water outlet mm 21 5 Pressure relief valve compression fitting mm 15 adapter supplied with boiler Buderus 6 Buderus 500 24C 28C Subject to modifications resulting from technical improvements Installation aT 500 Series wall mounted condensing gas Description Unit combi boiler 500 24C 500 28C Flue gas values Condensate water quantity natural gas 40 30 C l h 1 6 1 6 Exhaust fume mass flow rate Full load g s 10 6 10 6 Part load g s
16. Set the pressure gauge to 0 e Loosen the gas test nipple screw two turns Attach a tube from the pressure gauge to the gas test nipple the lower one gt fig 58 item 2 e Slowly open the gas shut off valve gt fig 57 item 2 e Measure the standing gas supply pressure e Pull off the tube from the gas test nipple Tighten the gas testing nipple screw Tighten the gas testing nipple screw 7215 3100 55 1TD Fig 55 DHW flow regulator 7215 3100 56 1TD Fig 56 DBA front Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 41 E Commissioning Measuring the working pressure Take the boiler out of service by pressing the mains switch gt fig 56 item 1 to 0 Close the gas shut off valve gt fig 57 item 1 Set the pressure gauge to 0 Loosen the gas test nipple screw two turns Attach a tube from the pressure gauge to the gas test nipple the lower one gt fig 58 item 2 Slowly open the gas shut off valve gt fig 57 item 2 e Ensure at least two radiators are open to hot water flow e Set the mains switch gt fig 56 item 1 to 1 oO 0 e Create a heat demand by pressing the service button gt fig 56 item 2 until an open ended spanner D appears in the top left hand corner of the i display l
17. de activating certain summer operation The A key when pressed gives the current operating status of the boiler Press the A key once to display the current DHW flow in l m Setting the warm start function e Press the menu button once e Use the and keys to turn the warm start func tion on or off Factory setting warm start function is on Buderus 7215 3100 52 1TD Fig 52 DBA display Hi 7215 3100 53 1TD Fig 58 DBA display Setting Meaning More energy efficient less chance of calcification longer waiting periods rol ECO cold start Maximum comfort due to short waiting period for warm water Not as energy efficient as the cold start and there is more comfort warm start chance of calcification Tab 4 Warm start function 38 Buderus 500 24C 28C Subject to modifications resulting from technical improvements Setting the domestic hot water DHW temperature e Press button twice then adjust the DHW tempera ture to the desired temperature 40 C 60 C using the A and A keys gt fig 54 item 1 Factory setting is 48 C Setting the boiler to summer operation When you want to make sure that your boiler will not oper ate for central heating in the summer then you can set the boiler to summer operation The boiler will then only oper ate for DHW e Press the button gt fig 54 item 2 three times The cu
18. each other F The contacts of the KIM EEPROM on or there is a short circuit to earth the DBA control panel circuit board may ground or the flow or safety sensor has be loose or short circuited detected a CH flow temperature of above 130 C r E Reset is carried out This code appears after the reset P The contacts of the flow sensor or safety button is pressed for 5 seconds sensor are broken Buderus 52 Buderus 500 24C 28C Subject to modifications resulting from technical improvements Appendix ey 5 2 Wiring diagram Warning Do not connect 230 V to the connection block on the back of the DBA 7 pees oo oe erg O0000000000000000 e0000000000000000 E AP i Tf fr D C0 SS Ta gt S JP1 T JP4 Ta iS S sS f E amp MCs 8 S a a6 aS a j High voltage DBA Low voltage X a MAINS SWITCH i T i i 20 A s lh R MAINS 230 VAC 50 Hz N HOL f S 3 22l HN uw o 45 L 5 i _JP1 DBA J Ste flue gas ermosta 1 ENO Q Switch contact i i 3 WAY VALVE do not 8 bX S ovac II use for 500 24C and 28C a
19. l Il OON i 24 VAC z 2 3 l i 24 VAC DX ok Nees wy i HW TANK SENSOR do not O use for 500 24C and 28C 2 JP4 ROOM THERMOSTAT OR i D ui i MODULINK 250 RF ERRO O LO 15 S o Flow sensor JP3 Safety sensor i Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 5 Appendix IMPORTANT The wires in this mains lead are coloured in accordance with the following code GREEN AND YELLOW EARTH BLEU NEUTRAL BROWN LIVE As the colours of the wires in the mains lead of of the appliance may not correspond with the coloured markings identi fying the terminals in your connector proceed as follows The wire coloured green and yellow must be connected to the terminal on the connector marked with the letter E or by the earth symbol or coloured green or green and yellow The wire coloured brown must be connected to the terminal marked with the letter L or coloured red The wire coloured blue must be connected to the terminal marked with the letter N or coloured black WARNING THIS APPLIANCE MUST BE EARTHED Ensure that your appliance is connected correctly if you are in any doubt consult a qualified electrician For location of individual components see service section and the exploded views in this manual 5 3 Residual pump lift This graphic shows the amount of pump lift remaining for the heating system 400 350 300 25
20. leak detector to check all connections for possible escapes The product must be certified as a gas leak testing agent DO NOT allow the product to come into contact with electrical wiring The test pressure of the gas pipe when the gas shut off valve is open may not exceed 150 mbar Warning ATTENTION N Check the used measuring nipples for gas tightness 2 1 4 Checking the gas type lt n l Type of gas Factory settings of gas burners Ensure that the boiler is set up to run on the gas type avail Natural gas When delivered ready for operation and set to Wobbe index 14 1 kWh m referred to 15 C 1013 mbar appli able If this is not the case then the boiler must not be put into operation e Check the gas type with your gas supplier and com cable for Wobbe index range 11 3 to pare this to the boiler s gas type as registered on the 15 2 kWh m3 Inscription on gas type identfication tag gt table 6 indicating label It is possible to change the boiler to another gas type Category setting 2H G 20_20 mbar gt table 5 This accessory can be ordered from your LPG After adaptation by a CORGI regis supplier tered installer the unit can be run on LPG Inscription on gas type indicating label Category setting 3P G 31_37 mbar Tab 5 Gas supply types Gas injectors Type of gas mm Venturi Buderus 500 24C 28C tubes Natural gas H G20 4 45 4 45 Standard LPG 3 45 3 45 Standard
21. out When the heat demand stops The gas valve closes The fan will run for a short time to purge the appliance The pump will continue to run for a short time to disperse any remaining heat energy from the boiler into the heating system If there has been a heat request then the three way valve will switch back to the central heating setting Follow the steps described in this chapter to properly commission the boiler and fill out the commissioning log book NOTE i If a fault occurs then refer to the servicing manual or contact Buderus Buderus 34 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 2 1 Preparing the boiler for operation Caution DO NOT operate the condensing gas boiler if large amounts of dust are present e g due to building work in and around the place of installation 2 1 1 Fill the heating system Caution A The wall mounted condensing gas combi boiler must not be activated at this stage a NOTE ter and domestic hot water on page 3 care fully Please read the notes on heating system wa e Loosen the automated air vent one turn gt fig 43 e f necessary open the CH flow and CH return servicing valves gt fig 44 item 1 and 2 e Connect filling loop gt fig 45 e Open both stop valves gt fig 45 e Fill the system to a pressure of approx 1 5 bar gt fig 44 item 3 e Close both stop valves e Vent the
22. rooms Key to abbreviations CB Connection Block CHF Central Heating Flow CHR Central Heating Return DHW Domestic Hot Water JB Junction Box LSV Lock Shield Valve MCW Mains Cold Water PL Permanent Live RT Room Thermostat RV ModuLink 250 RF Receiver TRV Thermostatic Radiator Valve Buderus 31 Buderus 500 24C 28C Subject to modifications resulting from technical improvements EE Installation Buderus 500 24C or 500 28C with external 230V controls a2 7215 3100 41 1TD Fig 41 1 Condensing gas boiler 500 24C 28C 2 radiator 3 reference room main living area 4 other rooms Key to abbreviations CB Connection Block CHF Central Heating Flow CHR Central Heating Return DHW Domestic Hot Water JB Junction Box LSV Lock Shield Valve MCW Mains Cold Water PL Permanent Live RT Room Thermostat T Timer TRV Thermostatic Radiator Valve Buderus 32 Buderus 500 24C 28C Subject to modifications resulting from technical improvements Ea Installation Buderus 500 24C or 500 28C with external Volt Programmable Room thermostat TRV M D E PHU unimu LSV 7215 3100 42 1TD Fig 42 1 Condensing gas boiler 500 24C 28C 2 radiator 3 reference room main living area 4 other rooms Key to abbreviations CB Connection Block CHF Central Heating Flow
23. the wall spacing brackets and hang this on the wall bracket gt fig 6 7215 3100 06 1TD Fig 6 Hanging the wall spacing bracket e Mount the two strips on the upper and lower wall spac ing brackets using the snap rivets gt fig 7 The lower wall spacing bracket is fitted upside down CSN compared to the upper wall spacing bracket ie with the hooks facing down Attach this lower wall spacing bracket to the wall o ae 7215 3100 07 1TD Fig 7 Mounting the lower bracket Buderus 12 Buderus 500 24C 28C Subject to modifications resulting from technical improvements e Mount the lower bracket on the wall and attach the manifold assembly If the manifold does not sit flat check the orientation of the lower wall spacing bracket gt fig 8 Make the pipework connections to the manifold See also subsection 1 8 e Open the case locking mechanism using a radiator key gt fig 5 item 1 The radiator key is included in the delivery of the boiler in the accessory bag e Remove the boiler case Remove the polystyrene foam piece from the top of the boiler Installation a Note If the boiler is not to be connected the pipe work immediately then place caps on the pipe connections Connect the manifold unions to the boiler using the seals supplied e Hang the boiler gt fig
24. water treatment only products suitable for use with Buderus heat exchang ers are permitted e g Sentinel X100 Your warranty is at risk if an incorrect water treatment product is used in conjunction with this appliance For more information contact Buderus Tech nical Product Support Department It is most important that the correct concen tration of the water treatment product is maintained in accordance with the manufac turer s instructions If the boiler is used in an existing system any unsuitable additives MUST be removed by thorough cleaning BS 7593 details the steps necessary to clean a domestic central heating system Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 3 E Regulations and directives Warning In hard water areas treatment to N prevent lime scale may be necessary how ever the use of artificially softened water is NOT permitted Under no circumstances should the boiler be fired before the system has been thoroughly flushed Do not use artificially softened water When using plastic pipes then they must contain a polymeric barrier It is allowed to use copper for the first 600 mm See also subsection 1 8 Pipe connec tions in this manual The domestic hot water service must be in accordance with BS 5546 and BS 6700 e The boilers are suitable for connection to most types of washing machine and dish washer appliances
25. 0 200 150 100 i 50 0 i 0 100 200 300 400 500 600 700 800 900 1000 4 7215 3100 74 1TD Fig 78 1 Buderus 500 24C and 500 28C series 2 Residual pump lift mbar 3 275 mbar at 900 I h 4 Flow l h Buderus 54 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 5 4 Spare parts list Appendix Fe The following are parts commonly required due to damage or expendability Their failure or absence is likely to affect safety or performance of this appliance For a pictorial representation of the part see the respective position number on the exploded view pictures on page 57 Description Product No 1 Casing 78155 2 Bracket 38092 3 Grommet cover 78145 4 Fan 73639 5 Fan seal set of 5 pc 73640s 6 Gas injector 2E 73210 7 Gas valve 73645 8 Venturi 73641 9 50mm seal 73574 10 Air silencer tube 73646 11 Gas air supply valve 73756s 12 Syphon 75986 13 Service set GLE complete also 7746900411 includes item 5 11 14 16 23 24 25 27 68 and 92 14 Burner seal set of 2 pc 8718600197 15 16 Heat exchanger Gas air supply 73728 seal 17 Backside heat exchanger 8718600023 18 Gasket
26. 2 mm 403 8 mm A 7215 3100 76 1TD A outside edge frame 1 CH flow 22 mm compression fitting Note 2 CH return 22 mm compression fitting See wall mounting template for the neces 3 DHW outlet 15 mm compression fitting sary clearances 4 MCW inlet 15 mm compression fitting The wall spacing frame may not always be 5 Gas Gas connection 22 mm compression fitting necessary 6 CDO Condensate drainage outlet 21 5 mm 7 PRV Pressure relief valve 15 mm compression fitting Buderus 8 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 1 3 Boiler locations and clearances Bathroom Installations This appliance is rated IP X4D The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current IEE BS 7671 Wiring Regulations and in Scotland the electrical provisions of the building regula tions applicable in Scotland with respect to the installa tion 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 commu nal 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 A
27. 4 3 4 3 Exhaust fume temperature full load Heating curve 75 60 C C 77 77 Heating curve 40 30 C C 55 55 Exhaust fume temperature partial load Heating curve 75 60 C C 60 60 Heating curve 40 30 C C 35 35 CO full load natural gas standard test gas G20 9 2 9 2 CO full load natural gas standard test gas LPG 10 3 10 3 Standard emission factor CO mg kWh lt 22 lt 22 Standard emission factor NO mg kWh lt 30 lt 30 Flow pressure available for use Pa 75 75 Flue gas system Type of exhaust fume connection C13 x C x C53 x C73 x Diameter of flue take off mm Concentric 60 100 Electrical data Mains connection voltage 50 Hz V 230 Electrical power consumption Full Partial load Standby W 110 88 4 Electrical protection rating IP X4D Boiler dimensions and weight Height x Width x Depth mm 780 x 460 x 330 780 x 460 x 330 Weight without casing kg 31 31 Weight without casing kg 3 3 Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements EE Installation 1 2 Dimensions connections and assembly 8 mm 330 mm 35 mm 460 mm 150 mm E E 5 mm 5mm a 1 A f 3 V4 a Le YY E fo N E A E 1 3 4 70 mm a 152 mm 1 2 5 85 mm z 157 mm 162 mm 7 93 mm a z ppc 6 108 mm 282 mm 287 mm 35
28. 7215 3100 05 2009 GB IE Installation and maintenance instructions Buderus 500 24C Buderus 500 28C aay Fee S benchmark Gas wall hung Boiler condensing For the installer Please read thoroughly Buderus E Contents Contents Preface Important general instructions Regulations and directives 3 The appliance is designed exclusively for heating water as part of a domestic central heating and or hot water sys Hazard definitions and abbreviations 5 tem Do not use the appliance for any other purpose Installation maintenance and repair must be carried out by a competent engineer e g CORGI registered Only 1 Installation 6 use the boiler in conjunction with Buderus accessories 1 1 Technical specifications 6 and spares Other accessories and consumables may be 1 2 Dimensions connections and assembly 8 used if they are expressly provided for the designated use i3 Beilerlossticns snd eisarances 9 and if system performance and safety are not affected in 1 4 Items supplied with unit 10 anyway 1 5 Hanging the boiler 11 The boiler is suitable for connection to fully pumped 1 6 Install the wall spacing frame 12 central heating systems ONLY 1 7 Water circulation system 13 1 8 Pipe connections 14 1 9 Flue installation 19 henchmen J 1 10 Electrical connections 25 1 11 External controls 26 BENCHMARK Log Book 112 System i a a All Buderus gas fired boilers include an installation com missioning and
29. Buderus 50 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 4 3 Cleaning or replacing the plate heat exchanger e Disconnect the boiler from the mains power supply e Drain the system gt page 36 e Remove the condensate trap and the syphon gt page 36 e Remove the two screws of the plate heat exchanger gt fig 76 e Remove the plate heat exchanger gt fig 77 e Hook up a descaling device and clean the plate heat exchanger e Thoroughly rinse the plate heat exchanger before reas sembly Replace the o rings when necessary Open a hot water faucet to rinse and purge the system Close the hot water faucet and reconnect the boiler to the mains supply 7215 3100 71 1TD Fig 76 Remove screws of plate heat exchanger 7215 3100 72 1TD Fig 77 Remove plate heat exchanger Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 51 5 Appendix 5 Appendix 5 1 Fault codes Code Key to display code Code Key to display code o 4 The flow sensor or safety sensor has B H After four startup attempts the system detected that the current CH flow tem has detected insufficient ionisation cur perature is higher than 95 C rent i C The flue gas STL flue monitoring devi
30. G Notes related to domestic hot water When connecting to suitable showers en sure that a The shower is capable of accepting mains pressures and temperatures up to 65 C b The shower is ideally thermostatic or pressure balancing Where temporary hardness exceeds 150 mg litre it is recommended that a proprietary scale reducing device is fitted into the boiler cold supply with the require ments of the local water company Caution Provision must be made to accommodate the expansion of DHW contained within the appliance where a back flow prevention de vice is fitted BS 67989 5 4 3 Safe handling of substances No asbestos mercury or CFCs are included in any part of the boiler and its manufacture Buderus 4 Buderus 500 24C 28C Subject to modifications resulting from technical improvements Hazard definitions and abbreviations is Hazard definitions and abbreviations Hazard definitions Danger Indicates the presence of hazards that will cause severe personal injury death or sub stantial property damage Warning Indicates the presence of hazards that can cause severe personal injury death or sub stantial property damage Caution Indicates presence of hazards that can cause minor personal injury or property dam age e Be a Oa NOTICE Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or proper
31. Spare is a terminal not connected to the circuit board and can be used as a connection point There are two strain relief clamps The clamps are sup plied in the accessory bag on top of the boiler The underside of the grey 230V cover contains a holder Hee eae wD for a spare fuse Only 2 5 Ampere slow blow silica filled Fig 39 Connection box 230 Volt connection fuses should be used 1 Nout Tighten the strain relief clamps to secure the cables F w Replace the grey 230V cover 4 Spare e Raise and secure the Boiler Control Unit DBA e Refit the boiler casing if necessary gt fig 5 1 11 3 Volt free external control device connection Remove the securing screw of the DBA and lower the DBA gt fig 32 Connect the wire to terminal 1 and 2 of the connection block marked Room Thermostat gt fig 37 Buderus 30 Buderus 500 24C 28C Subject to modifications resulting from technical improvements EE Installation 1 12 System examples NOTE These system schematics are simplified heating schematics showing the main electrical and water connec tions Buderus 500 24C or 500 28C with ModuLink 250 RF or other Buderus controls TRV A gt lt EW MCW PHU LSV 7215 3100 40 1TD Fig 40 1 Condensing gas boiler 500 24C 28C 2 RT programmer 3 ModuLink 250 RF 4 radiator 5 reference room main living area 6 other
32. W inlet CH return drain drainage hose oahwh Se l A TT i J i T Z 2 S pi TENN a 7215 3100 47 1TD Fig 47 Disconnect hose from condensate trap 7215 3100 48 1TD Fig 48 Remove the condensate trap and fill with water 36 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 2 1 2 DBA adjustments The boiler is equipped with a boiler control unit DBA This is the internal control of the boiler The DBA is located behind the access panel The DBA allows you to operate the boiler and to make adjustments in its settings DBA overview 1 Mains switch gt fig 49 Use this switch to turn the boiler on or off 2 Reset button gt fig 49 When a blinking code is in the display it is possible to try and restart the boiler by pressing this button NOTE It is not possible to reset the boiler when there is no fault code blinking in the display 3 Service button gt fig 49 The boiler will operate on partial load when the Service button is pressed once An open ended spanner I appears in the top left hand corner of the display gt fig 50 Press the A button if you want to make sure that the boiler is actually operating at partial load Lo appears in the display gt fig 51 7215 3100 49 1TD Fig 49 DBA mains switch reset
33. air from all radiators starting with the lowest radiator and working up to the highest point e Check the pressure after venting If the pressure has dropped under 1 0 bar then top up the system as described previously e Disconnect the filling loop and cap off m 7215 3100 43 1TD Fig 43 Automatic air vent 7215 3100 44 1TD Fig 44 Servicing shut off valves AUN CH flow DHW outlet Gas MCW inlet CH return 7215 3100 45 1TD Fig 45 Connecting filling loop AUN MCW inlet stop valve double check valve filling loop CH return Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 35 E Commissioning To drain the boiler take the following steps Close the MCW inlet and the CH return valve e Connect drainage hose gt fig 46 e Close the CH return and CH flow valves e Connect draining hose to draining point on the mani fold gt fig 46 item 1 e Open draining point to drain the boiler gt fig 46 item 1 Fill the condensate trap e Remove the condensate trap and fill with water gt fig 47 and fig 48 Buderus a JU 3 2 7215 3100 46 1TD Fig 46 Draining the boiler stop valve CH flow MC
34. ce C The system has detected an ionisation or the burner thermostat has detected current before burner startup or an ioni too high a temperature and has been sation current has been measured as opened soon as the burner shuts down g F The flow sensor and safety sensor have L The flame goes out during the operating after burner startup not detected any phase temperature increase in the heating 7 C The power supply was shut off during a water or they have determined that the crucial breakdown temperature difference between the flow sensor and safety sensor is too high q A The DBA control panel is defective P The flow sensor has detected a tempera F The contacts of the gas valve have been ture increase in the heating system broken water of over 5 C sec H The DBA control panel is defective A The tacho signal from the fan has failed L The contacts of the gas valve have been during the operating phase broken or the DBA control panel is L The tacho signal from the fan is not defective present during the preoperative or oper P The DBA control panel is defective ating phase or there is no current of air 4 Short circuit in the gas valve after a certain time E 7 y The fan runs too slowly or too fast 4 H The flow sensor and safety sensor have detected a CH flow temperature of over J The DBA control panel is defective 105 C 4 E The sensor test has failed A L The contacts of the flow sensor and G safety sensor are shorted to
35. combustion chamber and heat exchanger for contamination 3 2 3 Check the burner 3 2 4 Check the functioning and safety of the flue gas exhaust 3 2 5 Check the pre pressure of the expansion vessel 3 2 6 Check the programming of the room ther mostat Buderus 46 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 4 Maintenance NOTE The described cleaning of the burner and heat exchanger is only necessary when the boiler is heavily contaminated Otherwise it is sufficient to clean the burner and heat ex changer with a soft brush or compressed air without disassembling them 4 1 Cleaning the heat exchanger and burner Switch the boiler off by setting the mains switch to 0 gt fig 56 item 1 e Close the gas shut off valve gt fig 57 item 1 Unlock the securing screw with a radiator key and remove the casing e Loosen the gas connection between the gas supply a and the gas air unit gt fig 65 7215 3100 65 1TD Replace the flat seal between the gas pipe and the gas air unit gt fig 66 7215 3100 081 1TD e Remove the connectors gt fig 67 item 1 2 and 3 from the gas air unit e Remove the air silencer from the gas air unit gt fig 67 item 4 Then remove the connectors of the glow ignitor gt fig 67 item 5 and the ionisation electrode gt fig 67 item 6 5
36. djustment Measuring the ionisation current gt fig 63 Turn the mains power switch to 0 gt fig 56 item 1 e Loosen the connector and socket connection of the ionisation electrode and connect the multimeter in series Buderus 44 Buderus 500 24C 28C Subject to modifications resulting from technical improvements e On the measuring device select the u Amp d c range The measuring device must have a resolution of at least 1 uA 1 micro ampere e Set mains power switch to 1 gt fig 56 item 1 Set the boiler in to partial load by pressing the Service button once e Measure the ionisation current The ionisation current being checked must measure gt 2 pA gt 2 micro ampere direct current Enter the reading on the report form e Set the mains power switch to 0 gt fig 56 item 1 e Remove multimeter and restore the connector and socket connection to its original state Refit the casing and secure the boiler with the radiator key gt fig 64 e Set the mains power switch to 1 gt fig 56 item 1 2 1 11 Handing over After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions Hand over all relevant documentation to the end user and explain his her responsibilities under the relevant national and regional regulations Explain and demonstrate the lighting and shutting down procedures
37. e gt fig 59 item 2 e Open the gas shut off valve gt fig 57 item 2 e Set the mains switch to 1 gt fig 56 item 1 7215 3100 59 1TD Fig 59 Check the gas air ratio Set the boiler to partial load by pressing the service button once A symbol of an open ended spanner D appears in the upper left hand corner of the display see fig 60 7215 3100 60 1TD Fig 60 DBA with open ended spanner The optimum gas air ratio is 5 Pa 0 05 mbar The pressure difference should be between 10 and 1 2 1 0 Pa gt fig 61 NOTE If the reading is in the shaded area no adjust ment is required If this is not the case then adjustment is needed 15 10 5 0 5 Pa i 0 15 0 10 0 05 0 00 0 05 mbar Remove the safety screw with a flat head screwdriver gt fig 62 item 1 3 4 lt gt e Adjust the adjustment screw of the burner pressure to 7215 3100 61 1TD the correct gas air ratio using an 4 mm Allen key and by referring to fig 61 Fig 61 Pressure difference of gas air ratio at partial load 1 wron e Replace the safety screw gt fig 62 item 1 2 eee e Set mains power switch to 0 gt fig 56 item 1 3 left turn 4 right turn e Close the gas shut off valve gt fig 57 item 1 Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 43 E Commis
38. e at an incline of 50 mm per metre length to prevent condensate dripping from the flue terminal This means that the clear ance above the appliance must be increased to match the duct length See figure on page 8 NOTE a Take into account the extra depth of the boil er when using the wall spacing frame 1 9 5 Connecting the vertical flue adaptor e Push the vertical flue adaptor gt fig 23 onto the appliance flue connector Ensure that the flue adapter is fully engaged into the top of the boiler 1 9 6 Connecting the horizontal flue turret e Push the horizontal flue turret gt fig 23 onto the appliance flue connector Ensure that the flue turret is fully engaged into the top of the boiler Installation a 7215 3100 24 1TD Fig 24 Vertical flue adaptor 7215 3100 25 1TD Fig 25 Horizontal flue turret with flue gas testing point 1 Flue gas testing point Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 23 EE Installation 1 9 7 Installation of the horizontal flue The standard flue is suitable for lengths upto 660 mm gt fig 26 For longer flue runs upto 12 0 m extension air flue ducts are available NOTE Use the wall mounting template to help you mark the position of the side flue opening 1 9 8 Flue duct preparation and assembly Measure the flue length L Refer to figures 27 and 28 The len
39. ert of the stack The trap built into the boiler will provide this 75 mm gt fig 14 conden sate seal A o 6 7215 3100 14 1TD Fig 14 Internal termination of condensate drainage pipe to internal stack Boiler 21 5 mm min internal soil and vent stack No length restriction 450 mm min invert ORONT Buderus 16 Buderus 500 24C 28C Subject to modifications resulting from technical improvements External termination via internal branche e g sink waste The condensate drainage pipe should have a minimum outside diameter of 21 5 mm with no length restriction The connection should preferably be made downstream of the sink waste trap If the connection is only possible upstream then the air break is needed between the two traps This can be provided by the sink waste pipe gt fig 14 and fig 15 Installation a ine iN E 7215 3100 15 1TD Fig 15 External termination of condensate drainage pipe via internal discharge branch e g sink waste and condensate syphon Sink Boiler No length restriction 21 5 mm min open end of pipe direct into gully below ground but above water level PRONE 7215 3100 16 1TD Fig 16 External termination of condensate drainage pipe via internal discharge branch e g sink waste and condensate syphon Sink Boiler No length restriction 21 5 mm min open end of pipe direct into gully belo
40. g 36 7215 3100 36 1TD Fig 36 Hang bracket under boiler e Remove the securing screw gt fig 32 item 1 and lower the Boiler Control Unit DBA gt fig 32 item 2 Buderus 28 Buderus 500 24C 28C Subject to modifications resulting from technical improvements e Connect the two wires of cable from the ModuLink receiver to terminal 1 and 2 of the connection block on the back of the DBA gt fig 37 The wires are not polarity sensitive A green LED will light on the receiver when installed correctly and the boiler is reconnected to the mains electricity supply There is no requirement to setup the RF link between the thermostat and receiver This has been completed as part of the manufacturing process The room thermostat sends a signal to the receiver at least every 30 minutes to see if they are still in contact with each other If you want to test whether you have reception then press the M button on the thermostat for more than 5 seconds The thermostat will now send out a signal continuously The LED on the receiver flashes green and the thermostat shows connecting in the display The receiver will stay in this test mode until the button on the thermostat is pressed e Raise and secure the DBA Refit the boiler casing if necessary 1 11 2 External 230 V controls Caution This appliance must be earthed e Remove the securing screw and lower the DBA
41. gth L is from the centre line of the flue turret to the outside face of the wall NOTE The flue must be inclined from the boiler NOTE An inner flue finishing kit is provided which should be fitted to the ducts before assem bly When just the terminal assembly is to be used meas ure the length L from the raise ring back gt fig 29 The overall measurement for the outer duct is L minus 70 mm The overall measurement for the inner duct is L minus 50 mm Ensure that the cuts are made square and a free from burrs e f the final flue piece is an extension measure from the formed end back As before the final measurement are minus 70 mm for the outer and minus 50 mm for the inner e Assemble flue system completely Push the ducts fully together The assembly will be made easier if a solvent free grease is lightly applied to the male end of the ducts Buderus 7215 3100 26 1TD Fig 26 Installation with horizontal flue gas turret Maximum length Terminal assembly Flue turret Finishing kit Outer wall Sa Pons 7215 3100 27 1TD Fig 27 Flue length rear item A 150 mm without the use of a wall spacing frame item A 185 mm with the use of a wall spacing frame 7215 3100 28 1TD Fig 28 Flue length side 24 Buderus 500 24C 28C Subject to modifications resulting from technical improvements Push the assembly through
42. heat exchanger 8718600021 19 Heat exchanger 73659 20 Frontside heat exchanger 6718600141 21 Sight glass 73662 22 Combustion divider 73670 23 Ignition unit 8718600054 24 lonisation electrode 38320 25 lonisation electrode seal 73666s set of 2 pc 26 27 Bracket ionisation electrode and fe glow ignitor 2 pc 28 29 Concentric adapter 78120 30 100 mm Lipring 78121 31 60 mm seal bottom flue gas 73563 pipe 32 Flue gas pipe 78122 33 60 mm seal top flue gas pipe 73736 34 Flue gas pipe seal 73579 Description Product No 35 Flue gas thermostat STL 87105062670 push in type 36 Condensate collector 73630 37 Condensate trap 7746900187 38 Connection return 73583 39 Gas pipe 8718600028 40 Connection supply 73672 41 Automatic airvent 38618 42 Spring heat exchanger 73582s 43 O ring heat exchanger 73580s set of 10 pc 44 Heat exchanger seal 73584s set of 2 pc 45 Safety sensor 78154 46 Supply pipe 78130 46 Supply pipe 7746900068 47 Pump Uper 15 50 78142 48 Connection return pipe 78133 49 Return pipe 78132 50 Connection return combi 78165 51 Internal mechanism three way 73685 valve 52 Servomotor three way valve 73686 53 Securing pin of the servomotor 73687 54 Discharge pipe of pressure 78134 relief valve 55a Pressure relief valve 3 bar 78198 55b Key to Pressure relief valve 78202 3 bar 56 By pass 78143 57 Expansion ves
43. ing 3 mm contact separation on both poles or by a three pin plug and socket arrange ment Damaged mains supply cables must be replaced using cable as described above and fitted by a qualified electri cian The means of isolation must be accessible to the user after installation fig 30 item 1 The electrical connection to the mains supply should be readily accessible and adjacent to the boiler Installation a 7215 3100 29 1TD Fig 29 Flue terminal position Flue Finishing Kit Flue Terminal Outer Wall Face Raised Ring locating the terminal relative to the outside wall face PONS 7215 3100 30 1TD Fig 30 DBA Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 25 EE Installation Electrical wiring Caution N THIS APPLIANCE MUST BE EARTHED Ensure that your appliance is connected cor rectly If you are in any doubt consult a quali fied electrician NOTE x The wires in this mains lead are coloured in accordance with the following code EARTH GREEN AND YELLOW NEUTRAL BLUE LIVE BROWN The appliance mains cable wire colours may not correspond with the markings that identi fy the terminals on the fuse spur connector refer to the guide below e Connect green and yellow wire to terminal marked E or or coloured green or green and yellow e Connect brown wire to terminal
44. m Maintain a minimum side clearance of 5 mm gt fig 20 Ensure the flue is adequately supported Buderus recom mend securing each flue extension with a minimum of one wall bracket The additional flue parts listed can be ordered from your supplier Flue size 60 100 Flue size 80 125 optional For every bend or For every bend extension the or extension the 60 100 flue system max flue length 80 125 flue system max flue length L has to be L has to be reduced by reduced by 500 mm extension 0 5 m 500 mm extension 0 5 m 1000 mm extension 1 0 m 1000 mm extension 1 0 m 90 bend 1 4m 90 bend 1 6m 45 bend 0 7 m 45 bend 0 9m Tab 2 Tab 3 NOTE NOTE x The total reduction length must never exceed a Vertical adaptor 60 100 gt 80 125 is re quired for 80 125 flue gas systems because the flue outlet of the boiler is 60 100 the maximum flue length Buderus 22 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 1 9 4 Standard 100 mm flue systems The standard concentric flue system provides for a maxi mum horizontal straight length of upto 12 0 m for 60 100 flue connection see subsection 1 9 3 Full instructions for fitting this flue are in subsection 1 9 7 Installation of the horizontal flue on page 24 IMPORTANT Any horizontal flue system fitted to a conden sing boiler must be inclined towards the ap plianc
45. marked L or coloured red e Connect blue wire to terminal marked N or coloured black 1 11 External controls Buderus boilers are designed to modulate based on room temperature this reduces the amount of energy used to heat the property when compared with using 230V or volt free controls Buderus recommend thermostats from the ModuLink and RC series in order that the customer can benefit from the increased comfort and savings of modulating on room temperature The wall mounted condensing gas combi boiler can be fit ted with the following external controls 1 ModuLink 250 RF gt subsection 1 11 1 or other rec ommended Buderus 24V controls 2 Room temperature control device and timer at 230V connected under the grey cover gt subsection 1 11 2 3 ON OFF temperature controller volt free gt subsection 1 11 3 Connecting any external controls will require the case removal to gain access to the boiler control unit DBA Gain access to the DBA connection block e Remove the boiler s case gt fig 5 on page 11 e Remove the securing screw gt fig 32 item 1 e Lower the boiler control unit DBA gt fig 32 item 2 Buderus 7215 3100 31 1TD Fig 31 Electrical wiring 1 Permanent live 7215 3100 32 1TD Fig 32 Lower the DBA 26 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 1 11 1 Modulink 250 RF thermostat c
46. metres for the 60 100 flue gt table 2 35 metres for the 80 125 flue gt table 3 see also fig 22 and 23 When you have determined the length L for the flue sys tem add up all the bends and extensions used Refer to the appropriate table for the effective lengths of each bend or extension The total of the bends and extensions must not add up to more than the reduction lenghts of the flue length L Installation a 7215 3100 21 1TD Ti 7215 3100 22 1TD Fig 22 Vertical flue length Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 21 EE Installation Example 60 100 2 x 1 metre extension 2 0 m 2 x 90 bend 2 8 m Total effective length 4 8 m Maximum allowed is 12 m So this is allowed Example 80 1250 2 x 1 metre extension 2 0 m 2 x 90 bend 3 2 m Total effective length 5 2 m 7215 3100 23 1TD Maximum allowed is 35 m So this is allowed Fig 23 Horizontal flue length Take the flue terminal clearances into account when plan ning the layout of the place of installation see subsection 1 9 1 Siting the flue terminal on page 19 Maximum wall thickness without extensions is 415 m
47. n 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 Tab 1 Balanced flue terminal position Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in table 1 If the lowest part of the terminal is less than 2 metres above the level of the ground balcony flat roof or place to which any person has access the terminal must be pro tected by a guard 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 to combustible material Detailed recommendations on the protection of combustible material are given in BS 5440 1 2000 Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 19 zal Installation NOTE It is absolutely essential to ensure in prac tice that products of combustion discharg ing 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 air conditioning If this could occur the appliance MUST be turned off with the owners permission and labelled as unsafe until cor recti
48. n existing cupboard or compartment may be used provided that it is modified for the purpose In both cases details of essential features of cupboard compartment design including airing cupboard installation are to conform to the following BS 6798 No cupboard ventilation is required see Air Supply for details It is not necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed Neither is it necessary to ventilate a cupboard or compart ment in which the boiler is installed due to the low surface temperatures of the boiler casing during operation there fore the requirements of BS 6798 Clause 12 and BS 5440 2 may be disregarded The permanent clearances required are A in front 8 mm B below 21 mm C right side 5 mm D left side 5 mm E above 21 mm The position selected for installation MUST allow ade quate space for servicing A in front 350 mm B below 180 mm C right side 5 mm D left side 5 mm E above 200 mm In addition sufficient space may be required to allow lift ing access to the wall mounting bracket Installation a 600mm 600mm La 750mm 2250mm 600mm e 750mm rf 0O 2250mm S 600mm A 7215 3100 01 1TD Fig 1 A Radius Bathroom Installations E 7215 3100 02 1TD Fig 2 Compartment Installations Buderus Buderus 500 24C 28C
49. n section 1 6 CAUTION DO NOT remove the polystyrene foam bot tom slab until lifted into position During installation work cover the condens ing boiler and flue connection to prevent site dirt from entering Attach the wall mounting template e Drill the necessary holes e Attach the manifold assembly to the wall gt fig 4 item 1 e Make the pipework connections to the manifold e Attach the wall bracket gt fig 4 item 2 Open the locking mechanism using a radiator key gt fig 5 item 1 The radiator key is included in the delivery of the boiler in the accessories bag e Detach the casing of the condensing gas boiler gt fig 5 Remove the polystyrene foam piece from the top of the boiler Hang the condensing gas boiler onto the wall bracket gt fig 4 Installation a 7215 3100 04 1TD t Note If the boiler isn t connected to the pipework immediately place caps on the pipe connec tions e Connect manifold unions to the boiler using supplied seals 2 cm 7215 3100 05 1TD Fig 5 Remove casing Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 11 ai Installation 1 6 Install the wall spacing frame Attach the wall mounting template e Drill the necessary holes e Attach the wall bracket gt fig 4 item 2 e Mount the rubber stops in one of
50. onnection The ModuLink 250 RF thermostat modulates on room temperature The Buderus boilers work most efficiently with Buderus thermostats Therefore these thermostats are recommended by Buderus See subsection 1 12 for an installation example with the ModuLink 250 RF The ModuLink 250 RF thermostat comprises wall bracket receiver thermostat thermostat programmer refer to the instruc B For installation and operation of the Buderus tions supplied with that thermostat ModuLink Receiver and bracket installation Warning N Do not connect 230 V AC to the receiver The receiver is not waterproof Prevent water coming into contact with the receiver e Remove the receiver terminal cover gt fig 33 item 1 e Connect the grey 2 core cable supplied with ModuLink 250 RF thermostat to the receiver gt fig 34 The wires are not polarity sensitive To refit the cover slide back on and click into place gt fig 34 item 1 Installation a 7215 3100 33 1TD Fig 33 Receiver bracket 7215 3100 34 1TD Fig 34 Connect cable Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 27 ai Installation Slide the receiver securely into the bracket supplied with the boiler gt fig 35 7215 3100 35 1TD Slide the bracket in the guide rails on the underside of the boiler gt fi
51. rrent setting blinks e Use the A or A keys to adjust to desired setting To Central heating is on Central heating is off summer operation TH DHW is still available NOTE When summer operation is active then the boiler will not operate for central heating until summer operation has been deactivated Setting the flow temperature NOTE It is not possible to set the flow temperature when the boiler is set to summer operation e Press button gt fig 54 item 2 four times then adjust the flow temperature to the desired temperature 30 C 80 C using the and keys gt fig 49 item 1 Factory setting is 80 C Frost protection The boiler has an automatic frost protection When the CH flow temperature drops below 7 C then the boiler will start up 7215 3100 54 1TD Fig 54 DBA adjusting arrows Buderus 500 24C 28C Subject to modifications resulting from technical improvements Buderus 39 E Commissioning 2 1 3 Checking for gas leaks Use a suitable pressure gauge for the different pressure readings It should be able to handle pressures up to 50 mbar with an accuracy of 0 01 mbar minimum e Disconnect the system from the power supply e Check all sections of gas pipework and connections for signs of leaks before starting up the system for the first time If a leak is detected during tightness testing use an approved
52. s of Prac tice Regulations and directives ee The manufacturer s notes must not be taken in any way as overriding the statutory instrument laws The design and construction of the Buderus wall mounted condensing gas combi boiler 500 24C and 500 28C 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 For optimum long term reliable functioning under domes tic conditions the boiler must be inspected and main tained as per these instructions at least once a year by an officially recognised service engineer The term domestic conditions means that the boiler is used to provide central heating and or hot water to no more than one single family dwelling Failure to comply with these instructions will invalidate the appliance warranty Timer Frame 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 and BS 5440 1 The appliance must only be installed along with Buderus flue kits as these are certified for use with the boiler Warning Notes relating to the heating system water Thoroughly flush the system before it is filled with water Use only untreated water or water treatment product such as Sentinel X100 to fill and top up the system For more informa tion about Sentinel call 0151 420 9563 When using
53. s pump If an external pipe run is unavoidable then the run should be limited to 3 m in length Should this be exceeded then the pipework diameter should be increased to 32 mm It should be noted that the connection of a condensate pipe to a drain may be subject to local building controls 7215 3100 12 1TD Fig 12 Compression fitting Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 15 ai Installation Materials for condensate Note Ensure that the condensate trap is filled with water The condensate drainage pipe should be run in a stand ard drain pipe material e g PVC polyvinyl chloride PVC u unplasticized polyvinyl chloride ABS acryloni trile butadienestyrene PP polypropylene or PVC C cross linked polyvinyl chloride The condensate drain can be attached to the syphon Ensure that the black rubberised olive gt fig 13 is cor rectly aligned 7215 3100 13 1TD Fig 13 Condensate outlet Any internal pipework should be of a diameter to match the requirements of the condensate exit pipe on the appli ance Internal termination to internal stack The condensate drainage pipe should have a minimum outside diameter of 21 5 mm with no length restriction It should incorporate a trap with a 75 mm condensate seal and be connected to the stack at a point at least 450 mm 2 above the inv
54. sel pipe 78135 58 Expansion vessel 78163 59 Connection plate heat 78167 exchanger 60 DHW flow regulator 78138 61 DHW flow sensor 78137 62 Connection supply combi 78166 63 Flow sensor 78136 64 Mounting button 7746900854 65 Plate heat exchanger 78144 66 O ring set of 10 pc 78158s Buderus 55 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 5 Appendix Description Product No Description Product No 67 Clips set of 2x3 pc 78156s 106 68 Burner thermostat 7746900412 107 Receiver bracket 78200 69 CH connector 78161 108 Wall spacing frame 75972 70 Sanitary connector 78162 Spring gaspipe set of 5 pc 73531 71 DBA 24 S and 28 C 7746900063 LPG kit 24 kW 28 kW 73734 71 DBA 24C 7746900069 O ring sensor set of 10 pc 38434s 72 Power switch 73660 O ring 16x2 pressure relief 73729s 73 Cable harness 7746900064 valve set of 10 pc 74 Clips set of 5 pc 73653s Fuse 2 5 AT DBA 73739s l set of 10 pc 75 Clips set of 5 pc 73056s O ring large flow sensor 78153s 76 Condensate trap seal 73463 set of 10 pc 77 Drainpipe seal set of 5 pc 73638s O ring 9 19 x 2 62 sensor 78175s 78 O ring set of 10 pc 78151s supply return set of 10 pc 79 O ring small
55. service record log book The details of the 2 Commissioning 34 log book will be required in the event of any warranty work 2 1 Preparing the boiler for operation 35 being requested Please complete the appropriate sections on completion 5 of the installation and commissioning 3 Inspection 46 3 1 General directions 46 REMEMBER Please leave the log book with the 3 2 Preparing the boiler for inspection 46 installed boiler Gas Council Aplliance No 4 Maintenance 47 Buderus 500 24C 47 110 04 4 1 Cleaning the heat exchanger and burner 47 Buderus 500 28C 47 110 03 4 2 Cleaning the gongen ats trap and syphon 50 These Installation and maintenance instructions apply to 4 3 Cleaning or replacing the plate heat exchanger 51 Buderus wall mounted condensing gas combi boilers models 500 24C and 500 28C 5 Appendix 52 5d Bi n in Flue type C13 C334 C536 C73 52 Wiingdiagam 53 Type GB IE lloy3p 20 mbar 37 mbar 5 3 Residual pump lift 5A In this document NG 2H G20 20 mbar 5 4 Spare parts list 55 LPG 3P G31 37 mbar Electrical rating 230 VAC 50 Hz IP X4D Fuse rating 2 5 Ampere slow blow silica filled The boiler type consists of the following components 500 Gas condensing boiler 28 Maximum output is 28 kW C Combination boiler Integrated domestic hot water supply Other manuals available for this boiler are user manual service instructions Buderus 2 Buderus 500 24C 28C Subject to modifications resulting from technical impro
56. sioning Remove the tube from from the burner pressure testing nipple Tighten the screw on the burner pressure testing nip ple gt fig 59 item 1 e Open the gas shut off valve gt fig 57 item 2 Turn the mains power switch to 1 gt fig 56 item 1 NOTE Technically it is not necessary to use a com bustion analyzer for COs measurements The CO level is secured by the gas air ratio as described above A combustion analyzer if available can be used to confirm CO levels gt technical specifications on page 6 Caution N Check the test nipples for gas tightness 7215 3100 62 1TD Fig 62 Adjust gas air ratio 2 1 8 Gas rating test e Isolate all other appliances e Press the service button to set the boiler to full load Ensure that there is no modulating of the fan gas valve e Carry out the Gas Rating procedure as described in Essential Gas Safety 3rd edition on pages 169 176 2 1 9 Checking for leaks while boiler is in opera tion e Use an approved leak detector to check all connec tions for possible leaks The product must be certified as a gas leak testing agent e Do not allow the product to come into contact with the electrical wiring 2 1 10 Function testing NOTE i During initial start up and annual servicing make sure that all control regulating and safety devices are in full working order and if applicable check for correct a
57. the wall and slide the turret onto the flue connector Refer to figure 25 Ensure that the turret is fully engaged 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 fit ted The guard must give a clearance of at least 50 mm around the terminal and be fixed with corrosion resist ant screws 1 10 Electrical connections Mains connection to the appliance Warning Boiler damage A e Connect the supply cable supplied with the the boiler to the 230 Volt mains e DO NOT connect 230 Volts mains supply to any other point on the boiler Caution Electric shock Electrically isolate the appliance at the fused spur before removing the case gt fig 30 NOTE All Buderus boilers require a permanent mains supply of 230 Volts at 50 Hz Wiring to the boiler MUST be in accordance with the cur rent E E BS 7671 Wiring Regulations and any local regulations 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 The mains supply to the appliance and any system con trols thermostat timer must be from a dedicated fused spur The spur must be capable of being isolated by either a double pole switch hav
58. ty damage Abbreviations AB AV BCT BDV CB CH CHF CHR CT CWDO DHW DV LSV MCW JB PL Prog PRV RT RV TRV WC ZV Automatic Bypass Air Vent Buderus cylinder thermostat Buderus diverter valve Connection Block Central Heating Central Heating Flow Central Heating Return Cylinder Thermostat Condensate water drainage outlet Domestic Hot Water Diverter Valve Earth Live Lock Shield Valve Mains Cold Water Neutral Junction Box RTH Relay Permanent Live Programmer Pressure relief valve safety valve Room Thermostat ModuLink 250 RF Receiver Timer Thermostatic Radiator Valve micro as pA micro Amps Wiring Centre Two Port Zone Valve Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 5 EE Installation 1 Installation 1 1 Technical specifications 500 Series wall mounted condensing gas Description Unit combi boiler 500 24C 500 28C Type of gas supply as established in GB IE Iloy3p 20 mbar 37 mbar EN 437 GB IE natural gas H and LPG P Rated thermal load for heating kW 5 7 23 0 5 7 23 0 Rated thermal load for preparing hot water kW 5 7 23 0 5 7 28 5 Rated heating capacity for system temperature modulating from 30 to 100 Heating curve 75 60 C kW 5 3 22 0 5 3 22 0
59. ve action can be taken 1 9 2 Air supply and flue gas exhaust in a closed installation The boiler case incorporates the seal for the air supply system It is important that the case is fitted correctly To ensure optimal operation the 500 Series appliances must be connected to a Buderus horizontal or vertical flue terminal These terminals have been developed specifi cally for Buderus condensing gas boilers and have been comprehensively tested for trouble free operation when correctly installed 7215 3100 19 1TD Fig 19 Standard horizontal flue pack Standard horizontal flue pack gt fig 19 item 1 Flue turret 60 100 item 2 Horizontal flue terminal 60 100 item 3 Flue finishing kit 7215 3100 20 1TD Fig 20 Side flue and rear flue installation Buderus 20 Buderus 500 24C 28C Subject to modifications resulting from technical improvements Standard vertical flue pack gt fig 21 item 1 Vertical flue terminal 60 100 item 2 Weather collar item 3 Flue support bracket item 3 Vertical flue adaptor 1 9 3 Maximum Flue length A standard flue comprises a 90 degree takeoff bend and the horizontal flue outlet or straight takeoff and the vertical flue outlet The flue can be extended upto a maximum effective length L gt fig 22 and 23 The maximum effective flue length is 12
60. vements Regulations and directives All gas appliances must be installed by a competent per son in accordance with the current Gas Safety Installa tion and Use regulations Failure to install appliances correctly could lead to prose cution The appliance installation must comply with the current Gas Safety Regulations IEE Regulations Building Regulations Building Standards Scotland Consolidation Building Regulations Northern Ireland local water by laws Health and Safety Document 635 The Electricity Work regulations 1989 and any other local requirements The relevant British Standards should be followed including BS7074 1 Code of practice for domestic and hot water supply BS6891 Installation of low pressure gas pipework up to 28mm R1 BS5546 Installation of gas hot water sup plies for domestic purposes EN 12828 Central heating for domestic premises BS5440 1 Flues and ventilation for gas appli ances of rated heat input not ex ceeding 70 kW net Flues BS5440 2 Flues and ventilation for gas appli ances of rated heat input not ex ceeding 70 kW net Air Supply BS5449 Forced circulation of hot water systems BS7593 Treatment of water in domestic hot water central heating systems BS6798 Installation of gas fired boilers of rated input up to 70 kW net Where no specific instruction is given reference should be made to the relevant British Standard code
61. w ground but above water level SF PON gt Buderus Buderus 500 24C 28C Subject to modifications resulting from technical improvements 17 EE Installation Condensate absorption point The condensate drainage pipe should have a minimum outside diameter of 21 5 mm and the external pipe length should not be more than 3 m The condensate absorption point should be sited in a convenient position as close as possible to the boiler but not in the vicinity of other serv ices For information gt fig 17 Note When discharging condensate to an outside drain caution must be taken to ensure block age cannot occur during freezing conditions If this is likely to occur the use of a syphon trap is recommended 7215 3100 17 1TD Fig 17 External termination of condensate drainage pipe to absorption point External length of pipe 3 m max 21 5 mm min 1000 mm min 100 mm min plastic tube bottom of tube sealed limestone chippings Two rows of three 12 mm holes at 25 mm centres 50 mm from bottom of tube and facing away from house 8 Ground either or 9 25mmmin 10 300 mm min 11 hole depth 400 mm min SS OF NE Buderus 18 Buderus 500 24C 28C Subject to modifications resulting from technical improvements 1 9 Flue installation 1 9 1 Siting the flue terminal Installation a AN A y lt ve O A ius O A un n 7 A
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