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500 Range - 28c boiler ISM

1. Description Product No Description Product No 32 Flue gas pipe 78122 75 Clips set of 5 pc 73056s 33 60mm seal top flue gas pipe 73736 76 Condensate trap seal 73463 34 Flue gas pipe seal 73579 77 Drainpipe seal set of 5 pc 73638s 35 Flue gas thermostat STL 73376 78 O ring set of 10 pc 78151s 36 Condensate collector 73630 79 O ring small set of 10 pc 78152s 37 Condensate trap 78123 80 O ring 73x5 78177 38 Connection return 73583 81 O ring 48 9 x 2 62 78178 39 Gas pipe 78126 82 O ring set of 10 pc 78157s 40 Connection supply 73672 83 Screw screwcase set of 2 pc 78181s 41 Automatic airvent 38618 84 Drain plug 78139 42 Spring heat exchanger 73582s 85 RTH Converter 78079 43 O ring heat exchanger set of 10 pc 73580s 86 O ring set of 10 pc 38472s 44 Heat exchanger seal set of 2 pc 73584s 87 34 Seal set of 10 pc 15002s 45 Safety sensor 78154 88 O ring set of 10 pc 38478s 46 Supply pipe 78130 89 Cover seal 78174 47 Pump Uper 15 50 78142 90 Seal 73561 48 Connection return pipe 78133 91 O ring set of 2x2 pc 73642s 49 Return pipe 78132 92 Seal set of 10 pc 73738s 50 Connection return com
2. bs fig 16 Standard vertical flue pack Flow pressure available for use Pa Buderus 500 24 C 75 Buderus 500 28 C 75 table 2 Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 17 Maximum length of horizontal or vertical extensions for 60 100 flue system is L 12 m see fig 17 and fig 18 Maximum length of horizontal or vertical extensions for 80 125 flue system L 35 m see fig 17 and fig 18 Take the flue pipe clearances into account when planning the layout of the place of installation see subsection 1 7 1 Siting the flue terminal on page 16 Maximum wall thickness without extensions is 415 mm Maintain a minimum side clearance of 8 mm see fig 15 1 7 4 Additional flue parts The additional flue parts listed can be ordered from your supplier Flue size 60 100 For every bend or extension the 60 100 flue system max flue length L has to be reduced by 500 mm extension 0 5m 1000 mm extension 1 0m E 90 bend 1 4m 45 bend 0 7m Y NOTE The total reduction length must never exceed the maximum flue length Flue size 80 125 optional 80 125 flue system For every bend or extension the max flue length L has to be reduced by 500mm extension 0 5m 1000 mm extension 1 0m
3. 000000 10 T Technical specifications sssllssssuu 7 Type of gas supply ssesuess 7 36 V Vertical Wes oo eset i ts UE cs 17 W Wobbe index usssesses AA 36 Subject to modifications resulting from technical improvements Installation and maintenance instructions Buderus 500 24 C and 500 28 C 08 2006 Buderus http www buderus domestic co uk 49 Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 50 Installation and maintenance instructions Buderus 500 24 C and 500 28 C 08 2006 Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 51 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 531A 4666 08 2006 www buderus domestic co uk Buderus is a trading name of BBT Thermotechnology UK Ltd
4. aroom temperature control device at 230V connected to the rth converter see subsection 1 10 3 oran ON OFF temperature controller volt free see subsection 1 10 4 1 10 2 ModuLink 250 RF connection The ModuLink 250 RF thermostat modulates on room temperature The Buderus boilers work most efficient with Buderus thermo stats Therefore these thermostats are recommended by Buderus NOTE See the instructions of the other Buderus ther mostats for installation instructions Receiver bracket installation NOTE The receiver is not waterproof Avoid water coming into contact with the receiver when servicing the boiler Remove the casing of the receiver fig 26 item 1 Connect the thermostat s cable supplied with the thermostat to the receiver fig 27 Refit the casing fig 27 item 1 Subject to modifications resulting from technical improvements fig 26 Receiver bracket fig 27 Connect cable Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 23 3 Installation Slide the receiver into the bracket supplied with the boiler so that it is secured fig 28 Remove the boiler s casing Slide the receiver in the guide rails on the bottom part of the boiler fig 30 fig 30 Place receiver Buderus http www buder
5. sls 22 Electrical wiring diagram 04 22 System examples nanunua anana 28 Commissioning lesser 30 Preparing the boiler for operation 31 Inspection 1 cee eee eee 41 General directions 0 000 0a 41 Preparing the boiler for inspection 41 Maintenance asgi miata ia a a ia a 42 Cleaning the heat exchanger and burner 42 Cleaning the condensate trap and syphon 43 Cleaning or replacing the plate heat exchanger 44 Appendix eaea a a i a a a a 45 Fault codes enia eee ie ae EN 45 Residual pump lift 000 46 Spare parts list lille eese 46 Index IeLineeIR Ur ikke eat 49 G C Aplliance No Buderus 500 24 C Buderus 500 28 C 47 110 04 47 110 03 Other manuals available for this boiler are user manual Service instructions wall spacing frame instructions Subject to modifications resulting from technical improvements Preface These Installation and maintenance instructions apply to Buderus wall mounted condensing gas combi boilers 500 24 C and 500 28 C Model C369 C33 C30 C7309 Type GB IE Iloy3p 20 mbar 37 mbar In this document NG 2H G20 20 mbar LPG 3P G31 37 mbar 230 VAC 50 Hz IP X4D 2 5 Ampere slow blow sand filled Power rating Fuse rating The boiler unit consists of the following components 500 Gas condensing boiler 28 Maximum output is 28 kW C Combi
6. 90 bend iem T 45 bend oom NOTE Vertical adaptor 60 100 gt 80 125 is required for 80 125 flue gas systems because the flue outlet of the boiler is 60 100 Weathering slates for 60 100 and 80 125 Flat roof pitched roof Buderus http www buderus domestic co uk 18 E y Yj E La fig 17 Vertical flue length fig 18 Horizontal flue length Subject to modifications resulting from technical improvements Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 1 7 5 Standard 100 mm flue systems The standard concentric flue system provides for a max hori zontal straight length of upto 12 0 m for 60 100 flue connection see subsection 1 7 3 Full instructions for fitting this flue are in subsection 1 7 8 Installation of the horizontal flue on page 20 IMPORTANT Any horizontal flue system fitted to a conden sing boiler must be inclined towards the appli ance at an angle of 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 9 NOTE When using a wall spacing frame don t forget to take its
7. It should be noted that the connection of a condensate pipe to a drain may be subject to local building controls WARNING Any external run must be insulated with water proof insulation Material for condensate NOTE Ensure that the condensate trap is filled with water The condensate drainage pipe should be run in a standard drain pipe material e g PVC polyvinyl chloride PVC U unplasticized polyvinyl chloride BS acrylonitrile butadienes tyrene PP polypropylene polyprolene or PVC C cross linked polyvinyl chloride The condensate drain can be attached to the syphon fig 8 Any internal pipework should be of a diameter to match the requirements of the condensate exit pipe on the appliance Subject to modifications resulting from technical improvements fig 7 Compression fitting fig 8 Condensate outlet Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 13 Internal termination to internal stack The condensate drainage pipe should have a minimum outside diameter of 1 with no length restriction It should incor porate a trap with a 75 mm condensate seal and be connected to the stack at a point at least 450 mm above the invert of the stack The trap built into the boiler will provide this 75 mm fig 9 condensate seal External termination via internal branch
8. installation and commissioning REMEMBER Please hand the log book back to the user Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 3 Regulations and directives It is a requirement that all gas appliances are installed and serviced by a CORGI registered installer in accordance with the regulations Failure to install appliances correctly could lead to prosecution It is in your own interest and that of safety to ensure the law is complied with It is a requirement and in your own interest and that of safety that this boiler must be installed by a CORGI registered installer in accordance with the relevant requirements of the current Gas Safety Installation and Use Regulations The Building Regulations current I E E Wiring Regulations and the relevant British Standard Codes of Practise It is a requirement and in your own interest and that of safety that this boiler must be installed by a CORGI registered installer in accordance with the relevant requirements of the current Gas Safety Installation and Use Regulations The Building Regulations current I E E Wiring Regulations and the relevant British Standard Codes of Practise Detailed recommendations are contained in the following British Standard Codes of Practice BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation for gas appliances
9. Pressing the button again gives the current DHW tempera ture setting is displayed Pressing the button again gives the current setting of summer operation Pressing the button once more gives the current CH flow temperature setting 6 and 7 Up A and Down V keys see fig 43 These keys can be used for adjusting temperatures and activating or de activating certain summer operation The A key when pressed gives the current operating status of the boiler Press the key once to display the current DHW flow in l m Setting the warm start function Press the menu button once Use the and V keys to turn the warm start function on or off Factory setting warm start function is on Setting the domestic hot water DHW temperature Press button twice then adjust the DHW temperature to the desired temperature 40 C 60 C using the and keys see fig 48 item 1 Factory setting is 48 C Buderus http www buderus domestic co uk fig 47 DBA display Setting Meaning More energy efficient less chance of calcification longer waiting periods r i ECO cold start Maximum comfort due to short waiting period for warm water edi comfort warm start Notas energy efficient as the cold start and there is more chance of calcification table 3 Warm start function fig 48 DBA adjust
10. car port roof 200 mm Not recommended Terminal Position E From vertical drain pipes or soil 150 mm pipes F From internal or external corners 300 mm G Above adjacent ground roof or 300 mm balcony 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 1500 mm same wall L Horizontally from a terminal on the 300 mm wall M Adjacent to opening 300 mm N Above intersection with roof 300 mm O From a vertical structure on the roof 500 mm fig 13 Flue terminal position The flue must be installed in accordance with the recommen dations 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 appli cable 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 lowest part of the terminal is less than 2 metres ab
11. condensate drain connection see fig 63 item 1 and remove the syphon Rinse and refit the syphon fig 64 Remove the condensate trap Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 43 4 3 Cleaning or replacing the plate heat ae exchanger Disconnect the boiler from the mains power supply Drain the system see page 31 Remove the condensate trap and the syphon see page 32 Remove the two screws of the plate heat exchanger see fig 65 Remove the plate heat exchanger fig 66 Hook up a descaling device and clean the plate heat exchanger 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 fig 66 Remove plate heat exchanger Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 44 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 5 Appendix 5 1 Fault cod
12. end Assemble flue system completely Push the ducts fully together The slope of the terminal outlet must be face downwards see fig 24 item 1 The assembly will be made easier if a solvent free grease is lightly applied to the male end of the ducts NOTE An inner flue finishing kit is provided which should be fitted to the ducts before assembly Push the assembly through the wall and slide the turret onto the flue connector Refer to figure 20 Ensure that the turret is fully entered into the socket on the boiler Fromthe outside fix the flue finishing kitto 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 Buderus http www buderus domestic co uk Terminal Maximum length assembly Flue turret Wall fig 21 Installation with horizontal flue gas turret fig 22 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 Flue Terminal Raised Ring Outer locating the Wall terminal relative Face to the outside wall face fig 24 Flue terminal position Subj
13. left hand corner of the display fig 44 Press the button if you want to make sure that the boiler is actually operating at partial load Lo appears in the display fig 45 Subject to modifications resulting from technical improvements fig 43 DBA item 1 mains switch item 2 reset button item 3 service button item 4 display item 5 menu button item 6 adjusting arrow up item 7 adjusting arrow down MEM fig 44 DBA with open end spanner fig 45 DBA display Lo Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 33 The boiler operates at full load when the Service button is pressed again An open end spanner J appears in the top left hand corner of the display Press the button if you want to make sure that the boiler is actually operating at full load Hi appears in the display fig 46 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 see fig 43 The display visualizes settings adjustments and fault codes see fig 47 5 Menu button Men see fig 43 The menu button allows you to scroll through the menu items Pressing the button once the current warm start function setting is displayed
14. of rated input not exceeding 70 kW BS 5449 Forced circulation hot water systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd family Gases BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 60 kW BS 6891 Low pressure installation pipes BS 7593 1992 Code of practice for treatment of water in domestic hot water central heating Systems IGE UP 1b 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 combi boiler 500 24 C and 500 28 C 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 Buderus http www buderus domestic co uk NOTE The heating boiler is designed exclusively for heating water as part of a central heating system and or hot water system NOTE For optimum long term reliable functioning of the heating boiler and in order to be able to clai
15. 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 48 Description Product No Description Product No 1 Casing 78155 17 Backside heat exchanger 73657 2 Bracket 38092 18 Gasket heat exchanger 73578 3 Grommet cover 78145 19 Heat exchanger 73659 4 Fan 73639 20 Frontside heat exchanger 78125 5 Fan seal set of 5 pc 73640s 21 Sight glass 73662 6 Gas injector 2E 73210 22 Combustion divider 73670 7 Gas valve 73645 23 Glow ignitor 78105 8 Venturi 73641 24 lonisation electrode 38320 9 50mm seal 73574 25 lonisation electrode seal set of 2 pc 73666s 10 Air silencer tube 73646 26 Glow ignitor seal set of 2 pc 73665s 11 Gas air supply valve 73756s 27 Bracket ionisation electrode and 736675 12 Syphon 78173 glow ignitor 2 pc 13 Gas air supply 73663 28 Shield glow ignitor 38453 14 Burner seal set of 2 pc 73669s 29 Concentric adapter 78120 15 Burner 73668 30 100mm Lipring 78121 16 Heat exchanger Gas air supply seal 73728 31 60mm seal bottom flue gas pipe 73563 Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 46 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006
16. spacing frame CAUTION DO NOT remove the polystyrene foam bottom slab until lifted into position During installation work cover the wall mounted condensing gas boiler and the flue gas adapter to prevent site dirt from entering Hang the wall mounting template Drill the necessary holes fig 2 Installation Attach the manifold assembly to the wall fig 2 item 1 Make the pipework connections to the manifold Attach the wall bracket fig 2 item 2 Open the locking mechanism using a radiator key fig 3 item 1 The radiator key is included in the delivery of the boiler in the accessories bag Detach the casing of the condensing gas boiler fig 3 Remove the polystyrene foam piece from the top of the boiler Hang the condensing gas boiler onto the wall bracket fig 2 NOTE If the boiler isn t connected to the pipework immediately place caps on the pipe connec tions Connect manifold unions to the boiler fig 3 Remove casing 1 5 Water circulation system The central heating system should be installed in accordance with BS 6798 and in addition for smallbore and microbore systems BS 5449 or EN 12823 Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 11 1 6 Pipe connections Pipework from the boiler is routed downw
17. to 0 Connect a tube from the side of the pressure gauge to burner pressure testing nipple see fig 53 item 2 Open the gas shut off valve see fig 51 item 2 Set the mains switch to 1 fig 50 item 1 fig 53 Check the gas air ratio Set the boiler to partial load by pressing the service button once A symbol of an open end spanner P al appears in the upper left hand corner of the display see fig 54 rend fig 54 DBA with open end spanner The optimum gas air ratio is 5 Pa 0 05 mbar The pressure difference should be between 10 and 0 Pa wrong correct wrong see fig 55 If this is not the case then adjustment is needed Remove the safety screw with a flat head screwdriver fig 56 item 1 Adjust the adjustment screw of the burner pressure to the correct gas air ratio using a 4 mm socket head wrench 15 10 5 0 5 Pa and by referring to fig 55 0 15 0 10 0 05 0 00 0 05 mbar left turn i right turn fig 55 Pressure difference of gas air ratio at partial load Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 38 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 Replace the safety screw fig 56 item 1 Set mains power switch to 0 see fig 50 item 1 Shut the gas shut off valve see fig 51 item 1 R
18. www buderus domestic co uk Subject to modifications resulting from technical improvements 8 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 1 2 Dimensions connections and assembly 8mm 780 mm a O og OX d 157 mm 162 mm lt 460 mm 152 mm 222 mm 282 mm 287 mm 352 mm 403 8 mm outside edge frame 1 CH flow 22 mm compression fitting CH return 22 mm compression fitting DHW outlet 15 mm compression fitting MCW inlet 15 mm compression fitting he 3 3 Gas Gas connection 22 mm compression fitting CWDO Condensate water drainage outlet 1 O D PRV Pressure relief valve 15 mm compression fitting 8mm 330 mm 35 mm 21mm L Y A E yo 4 Li i 3 4 70 mm gt 1 2 5 85 mm i l 7 JISM 6 108 mm gt NOTE See wall mounting template for the necessary clearances The wall spacing frame may not always be necessary Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 9 1 3 Items supplied with unit Check the contents against the packing list to ensure that nothing is missing
19. 1 step 2 Clean the burner when necessary The burner may only be cleaned with a soft brush or compressed air Now the front cover of the heat exchanger can be removed by opening the latches fig 59 item 1 CAUTION Replace the burner seal after removing the burner from the gas air unit Buderus http www buderus domestic co uk irm un L3 1 fig 59 Loosen gas connection fig 681 Remove gas air unit Subject to modifications resulting from technical improvements 42 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 Remove the restrictor baffle from the heat exchanger fig 62 item 1 Inspect the heat exchanger When needed clean the heat exchanger with a soft brush or compressed air NOTE Only when a heat exchanger is heavily soiled is it recommended to drain the system to remove the heat exchanger for cleaning Checkthe seal for damage Always replace the seal when in doubt Reassemble in reverse order 4 2 Cleaning the condensate trap and syphon Remove the condensate trap fig 63 and fig 64 Clean the condensate trap with tapwater and a brush Fill the condensate trap with water and reassemble Undo the
20. 7215 3100 08 2006 GB IE en For the installer Installation and maintenance instructions Gas wall hung Boiler condensing Buderus 500 24 C Buderus 500 28 C Benchmark Please read thoroughly 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 Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 2 Installation and maintenance instructions Buderus 500 24 C and 500 28 C 08 2006 Contents 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 2 2 1 3 3 1 3 2 4 4 1 4 2 4 3 5 5 1 5 2 5 3 6 Installation 00 000 cece ee 7 Dimensions connections and assembly 9 Items supplied with unit 0 10 Hanging the boiler 0000 11 Water circulation system 0 11 Pipe connections 0 e eee eee 12 Flue installation llle 16 Electrical connections 05 21 DBA wiring diagram
21. 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 Subject to modifications resulting from technical improvements 4 Installation and maintenance instructions Buderus 500 24 C and 500 28 C 08 2006 It is not necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed due to the low surface temperatures of the boiler casing during operation therefore the requirements of BS 6798 Clause 12 and BS 5440 2 may be disregarded The permanent clearances required are in front 8 mm below 21mm right side 8mm left side 8mm above 21mm The position selected for installation MUST allow adequate space for servicing in front of the boiler See table below in front 350 mm below 180 mm right side 8 mm left side 8 mm above 200 mm In addition sufficient space may be required to allow lifting access to the wall mounting bracket Wall mounted condensing gas combi boilers must only be operated with Buderus purpo
22. Requirements to be met by the place of installation NOTE Observe all statutory building regulations applying to the place of installation DANGER Inflammable materials or liquids must not be stored or used near wall mounted condensing gas combi boilers The site of installation must be frost protected fig 1 Items supplied with unit Key to fig 1 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 Wall spacing frame instruction 1 x Envelope for Warranty card Som Row 7 Plastic bag containing the following accessories 4 x wall fixing screws 4 x wall plugs 4 x washers 8 x fixing screws for wall spacing frame Seals 1 x GJ2 1 2 x 34 22 mm 2 x 1 15 mm 1 x MCW inlet filter Initial start up sticker Second identification plate Pressure Relief Valve compression fitting 4 pipe Radiator key Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 10 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 1 4 Hanging the boiler NOTE Refer to manual of the wall spacing frame which is supplied with the unit for the correct mounting instructions when using a wall
23. al Volt Programmable Room thermostat p Te Key to abbreviations 500 24C 28C CB Connection Block CHF Central Heating Flow CHR Central Heating Return DHW Domestic Hot Water JB Junction Box RTH Relay LSV Lockshield Valve MCW Mains Cold Water PL Permanent Live PRT Programmable Room Thermostat Volt Free TRV iM Contacts PS MNHN lli T Timer TRV Thermostatic Radiator IEIET radiator I LSV reference room main living area j other rooms Valve fig 36 Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 29 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 Now a flame may or may not develop but the glow ignitor extinguishes A flame will establish and the glow ignitor extin guishes The operating controls are released o
24. amage WARNING Indicates the presence of hazards that can cause severe personal injury death or substantial property damage CAUTION Indicates presence of hazards that will or cause minor personal injury or property damage NOTICE Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage He gt amp Abbreviations AB Automatic Bypass AV Air Vent BCT Buderus cylinder thermostat BDV Buderus diverter valve CB Connection Block CH Central Heating CHF Central Heating Flow CHR Central Heating Return CT Cylinder Thermostat CWDO Condensate water drainage outlet DHW Domestic Hot Water DV Diverter Valve E Earth L Live LSV Lock Shield Valve MCW Mains Cold Water N Neutal JB Junction Box RTH Relay PL Permanent Live Prog Programmer PRV Pressure relief valve safety valve RT Room Thermostat RV ModuLink 250 RF Receiver T Timer TRV Thermostatic Radiator Valve WC Wiring Centre ZV Two Port Zone Valve Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 6 Installation and maintenance instructions Buderus 500 24 C and 500 28 C 08 2006 1 Installation 1 1 Technical specifications 500 Series wall mounted condensing gas Dimensions Unit combi boiler 500 24 C 500 28 C Type
25. ards as standard but may be routed upwards behind the boiler using the wall spacing frame supplied with the boiler In the items suplied with the boiler is an extra protection filter This filter protects the DHW sensor of the boiler Place the protection filter into the MCW inlet see fig 4 and fig 5 item 4 Connect pipes as shown in fig 5 Ensure that all pipework is routed so as to minimise any strain on the boiler fittings Buderus advises to use copper piping for the first 600 mm then it is allowed to switch to another approved pipe material 1 6 14 Gas Supply CAUTION Do not use galvanised radiators or pipes The gas installation must be installed in accordance with BS 6891 The complete installation MUST be tested for gas tightness and purged as described in IGE UP 1b CAUTION Pipework from the meter to the boiler MUST be of adequate size generally at least 022 mm 1 6 2 Gas connection Connect to gas supply according to relevant standards 1 6 3 Compression fitting pressure relief valve outlet Insert the small piece of pipe fig 6 Attach the compression fitting fig 7 Buderus http www buderus domestic co uk fig 4 Placing filter in MCW inlet fig 5 Pipe connections Key to fig 7 CH flow DHW outlet Gas MCW inlet CH return Somos fig 6 Ins
26. bi 78165 93 1 Seal set of 5 pc 73527s 51 Internal mechanism three way valve 73685 94 Casing lock 73901 52 Servomotor three way valve 73686 95 Cut off cock with pressure gauge 78150 53 Securing pin of the servomotor 73687 96 Valve Sanitary Hot 75962 54 Discharge pipe of pressure relief 78134 97 Gas valve 78201 valve 98 Valve Sanitary Cold 75963 55a Pressure relief valve 3 bar 78198 99 Valve CH return 75964 55b Key to Pressure relief valve 3 bar 78202 100 Spring set of 5 pc 73490s 56 By pass 78143 101 Spring Hydroframe set of 5 pc 78164s 57 Expansion vessel pipe 78135 102 Seal set of 10 pc 15033s 58 Expansion vessel 78163 103 1 Seal set of 5 pc 73527s 59 Connection plate heat exchanger 78167 104 Connection set combi 73784 60 DHW flow regulator 78138 61 DHW flow sensor 78137 105 MCW inlet filter 79316 62 106 Drainplug 78140 63 Flow sensor 78136 Spring gaspipe set of 5 pc 73531 64 LPG kit 24 kW 28 kW 73734 65 Plate heat exchanger 78144 O ring sensor set of 10 pc 38434s 66 O ring set of 10 pc 78158s _ O ring 16x2 pressure relief valve 237598 67 Clips set of 2x3 pc 78156s set of 10 pc Fuse 2 5 AT DBA set of 10 pc 73739s 69 CHconnector 78161 O ring large flow sensor 78153s 70 Sanitary connector 78162 set of 10 pc 71 DBA 24 S and 28 C 78127 _ Orting 9 19 x 2 62 sensor 781755 71 DBA 24 C 78199 supply return set o
27. d with boiler Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 7 500 Series wall mounted condensing gas Dimensions Unit combi boiler 500 24 C 500 28 C Flue gas values Condensate water quantity natural gas 40 30 C V h 1 6 1 6 Exhaust fume mass flow rate Full load g s 10 6 10 6 Part load g s 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 96 9 2 9 2 CO full load natural gas standard test gas LPG 926 10 3 10 3 Standard emission factor CO mg kWh 22 22 Standard emission factor NO mg kWh 30 30 Flow pressure available for use Pa 75 75 Flue gas system Type of exhaust fume connection C130 Caa09 Csa09 Cat Diameter of flue gas system mm 60 100 accessory Electrical data Mains connection voltage V 230 50 Hz Electrical power consumption Full Partial load W 110 88 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 Casing kg 3 3 Buderus http
28. e g sink waste The condensate drainage pipe should have a minimum outside diameter of 1 with no length restriction The connec tion should preferably be made downstream of the sink waste trap If the connection is only possible upstream then the air break is needed between the two traps This is normally provided by the sink waste pipe see fig 10 and fig 11 Buderus http www buderus domestic co uk internal soil and vent stack 021 5 mm min d No length restriction 450 mm min invert fig 9 Internal termination of condensate drainage pipe to Boiler UJ No length restriction Sink 921 5 mm min internal stack Open end of pipe direct into gully below ground but above water level fig 10 External termination of condensate drainage pipe via internal discharge branch e g sink waste and condensate syphon Boiler U 921 5 mm min Open end of pipe direct into gully below ground but above water level No length restriction fig 11 External termination of condensate drainage pipe via internal discharge branch e g sink waste proprietary fitting and condensate syphon Subject to modifications resulting from technical improvements 14 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 Condensate absorption point P P External length of The condensate drainage pipe
29. ect to modifications resulting from technical improvements 20 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 1 8 Electrical connections 1 8 14 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 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 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 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 25 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 back of the DBA Subject to modifications resultin
30. elevant 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 NOTE Always keep the user manual and installation and servicing instructions available for feed back Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 40 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 3 Inspection 3 1 General directions Do a visual and functional test of the installation 3 2 Preparing the boiler for inspection Disconnect the boiler from the mains power supply 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 Remove the burner housing or cover from the heating boiler NOTE If the gas supply pipes are to be disconnected from the burner the housing MUST ONLY be removed by a qualified service technician and checked for tightness on reassembly 3 2 1 Internal leak test Disconnect the boiler from the mains power supply Do not allow the product to come into contact with the electrical wiring 3 2 2 Check the combustion chamber and heat exchanger f
31. emove the tube from from the burner pressure testing nipple Tighten the screw on the burner pressure testing nipple fig 53 item 1 Open the gas shut off valve see fig 51 item 2 Turn the mains power switch to 1 see fig 50 item 1 CAUTION Check the test nipples for gas tightness NOTE Technically it is not necessary to use a combustion analyzer for COo 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 see technical specifications on page 7 2 1 8 Gas rating test Isolate all other appliances Press the service button to set the boiler to full load Ensure that there is no modulating of the fan gas valve 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 operation Use an approved leak detector to check all connections for possible leaks The product must be certified as a gasleak testing agent Do not allow the product to come into contact with the electrical wiring Subject to modifications resulting from technical improvements fig 56 Adjust gas air ratio Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 39 2 1 10 Function testing NOTE During initial start up and annua
32. ert pipe Subject to modifications resulting from technical improvements 12 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 1 6 4 Hot water temperature CAUTION DO NOT use galvanised pipes or fittings The hot water heat exchanger is made of copper and is liable to suffer the effects of electrolytic corrosion NOTE When using plastic pipes observe the supplier s instructions especially those refer ring to recommended jointing techniques and the notes relating to the heating system water on page 5 Connect pipes free of strain fig 5 1 6 5 Condensate removal Positioning and termination of the condensate drain pipe The condensate pipe should be run and terminate internally to the house soil and vent stack or waste pipe Alternatively the condensate can be discharged into the rainwater system if connected to a foul water draining system 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 condens pump If an external pipe run is unavoidable then the run should be insulated with water proof insulation limited to 3 m in length Should this be exceeded then the pipework diameter should be increased to 32mm and the pipework insulated using weather proof materials
33. es Code Key to display code Code Key to display code O Y The flow sensor or safety sensor has detected that the E A After four startup attempts the system has detected an current CH flow temperature is higher than 95 C insufficient ionisation current 1 The flue gas STL fume monitoring device has C The system has detected an ionisation current before detected a temperature higher than 105 C burner startup or an ionisation current has been The flue gas STL is opened measured as soon as the burner shuts down c F The flow sensor and safety sensor have after burner L The flame goes out during the operating phase startup not detected any temperature increase in the T The power supply was shut off during a crucial heating water or they have determined that the breakdown temperature difference between The flow sensor and safety sensor is too high H A The DBA control panel is defective P The flow sensor has detected a temperature increase F The contacts of the gas valve have been broken in the heating system water of over 5 C sec H The DBA control panel is defective qJ H The tacho signal from the fan has failed during the L The contacts of the gas valve have been broken or operating phase the DBA control panel is defective L The tacho signal from the fan is not present during the P The DBA control panel is defective preoperative or operating phase or there is no current nS of air after a certain t
34. external controls through the cable gland Identify the 230V terminal block by the shaded area and 230V label Connect the switch live to terminal 1 and a neutral to terminal 2 fig 33 item 2 Replace covers NOTE Terminal 3 fig 33 item 2 is not used 1 10 4 Volt free external control device connection Connect the black pre wired lead to a permanent live supply from the same fused isolator as all other controls on the heating system L N E fig 25 Remove the securing screw of the DBA and lower the DBA see fig 31 Remove the cover of the rth converter fig 33 item 1 Lead the control device wire through the cable lead Fix the wire to terminal 1 and 2 of the volt free connection fig 33 item 3 Buderus http www buderus domestic co uk To Boiler 4 32 2 0000 O 24Vac RTh fig 33 Connection box 230 Volt and Volt free connection Subject to modifications resulting from technical improvements 26 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 27 1 11 System examples i Buderus 500 24 C or 500 28 C with ModuLink 250 RF or other Buderus controls NOTE Example systems are to be re
35. f 10 pc 72 Power switch 73660 E Screw 4 x 20 Hydroframe 781795 73 Cable harness 78129 GSLO DNE 74 Clips set of 5 pc 73653s z Ee M Pump 78180s 107 Receiver bracket 78200 108 Wall spacing frame 75972 Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 47 Exploded view Combi unit Buderus 500 24 C 500 28 C SEO gt 101 86 56 As 0 79 5 5b 67 N 2 78 Buderus http www buderus domestic co uk 48 Subject to modifications resulting from technical improvements Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 6 Index A Automatic air vent 0 0000 cee eee 31 B Bracket for ModuLink 250 RF 10 E Electrical connections Mains connection esses 21 H Horizontal flue 0 00 17 l INSPECtION 2 a ee shh eee ae merge 41 M Mainteriatice ioc REID R N 42 manifold assembly 0200000eeeeee 11 P Pipe connections Hot water connection 0 00005 13 Place of installation
36. g from technical improvements fig 25 DBA Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 21 JP3 OOOOOOO0O0O000000000 JP4 OOcOOOOOOO000000000 uid Z uid uid Z uid uid ee poo o 0 8 0 M d c nnnnnnnunn y uid 2 5 pr ya aa o 0 9 O VL AAA amp nnnnnnnnnnnnnn oO ew uid 9 uid DBA Low voltage High voltage iagram d iring DBAw 1 9 Do not connect 230V to the connection block on the back of the DBA WARNING 1 10 Electrical wiring diagram JEnueui siy ui Smaja pepojdxe aui pue uonoes a2lAJes aes sjueuoduioo JenpiAipur JO uoneoo 404 ueio2oje peyrjenb e ynsuos yqnop Aue ur ase NOA JI 084109 pej2euuoo si eoueirjdde noA yeu euynsu3 qaaHigva aa LSNIN 39NVITddV SIHL SNINHVM 4oe q paJnojoo JO N 199 eui YIM Pal euruJe eui 0 pejoeuuoo eq JSNW eng peunojoo 9JIM AY PA peinojoo JO 7 19V Y YM pe ureuu euru eui 0 pejoeuuoo eq jsnui uMoJq peJnojoo 1M 9u Mo je pue ue9JD 10 ueeJ6 peinojoo 10 joquuAs yee y q 10 3 1949 eui uir pexeul 4012euuoo U uo euruJej eui 0 pejoeuuoo eq JsNW MoJje pue ueeJD peJnojoo eJIM yL MOJJO Se peeooJd 1012euuoo Jno ui speura eui BurAmnuepi SHulyseW peinojoo eui uir puods a1109 Jou Ae
37. garded as schematic representations only Condensing gas boiler 500 24C 28C RT programmer Q o Oo o ModuLink 250 RF TRV f PS TTT radiator P lt HITTITE radiator HLTH LSV i reference room main living area Hd other rooms fig 34 Buderus 500 24 C or 500 28 C with external 230V controls Condensing gas boiler 500 24C 28C HI LL VI radiator TUE TE LT d reference room main living area H other rooms fig 35 Buderus http www buderus domestic co uk 28 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 Key to abbreviations CB Connection Block CHF Central Heating Flow CHR z Central Heating Return DHW Domestic Hot Water JB Junction Block RTH Converter LSV Lockshield Valve MCW Mains Cold Water PL Permanent Live RT ModuLink 250 RF RV ModuLink 250 RF Receiver TRV Thermostatic Radiator Valve Key to abbreviations CB Connection Block CHF Central Heating Flow CHR Central Heating Return DHW Domestic Hot Water JB Junction Box RTH Relay LSV Lockshield Valve MCW Mains Cold Water PL Permanent Live RT Room Thermostat T Timer TRV Thermostatic Radiator Valve Subject to modifications resulting from technical improvements Buderus 500 24 C or 500 28 C with extern
38. ime H Short circuit in the gas valve 4 The fan runs too slowly or too fast EJI 4 H The flow sensor and safety sensor have detected a CH g flow temperature of over 105 C 3 E The sensor test has failed J The DBA control panel is defective L The contacts of the flow sensor and safety sensor are R shorted to each other or there is a short circuit to earth ground or the flow or safety sensor has detected a C CH flow temperature of above 130 C E The contacts of the KIM EEPROM on the DBA control P The contacts of the flow sensor or safety sensor are panel circuit board may be loose or short circuited broken r E Resetis carried out This code appears after the reset button 2 is pressed for 5 seconds Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 45 5 2 Residual pump lift This graphic shows the amount of pump lift remaining for the heating system Buderus 500 24 C and 500 28 C series 400 350 300 250 275 mbar 200 at 900 I h 150 Residual pump lift mbar 100 50 0 100 200 300 400 500 600 700 800 900 1000 Flow l h 5 3 Spare parts list The following are parts commonly required due to damage or expendability Their failure or absence is likely to affect
39. ing arrows Subject to modifications resulting from technical improvements 34 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 Setting the boiler to summer operation When you want to make sure that your boiler will not operate for central heating in the summer then you can set the boiler to summer operation The boiler will then only operate for DHW Press the button see fig 48 item 2 three times The current setting blinks Use the A or V keys to adjust to desired setting Central heating is on Central heating is off summer operation 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 EH Setting the flow temperature Press t button see fig 48 item 2 four times then adjust the flow temperature to the desired temperature 30 C 80 C using the and V keys see fig 43 item 1 Factory setting is 80 C It is not possible to set the flow temperature when the boiler is Set to summer operation Frost protection The boiler has an automatic frost protection When the CH flow temperature drops below 7 C then the boiler will start up 2 1 8 Checking for gas leaks Use a suitable pressure gauge for the different pressure read ings It should be able to handle pressures up to 50 mbar with an accuracy of 0 01 mba
40. l servicing make sure that all control regulating and safety devices are in full working order and if applicable check for correct adjustment Measuring the ionisation current fig 57 Turn the mains power switch to 0 see fig 50 item 1 Remove the casing Loosen the connector and socket connection of the ionisa tion electrode and connect the multimeter in series Onthe measuring device select the p direct current range The measuring device must have a resolution of at least 1 uA 1 micro ampere Set mains power switch to 1 see fig 50 item 1 Setthe boiler in to partial load by pressing the Service gee Measuring mejenisaton CUIRE button once 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 Set the mains power switch to 0 see fig 50 item 1 Remove multimeter and restore the connector and socket connection to its original state Refitthe casing and secure the boiler with the radiator key see fig 58 Set the mains power switch to 1 see fig 50 item 1 fig 58 Refit casing 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 r
41. m under the terms of the manufacturer s warranty the heating boiler must be inspected and maintained at least once a year under normal operating conditions by an officially recognized installation and service engineer The term normal operating conditions means that the heating boiler is used to provide central heating and or hot water to no more than one single family dwelling EJ NOTE When instructions aren t followed warranty i expires NOTE Condensing boilers work more efficient if the CH flow return temperature is as low as possible 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 and BS 5440 1 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 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
42. measurements into account when designing a flue system 1 7 6 Connecting the vertical flue adaptor Fit the vertical flue adaptor fig 19 onto the appliance flue connector 1 7 7 Connecting the horizontal flue turret Fit the horizontal flue turret fig 20 onto the appliance flue connector Subject to modifications resulting from technical improvements fig 19 Vertical flue adaptor Flue gas fig 20 Horizontal flue turret with flue gas testing point Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 19 1 7 8 Installation of the horizontal flue The standard flue is suitable for lengths upto 660 mm see fig 21 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 7 9 Flue duct preparation and assembly Measure the flue length L Refer to figures 22 and 23 NOTE The flue must be inclined from the boiler Mark off the lengths shown onto the ducts and cut the length The cuts must be square and free from burrs Terminal assembly outer air duct L 70 mm inner flue duct L 50 mm The measurement is made from the ridge at the terminal indicating the outer face of the wall Refer to figure 24 Extension air duct L 70 mm flue duct L 50 mm The measurement is from the formed
43. nation device with integrated hot water supply Important general instructions for use Only use the boiler in accordance with its designated use and the installation and maintenance instructions Installation maintenance and repair must be carried out by competent service engineers e g CORGI registered Only use the boiler in conjunction with the accessories and spare parts indicated in the installation and maintenance instructions Other 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 wall spacing frame 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 reci ESEE A N Benchmark 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
44. nce 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 to post purge The boiler will try to start up three times If there still is no flame developing after three times then the boiler will lock out When the heat demand stops The gas valve closes The fan will keep going for a short while to post purge the appliance The pump will continue for a while to disperse any remaining heat energy from the boiler to 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 commis sion the boiler and fill out the commissioning log book NOTE If a fault occurs then refer to the servicing manual or contact Buderus Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 30 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 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 instal lation 2 1 1 Fill the heating system WARNING The wall mounted condensing gas combi b
45. o not use artificially softened water Only plastic pipework containing a polymeric barrier should be used It is allowed to use copper for the first 600 mm See also subsection 1 6 Pipe connections in this manual NOTE i 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 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 requirements 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 device is fitted BS 67989 85 4 3 Safe handling of substances No asbestos mercury or CFCs are included in any part of the boiler and its manufacture Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 5 Hazard definitions and abbreviations Hazard definitions DANGER Indicates the presence of hazards that will cause severe personal injury death or substantial property d
46. of gas supply as established in GB IE Iloy3p 20 mbar 37 mbar EN 437 GB IE natural gas H and LPG 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 Heating curve 40 30 C kW 6 0 24 0 6 0 24 0 Seasonal efficiency SEDBUK for natural gas 96 90 3 90 3 for LPG 926 92 3 92 3 Max gas rate for heating m h 2 43 3 02 Max gas rate preparing hot water m h 2 43 2 43 Central heating installation Heating water temperature C 30 80 30 80 AT at residual head of 200 mbar C lt 20 20 Max operating pressure of boiler bar 3 0 3 0 Pump over run time min 5 5 Expansion vessel Capacity of expansion vessel l 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 Gas on installation frame compression fitting Q mm 22 CH flow return compression fitting mm 22 MCW inlet DHW outlet compression fitting mm 15 Condensate water outlet inch 1 Pressure relief valve compression fitting mm 15 adapter supplie
47. oiler must not be activated at this stage Loosen the automated air vent one turn fig 37 f necessary open the CH flow and CH return servicing valves fig 38 item 1 and 2 Wu DHW MCW NP me CH outlet Gas inlet CH flow return fig 38 servicing shut off valves Connect filling loop fig 39 Open both stop valves fig 39 Fill the system to a pressure of approx 1 5 bar fig 38 item 3 Shut both stop valves Disconnect the filling loop double check Vent all radiators from air starting with the lowest radiator valve filling loop and working your way up to the highest point pud d Check the pressure after venting If the pressure has dropped under 1 0 bar then top up the system as described previously fig 39 Connecting filling loop Disconnect the filling loop and cap off To drain the boiler take the following steps Close the MCW inlet and the CH return valve a 0 Connect drainage hose fig 40 ae Close the CH return and CH flow valves drainage hose ay stop valve sto Connect draining hose to draining point on the manifold valve i fig 40 item 1 Open draining point to drain the boiler fig 40 item 1 MCW CH inlet CH flo
48. or pollution 3 2 3 Check the burner 3 2 1 Check the functioning and safety of the flue gas exhaust 3 2 5 Check the pre pressure of the expansion vessel 3 2 6 Check the hot water cylinder for leakage 3 2 7 Check the programming of the room thermostat Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 41 4 Maintenance NOTE The described cleaning of the burner and heat exchanger is only necessary when the boiler is heavily soiled Otherwise it is sufficient to clean the burner and heat exchanger with a soft brush or compressed air without disassem bling them 4 1 Cleaning the heat exchanger and burner Switch the boiler off by setting the mains switch to 0 see fig 50 item 1 Close the gas shut off valve see fig 51 item 1 Unlock the securing screw with a radiator key and remove the casing Loosen the gas connection between the gas supply and the gas air unit fig 59 Remove the connectors fig 60 item 1 2 and 3 from the gas air unit Remove the air silencer from the gas air unit fig 60 item 4 Then remove the connectors of the ionisation electrode fig 60 item 6 and the glow ignitor fig 60 item 5 By turning the unit a quarter turn fig 61 step 1 the unit can be removed by lifting it out of the boiler fig 6
49. ove the level of the ground balcony flat roof or place to which any person has access the terminal must be protected by a guard Ensure that the guard is fitted centrally The flue assembly shall be so placed or 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 Subject to modifications resulting from technical improvements table 1 Balanced flue terminal position 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 air condi tioning If this could occur the appliance MUST be turned off with the owners permission and labelled as unsafe until corrective action can be taken DANGER Only use Buderus flue gas systems As other flue gas systems are not tested with this appliance Buderus http www buderus domestic co uk 16 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 1 7 2 Air supply and flue gas exhaust in a closed installation A ventilation cover is integrated into the 500 Series condensing gas boilers This c
50. over houses a number of components such as the burner and the heat exchanger Since this ventilation cover is part of the air supply system it is vital that it is always installed correctly To ensure optimal operation the 500 Series appliances must be connected to a Buderus horizontal or vertical flue terminal These terminals have been developed specifically for Buderus condensing gas boilers and have been comprehensively tested for trouble free operation when correctly installed Standard horizontal flue pack fig 14 item 1 Flue turret 60 100 item 2 Horizontal flue terminal 60 100 item3 Flue finishing kit Standard vertical flue pack fig 16 jtem 1 Vertical flue terminal 60 100 item 2 Weather collar item 3 Flue support bracket item 4 Vertical flue adaptor 1 7 3 Maximum Flue length The maximum pipe length of the air supply and flue gas exhaust pipes for the 500 Series condensing gas combi boilers is determined by the total pressure loss of all components in the flue gas exhaust air supply system See table Subject to modifications resulting from technical improvements fig 14 Standard horizontal flue pack 415 mm
51. ply 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 Natural gas a minimum of 30 mbar and a maximum 50 mbar nominal connection pressure 37 mbar for LPG Pull off the tube from the gas testing nipple Tighten the screw of the gas testing nipple ATTENTION Ifthe required connection pressure is incorrect contact your gas supplier Ensure that all disturbed joints and connections are checked for gas tightness on completion of tasks Subject to modifications resulting from technical improvements 1 2 fig 50 DBA front fig 51 Gas valve item 1 Gas valve closed item 2 Gas valve open fig 52 Measuring the gas supply pressure Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 37 2 1 7 Checking the gas air ratio and adjust as required Turn mains power switch to 0 fig 50 item 1 Remove the casing of the boiler Shut the gas shut off valve underneath the boiler see fig 51 item 1 Open at least two radiators Open the top measuring nipple see fig 53 item 1 with two turns Set the pressure gauge
52. r minimum Disconnect the system from the power supply 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 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 ATTENTION Check the used measuring nipples for gas tightness Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 35 2 1 4 Checking the gas type Type of gas Factory settings of gas burners It is very important that the gas type to which the boiler will be When delivered ready for operation and set connected corresponds to the gas type the boiler is equipped to Wobbe index 14 1 kWh m referred to with If this is not the case then the boiler must not be put into 15 C 1013 mbar applicable for Wobbe operation Natural gas H index range 11 3 to 15 2 kWh m Check the gas type with your gas supplier and compare Inscription on gas type indicating label this to the boiler s gas type as registered on the identfica Category setting 2H G 20 20 mbar
53. se made gas systems which are certified for this type of boiler Observe the relevant standards regulations and legislation of the country or region 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 Sentinel X100 to fill and top up the system For more information about Sentinel call 0151 420 9563 When using water treatment only products suitable for use with Buderus heat exchangers are permitted e g Sentinel X100 Your warranty is at risk if an incorrect water treatment product is used in conjunction with this appliance For more information contact Buderus Technical Product Support Department It is most important that the correct concentration of the water treatment product is maintained in accordance with the manufacturer s instructions If the boiler is used in an existing system any unsuitable additives MUST be removed by thorough cleaning BS 7593 1992 details the steps necessary to clean a domestic central heating system Subject to modifications resulting from technical improvements 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 D
54. should have a minimum pipe 3m max outside diameter of 1 and the external pipe length should not be more than 3 m The condensate absorption point should be sited in a convenient position as close as possible to the boiler but not in the vicinity of other services See fig 12 for informa tion 921 5 mm min 1000 mm min Ground either or NOTE When discharging condensate to an outside f 0100 mm min drain caution must be taken to ensure l plastic tube c blockage cannot occur during freezing condi E tions If this is likely to occur the use of a E syphon trap is recommended 2 bottom of E tube sealed m limestone chippings A hole depth 400 mm min Two rows of three 12 mm holes at 25 mm centres 50 mm from bottom of tube and facing away from house fig 12 External termination of condensate drainage pipe to absorption point Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 15 1 7 Flue installation 1 7 1 Siting the flue terminal under carport Minimum Spacing A Directly below above or alongside 300 mm an opening window air vent or other ventilation opening B Below guttering drain pipes or soil 200 mm pipes C Below eaves 200 mm D Below balconies or a
55. t 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 Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 36 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 Measuring the standing gas supply pressure Take the boiler out of service by pressing the mains switch fig 50 item 1 to 0 Close the gas shut off valve fig 51 item 1 Set the pressure gauge to 0 Attach a tube from the pressure gauge to the gas test nipple the lower one see fig 52 item 2 Slowly open the gas shut off valve fig 51 item 2 Measure the standing gas supply pressure Measuring the working pressure Take the boiler out of service by pressing the mains switch fig 50 item 1 to 0 Close the gas shut off valve fig 51 item 1 Set the pressure gauge to 0 Attach a tube from the pressure gauge to the gas test nipple the lower one see fig 52 item 2 Slowly open the gas shut off valve fig 51 item 2 Open at least two radiators Set the mains switch fig 50 item 1 to 1 Create a heat demand by pressing the service button fig 50 item 2 until an open end spanner D d appears in the top left hand corner of the display Measure the working gas sup
56. tion tag see table 5 After adaptation by a CORGI registered installer the unit can be run on LPG Inscription on gas type indicating label Category setting 3P G 31 37 mbar It is possible to change the boiler to another gas type see table 4 This accessory can be ordered from your supplier LPG table 4 Gas supply types Type of gas Gas injectors 2 mm Venturi Buderus 500 24 C 28 C tubes Natural gas H G20 4 45 4 45 Standard LPG 3 45 3 45 Standard table 5 Gas injector diameter 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 instal lation and the differences in water pressure The DHW flow regulator is located on the bottom frame of the boiler see fig 49 Adjust the DHW flow regulator fig 49 to the desired setting To increase the flow of hot water m turn valve clockwise To reduce the flow of hot water n turn valve counterclockwise fig 49 DHW flow regulator Factory setting 10 l 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 a
57. us domestic co uk Subject to modifications resulting from technical improvements 24 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 Connect the black pre wired lead to a permanent live supply from the same fused isolator as all other controls on the heating system L N E fig 25 Remove the securing screw of the DBA and lower the DBA see fig 31 fig 31 Lower the DBA Disconnectthe twin cable of the rth converter from terminal 1 and 2 of the connection block see fig 32 item 1 on the back of the DBA Connect the cable of the ModuLink 250 RF receiver to terminal 1 and 2 of the room thermostat connection on the back of the DBA see fig 32 item 1 converter EM Fer fig 32 Room thermostat connection on DBA Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 25 1 10 3 External 230V controls Connect the black pre wired lead to a permanent live supply from the same fused isolator as all other controls on the heating system L N E fig 25 WARNING This appliance must be earthed Remove the securing screw of the DBA and lower the DBA see fig 31 Remove the cover of the rth converter fig 33 item 1 Feed the 230V switch live and neutral from
58. w eouei dde y jo jo peaj sureui y ui SAAM eui jo sanojoo eui SY 3AM NMOHB8 TVHLR3N 360718 HLHV3 MOTT3A ANY N33H859 9poo Buiwojo y YM 92U8 pJ099 ui paJnoj oo aJe pes suw siu Ul SJM 9u p LNVLYOdII z PEN G eo co O d as zg g ace og On Su Zo Do o ws a gt m 5 gt WA JES E N 7a Mn tr amp o I ze x2 uz o o zi e E o gt p Zu z z A gt 9 a la o 9 ao X FL oo o gt o zo t z roa o E Ed 8 os A Is tc A QOO E 5 S S Az pally pues 8 MO q MOIS z ISNA m 5 ZH 0S OVA 0 c E SNIVIN A E J on 900 o o o o o o DUM aa St Flue gas thermostat 4 5 lonisation electrode Flow sensor Safety sensor HOT surface ignitor d Subject to modifications resulting from technical improvements Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 Buderus http www buderus domestic co uk 22 1 10 1 External controls The wall mounted condensing gas combi boiler can be fitted with the following external controls aModuLink 250 RF see subsection 1 10 2 or other recommended Buderus 24V controls
59. w return fig 40 Draining the boiler Subject to modifications resulting from technical improvements Buderus http www buderus domestic co uk Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 31 Fill the condensate trap Remove the condensate trap and fill with water see fig 41 and fig 42 fig 41 Disconnect hose from condensate trap fig 42 Remove the condensate trap and fill with water Buderus http www buderus domestic co uk Subject to modifications resulting from technical improvements 32 Installation and maintenance instructions for Buderus 500 24 C and 500 28 C 08 2006 2 1 2 DBA adjustments The boiler is equipped with a 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 adjust ments in its settings DBA overview 1 Mains switch see fig 43 Use this switch to turn the boiler on or off 2 Reset button e see fig 43 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 see fig 43 The boiler will operate on partial load when the Service button is pressed once An open end spanner appears in the top

500 Range - 28c boiler ISM

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