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Actions 7 - Lets Fix It

1. Set multimeter to measure resistance Check to see if the electrical resistance of the glow ignitor lies between 50 and 300 Q Connect the plug of the glow ignitor Fit the casing and place the boiler into operation see box 51 54 or 55 DANGER OF FATAL ACCIDENT A due to electric shock CAUTION A To prevent damage do not insert the measuring electrodes of the multimeter too far into the holes of the plug and socket connection Take the boiler out of serve and tip the DBA control panel forwards see box 43 44 47 or 63 Loosen the six screws and remove the rear section see box 70 Remove the plug of the glow ignitor see box 131 Boulter Buderus Ltd http www boulter buderus co uk 52 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 T K Set multimeter to measure resistance Check the mains cable of the glow ignitor for breaks The electrical resistance measured at each individual wire must be approximately 0 Q Check the mains cable of the glow ignitor for internal short circuits The level of electrical resistance measured between any two wires must be infinitely high Connect the plug of the glow ignitor Fit the DBA control panel and place the boiler into operation see box 51 54 or 55 DANGER
2. lt Normaly you see the current CH flow temperature By pushing the A button you will see the current operation code Blocking The boiler stops heating and will wait until the blocking is solved Locking Displaycode is blinking and also a blinking wrench yl appears The boiler stops heating and the pump is still running The only way to stop the locking is by pushing the reset S button We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 17 Display code S J Display indication Reset Key to display code required Standby Standby Standby Operating phase The boiler is in heating mode Operating phase The boiler is in hot water mode The symbol 6 lights up Operating phase Pump over run time via the external cylinder hot water heater The symbol 6 is off Operating phase The switch optimisation program is activated This program is activated if there is more frequently than once every 10 minutes a heating water requirement from an RC or ON OFF control signal This means that the boiler cannot be restarted until at least 10 minutes have elapsed since initial startup of the burner Pre operative phase The boiler prepares for burner startup whenever
3. Clean the heat exchanger with compressed air a high pressure hose or with water and a soft brush NJ A CAUTION When cleaning the heat exchanger never use a steel P Ci brush pues Neer AN wren using compressed air Use eye protection inhalation protection and hearing J protection E ff C gt 2 T WN I tr D o l 1 M Dns lt a SJ fn EFA LD o EE N 1 a A A A ooo a S Ly SS SS O Z f CAUTION Check the seal on the heat exchanger casing item 1 for TAN Observe the position of the heat exchanger during signs of ageing and replace if required itti fitting Insert the upper section of the heat exchanger at Replace the four O rings item 2 two on each side the top Fit the new or cleaned heat exchanger and all other components by following the above procedure in reverse A CAUTION The released coil item 1 touches the underside A CAUTION Insert a new heat exchanger gas air seal before fitting the gas air unit We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 71 Fill the heating system vent it of air open the gas tap and place the boiler into operation see box 59 or 52 to 58
4. Take the boiler out of operation see box 43 44 or 47 Close the cold water tap Drain the heating system see box 48 to 51 Open hot water tap Remove both screws from the plate heat exchanger Remove condensate trap or wad oe W T N Remove the plate heat exchanger Remove syphon We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 72 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Fit new plate heat exchanger Fit the new pressure relief valve and all other components Renew the four O rings if necessary by following the above procedure in reverse Refit the plate heat exchanger and secure with the two Fill the heating system vent it of air and place the boiler screws into operation see box 52 to 58 Open the cold water service valve Open the hot water tap in order to clean the new plate heat exchanger inside Close the hot water tap Fill the heating system see box 52 Fit the casing and place the boiler into operation see box 51 54 or 55 Take the boiler out of operation and drain the hea
5. OL The fan runs at 49 of capacity The 3 way valve turns to the hot water setting for two seconds The glow ignitor is activated for two seconds LiL Ignition phase The gas valve is opened The glow ignitor is activated for one second followed by alternating half second periods of inactivity and activity until five seconds have elapsed Does the ionisation current exceed 1 4 pA microamperes within 5 seconds Yes No _H The boiler is in hot water mode If there has been a power cut The startup load on the boiler is 49 for the first 13 seconds for the purposes of flow monitoring It is then increased or decreased accordingly The symbol 6 lights up Is the temperature in the plate heat exchanger higher than the temperature entered via the DBA control panel Yes No Is the CH flow temperature 46 C higher than the preset DHW temperature and or higher than 93 C Yes No U4 The gas valve is closed and the burner is shut down The symbol 6 goes out The fan stops after 30 seconds Is the CH flow temperature lower than the preset DHW temperature plus 35 C Yes No The gas valve is closed and the burner is shut down The symbol 6 goes out Start of pump over run time via the cylinder Start of pre purge phase 10 seconds The fan stops OH The pump stops The 3 way valve turns to the heating mode setting for two seconds The symbol Ol or lt eOr goes out Is there a current heat
6. 7214 8900 02 2005 GB EN For the installer Servicing manual Gas condensing boiler Buderus 500 24 S Buderus 500 24 C Buderus 500 28 C CTL Boulter Buderus Please read thoroughly before attempting fault diagnosis C 4 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 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 2 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 1 General 20 ouster wea oed Meee an 4 2 Servicing manual user guide 10 3 Operation 4426 vadee cohen te i 11 A PFPUNCHON 2 csice 3 aie cont ah ee ee ares es 14 5 SVMPIOMS e222 oon aorta eee ees 17 6 DIAQNOSIS s2c5 cose ite eee ace es 21 T PCUONS edie Lies eee ae eee 38 8 APPENA piraino chek eee eee ee 76 9 INEX 22nd cheer bee eae Sew eee ek 77 G C Aplliance No Buderus 500 24 S 41 110 24 Buderus 500 24 C 41 110 04 Buderus 500 28 C 4
7. Carry out a visual examination where possible and use a multimeter to check the electrical resistance of the thermostat lead Check for breakages and loose contacts step 5 Is the thermostat cable in good condition Yes step 7 No gt step 6 step 6 Replace the thermostat cable box 42 step 7 Check to ensure that enough thermostatic valves are open on the radiators convectors etc step 8 Are enough thermostatic valves open on the radiators convectors etc Yes gt step 10 No step 9 step 9 Open more thermostatic valves on the radiators convectors etc box 42 step 10 Attempt to rectify the fault by temporarily replacing the room thermostat or external temperature dependent controller step 11 Has the malfunction been repaired Yes box 42 No box 41 The flow NTC sensor has detected that the current CH flow temperature is higher than the temperature entered at the control unit or that it is higher than the CH flow temperature calculated according to heating requirements or that it is higher than the CH flow temperature calculated for the purposes of hot water supply Operating code step 1 Check to ensure that the CH flow temperature at the DBA control panel is higher than that entered at the controller see box 61 step 2 Isthe CH flow temperature at the DBA control panel adjusted correctly Yes step 4 No step 3 step 3 Adjust the CH flow temperature at the DBA control pan
8. for propane 92 3 92 3 92 3 Maximum gas consumption hot water tank m h 3 02 2 43 3 02 Maximum gas consumption heating m h 2 43 2 43 2 43 Boiler efficiency 40 30 C lower value upper value full load Ao 104 104 104 104 104 104 Boiler efficiency 40 30 C lower value partial load 107 107 107 Boiler efficiency 40 30 C upper value partial load 96 3 96 3 96 3 Boiler efficiency 75 60 C lower value upper value full load Yo 95 7 86 2 95 7 86 2 95 7 86 2 Boiler efficiency 75 60 C lower value upper value partial load 94 6 85 2 94 6 85 2 94 6 85 2 Chimney loss with burner shut down standby heat loss at nominal Yo 1 2 1 2 1 2 thermal load Hot water circuit AT at residual head of 200 mbar C lt 20 lt 20 lt 20 Maximum flow temperature C 80 80 80 Permitted system pressure bar 1 0 3 0 1 0 3 0 1 0 3 0 Expansion vessel Capacity of expansion vessel 7 5 7 5 7 5 Admission pressure of expansion vessel bar 1 0 1 0 1 0 Plate heat exchanger DHW flow rate at 35 C rise min 9 4 11 7 Supply pressure of hot water bar 0 8 10 0 0 9 10 0 Adjustable DHW temperature C 40 60 40 60 Pipe connections Condensate outlet O mm 21 5 21 5 21 5 CH flow return compression fitting O mm 22 0 22 0 22 0 MCW inlet DHW outlet compression fitting mm 15 0 15 0 15 0 Gas on installation frame compression fitting O mm 22 0 22 0 22 0 Pressure relief valve mm 15 mm adapter supplied with bo
9. gt box 41 No step 15 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 31 step 15 Replace the pump see box 101 box 42 eT The contacts of the flow NTC sensor or safety sensor are broken L 7 Locking boiler fault code TINY TINS step 1 Check the flow NTC sensor and safety sensor see box 104 step 2 Are the flow NTC sensor and safety sensor functioning correctly Yes step4 No gt step 3 step 3 Replace the flow NTC sensor and safety sensor see box 116 step 4 Check the cable of the flow NTC sensor and safety sensor see box 112 step 5 Are the cables in order Yes box 41 No gt step 6 step 6 Replace the cable loom or the affected part thereof box 42 The system has detected an insufficient ionisation current during the ignition phase Blocking boiler fault code Sais The system has detected an insufficient ionisation current after four startup x x attempts TAVI Locking boiler fault code step 1 Is the heating system propane gas fired Yes step 2 No gt step 3 step 2 Ensure that no nitrogen remains in the gas tank or gas flow pipes gt step 63 You should also consult your gas utility company step 3 Check whether the gas tap is open see box 59 step 4 Isthe gas tap open Yes step6 No step 5 st
10. 44 47 63 or 70 Put the boiler into operation see box 54 and 55 Open hot water tap Adjust the hot water in the Settings menu on the DBA control panel of the boiler to 60 C see box 61 and box 14 Set the multimeter to measure AC voltage Minimum measuring range 40V AC Plug and socket connection DBA control panel conn 6 7 3 6 2 5 Check whether with operating code HL active there is a voltage of 24 V AC at the plug in contacts item 6 and item 7 Close the hot water tap Check whether with operating code HH active there is a voltage of 24 V AC at the plug in contacts item 5 and item 6 Fit the DBA control panel and place the boiler into operation see box 51 54 or 55 We reserve the right to make technical modifications DANGER OF FATAL ACCIDENT A All work on gas supply pipes and gas fitting components must be carried out by a company registered and authorised for this purpose Take the boiler out of operation and close the gas tap see box 43 44 46 or 47 Open some of the radiator valves A CAUTION The pressure gauge should be accurate to 2 decimal places X 00 Reset the digital pressure gauge to zero CAUTION J Throughout the measuring operation keep the pressure gauge in the same position horizontal or vertical in which it was reset to zero Loosen by two turns the screw on the gas connec
11. Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 57 Put the boiler into full load operation see box 54 55 or 61 If the boiler goes into heating mode within approx 3 minutes H the cause of the fault lies outside the boiler Take the boiler out of operation see box 43 or 44 Remove the bridge connection Connect the ON OFF or modulating control element to the boiler Put the boiler into operation see box 51 54 or 55 DANGER OF DAMAGE TO THE SYSTEM A Before removing the servomotor check to see if the 3 way valve is in its heating mode position and wait for the boiler display code OH to appear This prevents sudden pressure surges occurring in the heating circuit while the removal operation is taking place and the resultant accidental opening of the pressure relief valve Remove the stop spring item 1 Remove the servomotor CAUTION A As the water pressure and pipework resistance in the plumbing system can vary widely with each situation it is important to adjust correctly the DHW flow rate at the boiler Take a DHW flow rate reading see box 12 Adjust the DHW flow rate at the flow regulator for hot water To check the DHW flow rate press and hold the down arrow and read off the display in Itrs m To increase the DHW flow rate turn the flow regulator in direction To red
12. j a i Me Le 26 10 27 28 29 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 8 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C e Issued 02 2005 Item 1 Item 2 Item 3 Item 4 Item 5 Item 6 Item 7 Item 8 Item 9 Item 10 Item 11 Item 12 Item 13 Item 14 Item 15 Item 16 Item 17 Item 18 Item 19 Item 20 Item 21 Item 22 Item 23 Item 24 Item 25 Item 26 Item 27 Item 28 Item 29 lonisation electrode Glow ignitor Automatic air vent Safety sensor Clamp for heat exchanger cover Plate heat exchanger Condensate trap Flow NTC sensor DHW flow regulator Pressure gauge Concentric flue gas adaptor Fan Frame Gas Air unit Sight glass Gas valve Heat exchanger Gas supply pipe Identification plate of boiler Air silencer tube Flue gas pipe Flue gas safety temperature limiter STL Pump 15 50 Pressure relief valve discharge pipe Syphon Identification plate showing gas category Connection block DBA control panel RTH converter junction box We reserve the right to make technical modifications WARNING A DANGER OF FATAL ACCIDENT FROM EXPLOSIVE FUMES If you smell gas There is a danger of explosion No naked lights No smoking DO NOT use a naked light to detect possible leaks DO NOT operate any device that is likely to produce spa
13. step6 No gt step 8 step 6 Check to ensure that the connections of the external control unit are attached to terminal 1 and 2 of the connection block indicated by a clock inside a rectangle see box 286 and box 285 item 3 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 26 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 step 7 Is there a permanent link between terminal 1 and 2 on the volt free connecter Yes step 8 No gt step 9 step 8 Check the cable connection between the RTH converter Junction box and terminal 1 and 2 on the DBA box 42 step 9 Check the external cable connections and control devices step 10 Has the malfunction been repaired Yes box 42 No box 41 The switch optimisation program is activated This program is activated if there is more frequently than once every 10 minutes a heating water requirement from an Boulter Buderus controller or ON OFF controller signal This means that the boiler cannot be restarted until at least 10 minutes have elapsed since initial startup of the burner Operating code step 1 Check to ensure that the connections of the control device are correctly fitted at the boiler and control device step 2 Is the control device connected correctly Yes gt step 4 No step 3 step3 Connect the control device correctly gt box 42 step 4
14. 21 step 22 We reserve the right to make technical modifications Use single or multiple operation of the v and A buttons to activate and disable hot water mode Prt Ol Hot water mode to ECO Pr F Hot water mode to warm start Press the en button once WAWZ WA fit As soon as the DHW temperature in C appears on the display Bu you can read the current DHW temperature or adjust it as required See also box 18 Adjust DHW temperature No Lower lower the DHW temperature with the V button Higher increase the DHW temperature with the A button Press the m button once Pest TH Configured heating mode As soon as Pr is displayed you can verify the current heating mode of adjust it as required See also box 18 Adjust configured heating mode No Use single or multiple operation of the v and A buttons to activate and disable heating mode NZ l F TI Heating mode on Fr TIT Heating mode off 7 Xx Press the en button once HTI is displayed you can verify Ou Configure CH flow temperature in C See also box 18 As soon as the current CH flow temperature or adjust it as required Adjust CH flow temperature No Lower lower the CH flow temperature with the V button Higher increase the CH flow temperature with the A button Has at least 10 s
15. 24 C and 500 28 C Issued 02 2005 Take the boiler out of operation see box 43 44 or 47 VID A hte U R Set multimeter to measure resistance Check the electrical resistance of the flue gas STL Check the temperature of the flue gas at the test point on the flue pipe Compare the flue gas temperature reading with the measured electrical resistance see box 124 Flue gas STL Temperature Status Resistance in Q lt 105 C closed 0 gt 105 C open infinitely high Insert both plugs at the flue gas STL and fit the cover on the test point of the flue pipe Put the boiler into operation see box 51 54 or 55 We reserve the right to make technical modifications DANGER OF FATAL ACCIDENT A due to electric shock Take the boiler out of service and tip the DBA control panel forwards see box 43 44 47 or 63 Loosen the six screws and remove the rear section see box 70 Remove both plugs of the flue gas STL see box 121 ooo0oo000808000000000 T D l Set multimeter to measure resistance Check the cables of the flue gas STL for breaks The electrical resistance measured at each individual wire must be approximately 0 Q Check the cables of the flue gas STL for internal short circuits The level of electrical resistance measured between two wires chosen at random must be infinitely high Insert both plugs at the f
16. OF FATAL ACCIDENT A due to electric shock Take the boiler out of operation see box 43 44 or 47 Remove the plug of the glow ignitor see box 131 ABE MH Loosen the fixing nut of the glow ignitor item 1 Remove the mounting plate item 2 Detach the glow ignitor item 3 We reserve the right to make technical modifications A CAUTION The filament of the glow ignitor consists of sintered material and is highly breakable Fit a new glow ignitor Connect the plug of the glow ignitor Put the boiler into operation see box 51 54 or 55 Take the boiler out of operation see box 43 44 or 47 f 6p Y wad J lt i S MUS fX 7 AS A A A UON Pull out the ionisation electrode plug item 1 Use a multimeter that is specially designed to measure the ionisation current Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 53 Connect the plug of the ionisation electrode Put the boiler into operation see box 51 54 or 55 DANGER OF FATAL ACCIDENT A due to electric shock Take the boiler out of service and tip the DBA control panel forwards see box 43 44 47 or 63 Loosen the six screws and remove the rear section see box 70 Remove the plug of the ionisation electrode see box 144 Set the multimeter to measure direct current Me
17. a heating requirement or hot water requirement arises Ready for operation The boiler is in ready mode There is a current heat requirement but too much energy has been supplied Standby for operation The boiler is in ready mode There is no current heat requirement Ignition phase The gas valve is activated Startup phase The boiler starts up after activation of the mains power supply or completion of a system reset This code is displayed for a maximum of 4 minutes Operating phase The flow sensor has detected that the current CH flow temperature is higher than the temperature entered at the control unit or that it is higher than the CH flow tempera ture calculated according to heating requirements or that itis higher than the CH flow temperature calculated for the purposes of hot water supply Fault No The flow sensor or safety sensor has detected that the 1 current CH flow temperature is higher than 95 C Fault Yes The flue gas STL fume monitoring device has detected 2 a temperature higher than 105 C The flue gas STL is opened Fault No The flow sensor and safety sensor have after burner 1 startup not detected any temperature increase in the heating water or they have determined that the temperature difference between The flow sensor and safety sensor is too high Other symptoms No indication on DBA control panel display Hot water mode to warm start No or insufficient hot wa
18. and 500 28 C safety sensor flow sensor o pin 1 O O O O O O O O 8 O e O 2 pin 17 o pin 1 a O O O O 8 O O O Oo O Oo Oo O e pin 17 4 pin 4 o q SE ro d pin1 pin6 o q o o E o 4 pini DBA Low voltage High voltage RTH converter or 1 O 2 ON OFF controller 2 00 o 1 aa O hot water tank sensor o 4 OO 24VAC 500 earth 6 O 5 o 3 way valve 7 Mains 230 VAC 50 Hz V OD000000000000000 000000 i 24 VAC 0009 Turbine 2 hot water sensor 0 VAC switch contact CO0 OF O8 O OH OW mmr DBA 24V AC external 3 way valve gas valve Boulter Buderus 2 flue gas thermostat LODH ionisation electrode JP4 We reserve the right to make technical modifications 76 Mains 230 VAC 50 Hz OOD O46 O N L OO glow ignitor ooo o Oo Oo oo Oo CO OPO Ff 120 VAC P1 00 Cy Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 2
19. breaks The electrical resistance measured at each individual wire must be approximately 0 Q Check the power supply cable of the fan for internal short circuits The level of electrical resistance measured between two wires chosen at random must be infinitely high See also box 287 Insert the fan connection plug Refit the DBA control panel following the above procedure in reverse order Refit the casing and place the boiler into operation see box 51 53 54 or 55 Boulter Buderus Ltd http www boulter buderus co uk 42 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 DANGER OF FATAL ACCIDENT A due to electric shock CAUTION A To prevent damage do not insert the measuring electrodes of the multimeter too far into the holes of the plug and socket connection Take the boiler out of service and tip the DBA control panel forwards see box 43 44 or 47 or 63 Loosen the six screws and remove the rear section see box 70 ooo0oo0oo0o0000000600000 eoeooo0oo0oo0000000000 N L m y Pull out the tacho cable plug item 1 Set multimeter to measure resistance Attach the multimeter Check the tacho cable of the fan for breaks The electrical resistance measured at each individual wire must be approximately 0 Q Check the tacho cable
20. buderus co uk e mail sales boulter buderus co uk 721 489A 2219A 02 2005
21. first 600 mm NOTE Notes relating to domestic hot water The domestic hot water service must be in accordance with BS 5546 and BS 6700 The boilers are suitable for connection to most types of washing machine and dishwasher appliances When connecting to suitable showers ensure that a The 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 j CAUTION Provision must be made to accommodate the expan sion of DHW contained within the appliance where a back flow prevention device 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 We reserve the right to make technical modifications Hazard definitions DANGER A Indicates the presence of hazards that will cause severe personal injury death or substantial property damage WARNING A Indicates the presence of hazards that can cause severe personal injury death or substantial property damage A 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 i
22. installing the new pump Install the new pump Insert the power supply plug of the pump fill and vent the heating system of air and put the boiler into operation see box 57 to 60 Fit casing see box 51 Put the boiler into operation see box 54 or 55 Open the hot water tap and wait for the boiler to start up then gradually close the hot water tap to bring the CH flow temperature to over 80 C Take the boiler out of operation and remove the casing Clean the pump impeller wheel see box 43 44 or 47 Refit the top section of the pump Fill and vent the heating system see box 52 to 58 Fit casing see box 51 DANGER OF FATAL ACCIDENT A due to electric shock Take the boiler out of operation and drain the heating system see box 43 44 47 45 49 or 50 Remove the power supply plug of the pump see box 92 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 47 A ha hN Pull out the plug of the flow NTC sensor Set multimeter to measure resistance Measure the resistance of the flow NTC sensor Measure the electrical resistance of the flow NTC sensor and safety sensor l l Measure the electrical resistance of the flow NTC
23. of the fan for internal short circuits The level of electrical resistance measured between two wires chosen at random must be infinitely high Connect the tacho cable plug Refit the DBA control panel following the above procedure in reverse order Refit the casing and place the boiler into operation see box 51 53 54 or 55 We reserve the right to make technical modifications DANGER OF FATAL ACCIDENT A due to electric shock DANGER OF FATAL ACCIDENT A All work on gas pipework and gas fitting components must be carried out by a company registered and authorised for this purpose NOTE Please observe the fitting instructions supplied with the fan Take the boiler out of operation and close the gas tap see box 43 44 46 or 47 Pull out the power supply plug of the gas valve item 1 Loosen the union nut item 2 Detach the air silencer tube item 3 Pull out both fan plugs item 2 Pull out the glow ignitor plug item 3 Pull out the ionisation electrode plug item 1 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 43 Twist drawing 1 the fan in the direction of the arrow to remove drawing 2 Check to see if the fan is soiled or wet Check to see if the fan impeller has come loose at the motor spindle Loosen the three screws
24. right to make technical modifications Take the boiler out of operation and drain the heating system see box 48 to 51 Remove the servomotor of the Boulter Buderus 24V AC external 3 way valve see box 213 or 218 Remove the drive mechanism of the Boulter Buderus 24V AC external 3 way valve using the wrench supplied with the drive mechanism CAUTION A Note that water will squirt out when the drive mechanism is removed Have a bucket and a supply of dry cloths to hand Fit the new drive mechanism to the Boulter Buderus 24V AC external 3 way valve Connect the servomotor of the Boulter Buderus 24V AC external 3 way valve by following the above procedure in reverse order Fill the heating system vent it of air and place the boiler into operation see box 52 to 58 Use the letters marked on the 3 way valve to check whether the Boulter Buderus 24V AC external 3 way valve is correctly fitted A flow of storage type water heater B CH flow AB boiler flow Boulter Buderus Ltd http www boulter buderus co uk 64 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Plug in contacts Purpose Plug in contacts on DBA control of Boulter panel Buderus 24V AC external 3 way valve 5 24V AC 2 6 OV AC 3 7 6 Take the boiler out of operation and remove the DBA control panel see box 43
25. see box 221 step 46 Is the drive mechanism of the Boulter Buderus 24V AC external 3 way valve working correctly Yes box 41 No step 47 step 47 Replace the internal components of the Boulter Buderus 24V AC external 3 way valve see box 224 box 42 step 48 Check the wiring of the Boulter Buderus 24V AC external 3 way valve between the connection box or moving plug and socket connection and the DBA control panel as per box 287 On combi boiler supply hot water available but no heating operation On system boiler supply no heating operation Hot water may be available but no heating operation step 1 Check to ensure that the power supply cable to the RTH converter Junction box has been installed correctly see box 285 step 2 Is the 230V connection to the RTH converter Junction box fitted correctly Yes step 4 No step 3 step 3 Correctly attach the switch live to terminal 1 and Neutral to terminal 2 on the 230V connector see box 285 step 4 Disconnect black leads from terminals 1 amp 2 on the back of the DBA and test for continuity between the two box 42 leads No continuity check S L and N connections are made correctly and that there is 230v between the two Replace RTH converter Junction box Continuity reconnect the cables to terminals 1 amp 2 and check the connections between the terminals and the DBA step 5 Is the volt free connection to the RTH converter Junction box fitted correctly Yes
26. storage type water heater atleast Yes step 28 5 C below the temperature set at the DBA control panel No gt step 21 step21 Is there a current heat requirement from the room temperature controller Yes step 46 No step 22 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 14 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 step 22 step 23 step 24 step 25 step 26 step 27 step 28 step 29 step 30 step 31 step 32 step 33 step 34 step 35 step 36 step 37 step 38 step 39 step 40 step 41 step 42 step 43 step 44 step 45 step 46 step 47 step 48 We reserve the right to make technical modifications Is the current CH flow temperature lower than 7 C frost protection No The pump is run for 10 seconds in order to prevent it from seizing up Have 10 seconds elapsed Yes No Is the plate heat exchanger triggered and or is the temperature in the external storage type water heater atleast Yes 5 C below the temperature set at the DBA control panel No Is there a current heat requirement from the room temperature controller Yes No Is the current CH flow temperature lower than 7 C frost protection Yes No The symbol Ol or or for hot water mode on the DBA control panel display lights up
27. with fault The error code which is now displayed can be found in box 20 Deal with the fault Operating phase step11 OH Operating code See also box 20 The boiler is ready for operation No current heat requirement step12 Start of pump over run time via the heating system The pump over run time via the heating system factory adjusted to 5 minutes via the external reservoir set to 30 40 seconds via the plate heat exchanger ECO set to 30 40 seconds via the plate heat exchanger warm start set to 30 seconds after service mode 1 minute step13 Has the pump over run time expired Yes step 18 No step 14 step14 Is the boiler set to warm start for hot water and or is an external storage type water heater connected Yes step 15 No step 16 step15 Isthe plate heat exchanger triggered and or is the temperature in the external storage type water heater atleast Yes step 28 5 C below the temperature set at the DBA control panel No gt step 16 step16 Is there a current heat requirement from the room temperature controller Yes step 46 No step 19 step17 Is the current CH flow temperature lower than 7 C frost protection Yes step 62 No gt step 18 step18 The pump stops step19 Has the pump been out of use for more than 24 hours Yes step 23 No step 20 step20 Is the plate heat exchanger triggered and or is the temperature in the external
28. 0 OFF see box 43 Remove casing see box 47 ape 7 Il Sw G IRS Sa Wi Nee double ZA JE Aire B E check s a H au Baily valve filling loop a Y E DHW Loosen by one turn the sealing cap on the automatic air cold return vent located on the top left hand part of the boiler Connect filling loop accessory see box 50 item 6 Open both stop valves Fill the system to a pressure of approx 1 5 bar Shut both stop valves Disconnect the filling loop Vent all radiators from air starting with the lowest radiator and working your way up to the highest point Check the pressure after venting If the pressure has dropped under 1 0 bar then top up the system as described previously Disconnect the filling loop and cap off yl d Key to terms 1 CH flow 2 DHW outlet combination boilers only 3 Gas connection 4 MCW inlet combination boilers only 5 CH return Connect the hose item 6 to the drain cock of the boiler Open the filling and draining cock and drain the heating system see box 53 Turn the mains switch to ON Fit the casing and use the radiator key to turn the casing lock to closed We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C
29. 00 24 C and 500 28 C e Issued 02 2005 No indication on DBA control panel display step 1 Check to ensure that the power supply cable to the mains switch box has been installed correctly step 2 Is the power supply cable to the mains switch box correctly installed Yes step4 No step 3 step 3 _ Install the power supply cable correctly see box 54 box 42 step 4 Check to ensure that the operating switch on the boiler DBA control panel is set to position 1 as per box 55 step 5 Is the operating switch on the boiler DBA control panel set to I ON Yes step 7 No gt step 6 step 6 Turn the operating switch on the DBA control panel of the boiler to position 1 ON see box 55 box 42 step 7 Check to the ensure that there is a 230V AC power supply at the mains switch step 8 Is there a 230V AC supply at the mains switch Yes step 10 No step 9 step 9 Deal with any problem in the electrical system box 42 step 10 Measure the resistance of the 230V AC power supply cable step 11 Is the resistance of the 230V AC power supply cable within the specified limits Yes step 22 No step 21 step 12 Replace the cable loom or the affected part thereof box 42 step 13 Use a multimeter to check the fuse on the inside of the DBA control panel see box 62 to 65 step 14 Is the fuse working correctly Yes box 41 No step 15 step 15 Replace fuse see box 62 s
30. 00 eee box 275 Replace the pump 0 00 c cece eee ete e enn nnes box 101 Replace the sight glass 2 0 cee eee eee box 253 Replace clean condensate trap and syphon box 256 Replace clean the heat exchanger box 259 S SHULING OOW 2sen5e2areiecdeosbe ie e i e e ENEA box 43 T Technical specifications ccc eee box 5 V Vent the gas flow pipe 0 ccc ee eee eee box 239 W Wining diagram seg adeir oredr a riean i eedas pews ebaeeaee box 287 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Tf We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk a 78 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk D et Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C e Issued 02 2005 79 Boulter Buderus Boulter Buderus Ltd Magnet House 30 Whitehouse Road lpswich Suffolk IP1 5JA Telephone 0044 0 1473 241555 Fax 0044 0 1473 241321 Sales Boilers 0044 0 1473 243780 Customer Services gas 0044 0 870 421 5933 Technical Product Support gas 0044 0 870 421 5944 http www boulter
31. 02 2005 Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No step 22 step 21 gt box 42 gt box 41 step 24 gt box 42 gt step 28 step 27 box 42 step 31 gt step 30 gt step 34 gt step 32 gt step 36 gt step 63 gt step 39 gt step 57 gt step 69 gt step 38 box 42 step 42 step 41 box 42 step 44 gt step 45 box 42 gt step 48 step 47 box 42 Boulter Buderus Ltd http www boulter buderus co uk 23 step 48 Check the standing and working gas pressures see box 230 step 49 Are the standing and working pressures correct Yes step 51 No gt step 50 step 50 If the standing and working gas input pressures are not detected consult your gas utility company box 42 step 51 Check the gas air ratio see box 233 step 52 Is the gas air ratio correct Yes step 54 No gt step 53 step 53 Adjust the gas air ratio see box 233 box 42 step 54 Check the plate heat exchanger or the external hot water cylinder for furring step 55 Is the plate heat exchanger or hot water cylinder furred up Yes step 56 No gt box 41 step 56 Decalcify the plate heat exchanger and or hot water cylinder see from box 269 box 42 step 57 3 way valve Che
32. 1 Flow NTC sensor 2 Safety sensor Set multimeter to measure resistance Check the cables of the flow NTC sensor and safety DANGER OF FATAL ACCIDENT sensor for breaks The electrical resistance measured at A due to electric shock each individual wire must be approximately 0 Q CAUTION Check the cables of the flow NTC sensor and safety J To prevent damage do not insert the measuring sensor for internal short circuits The level of electrical electrodes of the multimeter too far into the holes of the resistance measured between two wires must be plug and socket connection infinitely high Take the boiler out of service and tip the DBA control panel Measure the electrical resistance of the flow NTC sensor forwards see box 43 44 47 or 63 and check the earth ground connection of the safety Loosen the six screws and remove the rear section sensor This must be infinitely high see box 70 Pull out the plugs of the flow NTC sensor and safety sensor see box 105 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 49 Room Controlle Hot water tank sensor 24 VAC 3 way valve 6 7 A CAUTION Note that water will squirt out when the sensor is removed Have a bucket and a supply of d
33. 1 110 03 Other manuals available for this boiler are user manual installation and maintenance instructions wall spacing frame instructions We reserve the right to make technical modifications These service instructions apply to Boulter Buderus wall mounted condensing gas boilers 500 24 S 500 24 C and 500 28 C Model C43 x C33 C530 C730 Type GB IE Iloy3p 20 mbar 37 mbar Power rating 230 VAC 50 Hz IP X4D Fuse rating 1 25 Ampere slow blow The boiler unit consists of the following components 500 Gas condensing boiler 28 Maximum output is 28 kW C Combination boiler with integrated hot water supply S System boiler Important general instructions for use Only use the boiler in accordance with its designated use and the service 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 maintenance and service 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 P
34. 2005 Remove the fan see box 76 to box 79 Check to see if the non return valve item 5 and 6 if fitted is soiled or defective Loosen the upper nut item 2 Loosen the two lower nuts item 1 Turn the securing plate 180 counterclockwise item 3 Remove the fan part item 7 Bend the silicon seal item 4 Remove the plastic valvehousing item 5 Check the silicon valve item 6 and replace when necessary After checking refit all components in reverse order Make sure that the cam item A of the silicon valve is mounted in the correct manner A First tighten the upper nut item 2 then tighten the lower two nuts item 1 Refit all other components in reverse order then put the boiler into service see box 51 54 or 55 Take the boiler out of operation see box 43 44 or 47 Remove the air intake duct see box 77 Remove the Venturi see box 81 item 1 We reserve the right to make technical modifications Check the article number of the Venturi against those listed in the table in box 5 Check to ensure that the correct Venturi has been fitted This is done by comparing the article numbers listed against the number on the Venturi item 1 see box 5 Check the Venturi for soiling Refit the Venturi and fan by following the above procedure in reverse order Refit the air silencer tube Refit the casing and place the boiler into operation see
35. 4 S 500 24 C and 500 28 C Issued 02 2005 C 2 ole a y ORC Turn the mains switch on the DBA control panel of the boiler to position 0 OFF see box 43 as step 3 Turn the mains switch on the DBA control panel of the boiler to position 1 ON see box 55 a The fault is now rectified Your Buderus 500 should be working now We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk a ae Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C e Issued 02 2005 37 box 43 Shutting down Turn the mains switch on the boiler to position 0 OFF item 1 Turn the mains switch to OFP Use a radiator key to turn the casing lock to open then remove casing box 48 Draining the system Take the boiler out of operation see box 43 44 45 46 or 47 Co OO Co OT Key to terms see box 4 1 CH flow 2 DHW outlet combination boilers only 3 Gas connection 4 MCW inlet combination boilers only 5 CH return Close the servicing valves item 6 if fitted We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk ae Og NE SEE EE 38 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 box 52 Filling the system and venting it of air Turn the operating switch on the boiler to position
36. 4 S 500 24 C and 500 28 C Issued 02 2005 A Adjust the output flow rate applies to combination DOIGIS ODIY 22 062 22 nene e e a E ata ha Bak weed box 180 C Check and replace the ionisation electrode box 155 Check fan activation 230V AC eee ee box 66 Check fan power supply cable 230 VAC box 69 Check fan tacho cable 0 ccc teens box 73 Check fan and or replace naaa cece eee ene box 76 Check gas valve electrical resistance of power supply cable aeons Suede rs ere cachet etch ea a A box 167 Check the Boulter Buderus 24V AC external 3 way valve activation 1 0 cee eee box 212 Check the Boulter Buderus 24V AC external 3 way valve activation 2 0 0 ccc tenes box 228 Check the Boulter Buderus 24V AC external 3 way valve drive mechanism 0000 e cence box 221 Check the Boulter Buderus 24V AC external 3 way valve installation 0 ccc eee ene box 227 Check the Boulter Buderus 24V AC external 3 way valve movement of the servomotor box 211 Check the Boulter Buderus 24V AC external 3 way valve power supply cable 0000 eee box 220 Check the by pass valve 0 c cece eee nes box 14 Check the flow safety and DHW temperature sensors CADIOS turk dor Se On ae oe ab Eek Ree She es box 112 Check the flow safety and DHW temperature sensors applies to extern
37. 9 step 40 Does the Boulter Buderus 24V AC external three way valve actuate correctly Yes step 41 No step 42 step 41 Replace the servomotor of the Boulter Buderus 24V AC external three way valve see box 218 box 43 step 42 Check the wiring of the Boulter Buderus 24V AC external three way valve see box 221 step 43 Is the wiring of the Boulter Buderus 24V AC external three way valve in correct condition Yes step 47 No step 44 step 44 Replace the wiring of the Boulter Buderus 24V AC external three way valve gt box 43 step 45 Check the drive mechanism of the Boulter Buderus 24V AC external three way valve see box 222 step 46 Is the drive mechanism of the Boulter Buderus 24V AC external three way valve working correctly Yes box 42 No step 47 step 47 Replace the internal components of the Boulter Buderus 24V AC external three way valve see box 225 gt box 43 step 48 Check the wiring of the Boulter Buderus 24V AC external three way valve between the connection box or moving plug and socket connection and the control panel as per box 288 On combi boiler supply hot water available but no heating operation On system boiler supply no heating operation Hot water may be available but no heating operation step 1 Check to ensure that the power supply cable to the RTH converter Junction box has been installed correctly see box 286 step 2 Is the 230V connection to the RTH converter Ju
38. Boulter Buderus Ltd http www boulter buderus co uk 29 ole E lt Is the mains voltage sufficient es gt step 15 Z O step 14 The cause of the fault lies in the electrical system box 42 Replace fan see box 76 Has the malfunction been repaired Yes box 42 No box 41 box 30 No current of air after a certain time Locking boiler fault code Attempt to rectify the fault by temporarily replacing the fan see box 76 Has the malfunction been repaired Yes box 42 No box 41 The fan runs too slowly or too fast Locking boiler fault code Check the plug and socket connection of the fan tacho cable This is the narrow plug see box 78 item 2 Is the plug and socket connection in full working order es step 4 No step 3 Reconnect the plug and socket connection see box 78 item 2 box 42 Check tacho cable of fan see box 73 Is the tacho cable in full working order es step7 No step 6 Replace the tacho cable box 42 step 7 Check to ensure that the mains voltage at the earthed grounded plug is between 195V and 253V AC step 8 Isthe mains voltage sufficient es step 10 No step 9 The cause of the fault lies in the electrical system box 42 Check to see if there is a restriction in the fan burner heat exchanger or flue gas system Is there a restriction es step 12 Z O s
39. Issued 02 2005 39 Vent the pump CAUTION A Correct venting of the pump will help ensure that it runs for its specified service life The sliding bearing which is located behind the vent screw is lubricated with heating system water Once the heating system has been completely purged of air check the pressure at the analogue pressure gauge If the pressure is lower than 1 0 bar the boiler should be topped up as described above Close the water tap In the case of system boilers 1 Close the filling loop of the boiler see box 50 item 2 Turn the operating switch on the boiler to position 1 Remove the hose ON item 1 Fit the sealing cap to the filling and draining cock l In the case of combination boilers Fill the heating system to a pressure of approximately 1 5 bar then close the filling loop Close the filling loop Vent all the air vent points in the heating system working Remove the hose from bottom to top in order to allow all air in the heating system to escape Fit casing see box 51 Configure target adjustments using the Settings menu on the DBA control panel of the boiler see box 61 Loosen by two turns the vent screw item 1 on the front of the pump A CAUTION Water will also squirt out Open the gas tap item 2 Put the boiler into operation see box 53 54 o
40. O Plate heat exchanger warm start After service mode We reserve the right to make technical modifications Unit h g s g s C C C C ppm mg kWh ppm mg kWh Pa Vac kg kg 500 24 S 500 24 C 500 28 C 10 6 4 3 77 55 60 35 9 2 10 3 lt 30 lt 22 75 230 50 Hz IP X4D 4 88 110 780 x 460 x 330 780 x 460 x 330 780 x 460 x 330 30 31 31 33 34 34 Iloy43p 20 mbar 37 mbar natural gas H and propane P 4 45 4 45 4 45 3 45 3 45 3 45 423 072A 423 072A 423 072A Delivered Sogo for operation adjusted to Wobbe index 14 1 kWh m with reference to 15 C 1013 mbar applicable to Wobbe index range 11 3 to 15 2 kWh m Markings on gas classification plate Configured category G 20 2E 20 mbar Deemed suitable for use with propane after inspection by a registered Corgi heating engineer Markings on gas classification plate Configured category 3P G 31_30 50 mbar UP 15 50 5 minutes 5 minutes 5 minutes 30 40 seconds 30 40 seconds 30 40 seconds 30 seconds 30 seconds 1 minute 1 minute 1 minute Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 7 box 6 Overview Buderus 500 11 12 1 13 2 14 O m o lt a uderus 8 ED i P PN LQ a Sai j AD i Pn r
41. O4 The gas valve is closed and the burner is shut down step54 The symbol 6 goes out step55 The fan stops step56 Is the CH flow temperature 6 C lower than the target setting Yes step 47 No gt step 53 step57 The symbol TH goes out step58 OH The gas valve is closed and the burner is shut down step59 The symbol 6 goes out step60 Start of pump over run time via the heating system The pump over run time via the heating system is 5 minutes Start of the post purge phase of fan 10 seconds step61 The fan stops step 13 step62 The symbol T lights up step63 OL The fan starts up The pump is started up The glow ignitor is activated for seven seconds step 64 LiL_ Ignition phase The gas valve is opened step65 Does the ionisation current exceed 1 4 pA microamperes within 5 seconds Yes step 66 No box 36 step 66 H_ The symbol 6 lights up The boiler is in heating mode step67 Is the current CH flow temperature higher than 15 C Yes step 68 No step 67 step68 The symbol T goes out step69 OH The gas valve is closed The burner is shut down The symbol 6 goes out step70 Start of pump over run time via the heating system The pump over run time via the heating system is 5 minutes Start of the post purge phase of fan 10 seconds step71 The fan stops step 13 We re
42. TC sensor and safety sensor is excessive Blocking boiler fault code The flow NTC sensor has detected a temperature increase in the heating system water of more than 5 C sec Blocking boiler fault code aa The flow NTC sensor and safety sensor have detected a CH flow temperature of over x mr 105 C HAVIS Locking boiler fault code Short circuit between flow NTC sensor or safety sensor AAM E Locking boiler fault code TIAV TINS step 1 Are the servicing valves open Yes step3 No step 2 step 2 Open the servicing valves see box 53 step 3 Isthe pressure in the heating system at least 1 bar Yes step5 No step 4 step 4 Fill and vent the heating system see box 52 step 5 Are enough thermostatic valves open on the radiators convectors etc Yes step7 No gt step 6 step 6 Open more thermostatic valves on the radiators convectors etc box 42 step 7 Check the flow NTC sensor and safety sensor see box 104 step 8 Are the flow NTC sensor and safety sensor in order Yes step 10 No step 9 step 9 Replace the flow NTC sensor or safety sensor see box 116 box 42 step 10 Check the cable between the flow NTC sensor or safety sensor for short circuits see box 112 step 11 Check the pump see box 89 to 100 step 12 Is the pump working correctly Yes step 14 No gt step 13 step 13 Replace the pump see box 101 step 14 Check to ensure that the internal by pass v
43. acity Is the incoming gas supply of sufficient capacity Upgrade internal pipe work Consult your gas utility company accordingly Measure the gas air ratio during the startup phase see box 233 Is the gas air ratio correctly adjusted Adjust the gas air ratio see box 233 Check to ensure that the correct gas injector see box 83 item 1 and the correct Venturi see box 87 item 1 are fitted as specified See also box 5 Is the correct gas injector and Venturi fitted Fit the correct gas injector and or Venturi see box 5 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No box 41 gt step 20 gt step 62 step 24 gt step 23 gt step 62 gt step 26 gt step 23 gt step 41 gt step 28 step 31 gt step 30 gt step 62 gt step 33 gt step 34 gt step 62 box 41 gt step 36 gt step 62 gt step 40 gt step 39 gt step 62 gt step 62 step 44 gt step 43 gt step 62 step 47 gt step 46 gt step 62 Boulter Buderus Ltd http www boulter buderus co uk 33 step 47 The following components must be checked for soiling damage and or correct installation condensate trap and
44. al cylinder only 06 box 104 Check the flue gas STL es box 120 Check the flue gas STL cable 000 eae box 126 Check the gas valve activation 0 00 cee eae box 164 Check the gas valve internal electrical resistance box 171 Check the gas valve power supply plug box 161 Check the glow ignitor activation box 130 Check the glow ignitor power supply cable box 137 Check the glow ignitor resistance box 134 Check the internal 3 way valve activation box 185 Check the internal 3 way valve drive mechanism box 195 Check the internal 3 way valve movement of the servomotor box 181 Check the internal 3 way valve power supply cable box 191 Check the ionisation circuit earth ground lead box 160 Check the ionisation electrode cable box 151 Check the ionisation electrode short circuits box 148 Check the pressure control valve 00 0c eee eaes box 85 Check the pump activation 0 000 c eee eee eee box 91 Check the pump mechanical restrictions box 89 Check the pump power supply cable box 95 Check the pump soiling 00 0 e eee neces box 97 Check replace fuses 1 0 0 ccc cece teen teens box 62 D Draining th
45. alve in the boiler or the external overflow valve in the heating system are working correctly Possible to adjust external overflow valve to max 25 kPa if fitted step 15 Is the by pass valve working correctly Yes box 41 No step 14 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 28 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 step 16 Replace the by pass valve The flue gas STL fume monitoring device has detected a temperature higher than 105 C The flue gas STL is open Locking boiler fault code step 1 Check to ensure that the restrictor baffle has been installed as per box 261 item 1 step 2 Has the restrictor baffle been fitted Yes No step 3 Fit the restrictor baffle see box 261 item 1 step 4 Check the entire system of flue gas pipe for restrictions step 5 Is the entire system of flue gas pipe in full working order Yes No step 6 Deal with restriction step 7 Check the flue gas STL see box 120 step 8 Is the flue gas STL working correctly Yes No step9 Replace the flue gas STL see box 129 step 10 Check the wiring of the flue gas STL see box 126 step 11 Is the wiring of the flue gas STL in full working order Yes No step 12 Replace the cable loom or the affected part thereof The tacho signal from the fan has failed during the operating phase Blocking boiler
46. asuring range Microamperes pA oo eo0oo0oo0o0o0000000000 Connect the multimeter in series the ionisation circuit Put the boiler into service mode see box 54 55 or 13 Check to see if the ionisation current during service mode operating code Lo gt 5 pA micro amperes and with operating code H gt 25 pA The value is O zero or between 1 3 and 50 pA Take the boiler out of operation see box 43 or 44 Detach the multimeter Connect the plug of the ionisation electrode Turn the operating switch on the boiler to position 0 see box 55 Put the boiler into operation see box 51 54 or 55 Set the multimeter to measure resistance Take the boiler out of operation see box 43 44 or 47 Take a reading at the ionisation electrode to check whether there is a possible break in the cable of the electrode The electrical resistance of the cable must be approximately 0 Q Loosen the plug in connection of the ionisation electrode see box 144 Set multimeter to measure resistance Take a reading at the electrode to check whether there is Take an earth ground reading check whether there is a a possible short circuit between the ionisation electrode possible short circuit between the cable of the ionisation and earth ground The electrical resistance between the electr
47. box 51 53 54 or 55 Remove casing see box 47 Remove the vent screw on the front of the pump see box 57 A CAUTION Note that water will squirt out when the vent screw is removed Have a bucket and a supply of dry cloths to hand Put the electrical system of the boiler into operation see box 54 and 55 Check to see if the pump is running The pump may become mechanically blocked if the heating system has been out of use for an extended period Insert a screwdriver and attempt to make the pump turn Use the screwdriver to turn the fan wheel in the direction of rotation shown on the identification plate of the pump Refit the vent screw to the pump Fit casing see box 51 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 45 DANGER OF FATAL ACCIDENT A due to electric shock CAUTION A To prevent damage do not insert the measuring electrodes of the multimeter too far into the holes of the plug and socket connection A CAUTION Close gas valve during pump test Take the boiler out of operation see box 43 44 or 47 Set the multimeter to measure AC voltage Minimum measuring range 250V AC Put the boiler into operation see box 54 and 55 Carry out a multimeter check to verify whether 230V AC is present at both outer contacts L and N of the power supply plug of the p
48. cations Check the plug and socket connection on the EEPROM KIM To Boiler KOKO Remove the casing lock and lower the DBA Remove the cover from the RTH converter Junction box item 1 Run the 230V power supply cable through the cable pipework Connect the 230V cable to item 1 The switch live should be connected to terminal 1 and the Neutral to terminal 2 of the 230V connection item 2 Boulter Buderus Ltd http www boulter buderus co uk 74 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 ee box 286 Check the junction box 0 Volt room temperature connection Remove the casing lock and lower the DBA see box 285 Remove the cover from the RTH converter junction box see box 285 item 1 Run the volt free power supply cable through the cable pipework Connect the volt free cable at position 1 and 2 of the volt free connection see box 285 item 3 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 75 JP3 JP4 JP2 JP1 L g Jajiog OL EJ 2 4 Boulter Buderus controller 1 only for Buderus 500 24 S remove the link at the connection of the hot water tank sensor 2 only for Buderus 500 24 C
49. ck the startup of the servomotor of the internal 3 way valve see box 181 and box 185 step 58 Does the servomotor of the internal 3 way valve start up correctly Yes step 59 No gt step 60 step 59 Replace the servomotor of the internal 3 way valve see box 190 box 42 step 60 Check the wiring of the internal 3 way valve see box 191 step 61 Is the cable correctly connected and free of damage Yes box 41 No step 62 step 62 Replace the cable loom or the affected part thereof box 42 step 63 Check to ensure that the Boulter Buderus 24V AC external 3 way valve has actuated correctly see box 212 and box 228 parts 1 and 2 step 64 Does the Boulter Buderus 24V AC external 3 way valve actuate correctly Yes step 65 No gt step 66 step 65 Replace the servomotor of the Boulter Buderus 24V AC external 3 way valve see box 217 box 42 step 66 Check the wiring of the Boulter Buderus 24V AC external 3 way valve see box 220 step 67 Is the wiring of the Boulter Buderus 24V AC external 3 way valve in correct condition Yes step 71 No gt step 68 step 68 Replace the wiring of the Boulter Buderus 24V AC external 3 way valve box 42 step 69 Check the drive mechanism of the Boulter Buderus 24V AC external 3 way valve see box 221 step 70 Is the drive mechanism of the Boulter Buderus 24V AC external 3 way valve working correctly Yes step 42 No step 71 step 71 Replace the driv
50. ction product to check the gas connection pressure measurement nipple for leaks Use an authorised foam type leak detection product for this purpose Fit the casing and place the boiler into operation see box 51 54 or 55 DANGER OF FATAL ACCIDENT A All work on gas pipework and gas fitting components must be carried out by a company registered and authorised for this purpose Take the boiler out of operation and close the gas tap see box 43 44 46 or 47 Open some of the radiator valves We reserve the right to make technical modifications Reset the digital pressure gauge to zero CAUTION A Throughout the measuring operation keep the pressure gauge in the same position horizontal or vertical in which it was reset to zero Loosen by two turns the screw on the burner pressure measurement nipple item 1 Connect the pressure gauge to the burner pressure measurement nipple item 2 Open the gas cock and place the boiler into service mode see box 59 54 55 or 13 Press the service button once 25 Capacity during service mode is at L max heating circuit capacity D Wait a short time for the boiler to be adjusted downwards 15 10 5 0 5 Pa 0 15 0 10 0 05 0 00 0 05 mbar C D Key to terms A correct B false C turn anticlockwise D turn clockwise Check the gas air ratio during se
51. dicates which subsection operating step you should proceed cross reference Section Cross reference to subsection or operating step Subsection box heck the actuation of the servomotor of the internal three way valve see box 186 step 29 Does the servomotor of the internal three way valve start up correctly gt step 30 gt step 31 step 30 Replace the servomotor of the internal three way valve see box 191 box 43 step 31 Check the power supply cable of the internal three way valve see box 192 step 32 _ Is the power supply cable of the internal three way valve in good condition Yes box 42 No step 33 step 33 Replace the cable loom or the affected part thereof box 43 step 34 Check the movement of the servomotor of the Boulter Buderus 24V AC external three way valve see box 212 step 35 Does the servomotor of the Boulter Buderus 24V AC external three way valve operate correctly Yes step 36 No step 39 step 36 Check to ensure that the the Boulter Buderus 24V AC external three way valve has been fitted correctly see box 228 step 37 Has the Boulter Buderus 24V AC external three way valve been fitted correctly Yes step 45 No step 38 step 38 Install the Boulter Buderus 24V AC external three way valve correctly see box 228 box 43 step 39 Check to ensure that the Boulter Buderus 24V AC external three way valve is actuated correctly see box 213 and box 22
52. dicator g y or e light up Yes step 25 No step 19 step 19 Check the turbine flow meter see box 104 or DWH temperature sensor of any external storage type water heater that might be fitted We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 22 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 step 20 step 21 step 22 step 23 step 24 step 25 step 26 step 27 step 28 step 29 step 30 step 31 step 32 step 33 step 34 step 35 step 36 step 37 step 38 step 39 step 40 step 41 step 42 step 43 step 44 step 45 step 46 step 47 We reserve the right to make technical modifications Is the turbine flow meter working correctly along with DHW temperature sensor of any external storage type water that might be fitted Replace the turbine flow meter or DHW temperature sensor of any external storage type water heater that might be fitted Check the cable of the turbine flow meter see box 112 or cable of the DHW temperature sensor of any external storage type water heater that might be fitted Is the cable correctly connected and free of damage Replace the cable loom or the affected part thereof Check to ensure that the boiler starts up to supply hot water see box 15 Does the boiler start up Interpret current display codes box 20 and deal with fault Check to ensure that t
53. e mechanism of the Boulter Buderus 24V AC external 3 way valve see box 221 step 72 Check the wiring of the Boulter Buderus 24V AC external 3 way valve between the connection box or moving plug and socket connection and the motor of the Boulter Buderus 24V AC external 3 way valve see box 287 step 73 Is the wiring in order Yes box 41 No step 74 step 74 Replace the cable loom or the affected part thereof box 42 On combi boilers hot water available but no heating operation On system boilers no heating operation Hot water may be available but no heating operation step 1 Check to ensure that the power supply cable to the mains switch box has been installed correctly see box 54 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 24 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 step 2 Check to ensure that the preset room temperature or heating configuration of the Boulter Buderus controls or ON OFF controller has been adjusted to a high enough setting See operating instructions step 3 Isthe preset room temperature or heating configuration of the Boulter Buderus controls or ON OFF controller Yes step5 adjusted to a high enough setting No step 4 step 4 Adjust the preset room temperature controller or heating configuration of the Boulter Buderus controls or box 42 ON OFF controller to a highe
54. e system 0 00 2 epee nes box 48 F Filling the system and venting it of air box 52 Witla StartUp eisrean ee a sy aue tare ease nutte ate a box 59 Internal 3 way valve replace the servomotor box 190 M Measure and adjust the gas air ratio 00000 box 233 Measure the gas input pressure static and dynamic box 230 Measure the ionisation current 00000 ee eees box 143 We reserve the right to make technical modifications R Removal of caSing 0 02 rere Ar e eee box 47 Replace plate heat exchanger 00 eee eae box 269 Replace the automatic air vent 0 cece eae box 242 Replace the Boulter Buderus 24V AC external 3 way valve drive mechanism 00 cee eee eens box 224 Replace the Boulter Buderus 24V AC external 3 way valve Servomotor 00 0 EEE A box 217 Replace the burner 0 cece eee eens box 245 Replace the DBA control panel 0 000 ae box 281 Replace the flow NTC sensor and or safety sensor box 116 Replace the flue gas STL 0 cece ee box 129 Replace the gas valve sii vest eel anata eas box 174 Replace the glow ignitor 00 c eee eee box 140 Replace the internal 3 way valve 0000 eee aee box 203 Replace the internal 3 way valve drive mechanism box 198 Replace the pressure relief valve 0
55. econds passed without a button being pressed and or was mains supply interrupted No Press the m button once Any adjustments that you have made will now be confirmed Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Yes Yes Yes Yes step 11 step 12 step 15 gt step 16 step 19 gt step 20 step 22 step 21 step 1 Boulter Buderus Ltd http www boulter buderus co uk 13 Start phase step 1 Turn the mains switch to ON step 2 Turn the operating switch on the DBA control panel of the boiler to position 1 ON see also box 11 step 3 Is a 3 way valve fitted Yes step 4 No gt step 6 step 4 Is the 3 way valve set to hot water mode Yes step5 No gt step 6 step 5 The Boulter Buderus 24V AC external 3 way valve is turned to heating mode in 7 5 seconds while an internal 3 way valve is turned to heating mode in 2 seconds step 6 OD The display on the DBA control panel of the boiler is checked maximum of one second step 7 24 Current CH flow temperature in C See also box 20 step 8 LiL The boiler begins to warm up Start of pre purge phase The fan runs for 15 seconds at about 60 of maximum speed Checking phase step 9 Has the pre purge been completed correctly Yes step 11 No gt step 10 step10 Deal
56. el to a higher setting see box 61 box 42 step 4 Check to ensure that enough thermostatic valves are open on the radiators convectors etc step 5 Are enough thermostatic valves open on the radiators convectors etc Yes step 7 No gt step 6 step 6 Open more thermostatic valves on the radiators convectors etc gt box 42 step 7 Check to see if a hot tap or taps have been opened on brief consecutive occasions We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 27 step 8 Have a hot water tap or taps been opened briefly and consectutively on several occasions Yes step9 No box 15 step 9 Inform the user that the fault has been caused by opening hot taps on many brief consecutive occasions box 42 step 10 Check the electrical resistance of the DHW temperature sensor see box 104 step 11 Is the electrical resistance of the DHW temperature sensor in order Yes box 41 No step 12 step 12 Replace the DHW temperature sensor The flow NTC sensor or safety sensor has detected that the current CH flow temperature is higher than 95 C Blocking boiler fault code The flow NTC sensor and safety sensor have not after burner startup detected any temperature increase in the heating system water or the temperature difference between the flow N
57. electrode see box 37 Close the gas cock see box 46 Remove the digital pressure gauge and close the burner pressure connection nipple Open the gas cock see box 59 and run the boiler at full load once more see box 59 or box 13 Deactivate heat requirement see box 13 and check to see if the gas valve is still powered after the heat requirement indicator goes out see box 165 item 1 and 2 Is the gas valve still powered Yes box 41 No gt step 6 Replace the gas valve see box 174 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 35 ice The power supply was shut off during operation Eig Locking boiler fault code TINY TINS step 1 Reset the boiler with button 6 or by turning the operating switch to OFF and then ON again step 2 Is the error code still displayed Yes step3 No gt box 42 step 3 Interpret the fault code now displayed in box 20 and deal with the malfunction The contacts of the gas valve have been broken WYANT 1 Locking boiler fault code TINY TINS step 1 Check the plug and socket connection of the gas valve see box 161 step 2 Is the plug and socket connection in full working order Yes step4 No gt step 3 step 3 Reconnect the plug and socket connection see box 161 box 42 step 4 Measure the cable between the gas valve and DBA control panel see bo
58. ep 5 Open the gas tap see box 59 gt step 63 step 6 Check the static and working gas pressure see box 230 step 7 Are the static and working gas pressures correct Yes step 14 No gt step 8 step 8 Check to see if there is a restriction in the pipework between the gas tap and gas valve step 9 Is there a restriction Yes step 10 No step 11 step 10 Deal with restriction step 63 step 11 Check for restrictions in the remaining section of the gas flow pipe step 12 Is there a restriction Yes step 13 No gt step 38 step 13 Deal with restriction step 63 step 14 Has the gas flow pipe been bled of air Yes step 16 No step 15 step 15 Vent the gas flow pipe of air see box 239 step 62 step 16 Check to see if the glow ignitor activates with the operating code OL see box 130 step 17 Does the glow ignitor activate with the operating code UL Yes step 21 No gt step 18 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 32 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 step 18 step 19 step 20 step 21 step 22 step 23 step 24 step 25 step 26 step 27 step 28 step 29 step 30 step 31 step 32 step 33 step 34 step 35 step 36 step 37 step 38 step 39 step 40 step 41 step 42 step 43 step 44 s
59. f this malfunction the pump is started up and remains in continuous operation in order to minimise the possibility of the heating system freezing up We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 19 Er Symptoms box 20 Display codes Display indication Reset required Other symptoms Diagnosis Bo No heating operation and no hot water Fault box 41 Short circuit in the gas valve Fault No heating operation and no hot water The contacts of the KIM EEPROM on the DBA control No heating operation and no hot water box 41 panel circuit board may be loose or short circuited The DBA control panel is defective Fault Applies only to a system blocking error flashing Reset is carried out display code This code appears after the reset button Oi is pressed for 5 seconds 1 This error code may deactivate again automatically after a specific time without reset Heating and hot water are now available once more 2 In the event of this malfunction the pump is started up and remains in continuous operation in order to minimise the possibility of the heating system freezing up We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 20 Servicing manual Gas condensing boiler Buderus 500 24 S 5
60. fault code The tacho signal from the fan is not present during the pre operative or operating phase Locking boiler fault code step 1 Check to ensure that both plug and socket connections of the fan are correctly fitted see box 246 item 1 step 2 Are the plug and socket connections fitted correctly Yes No step 3 Reconnect the plug and socket connection of the fan step 4 Check fan 230V AC supply see box 66 or box 287 step 5 Does activation take place correctly Yes No step 6 Check the power supply cable of the fan 230V AC see box 69 step 7 Is the power supply cable of the fan in full working order Yes No step 8 Replace the cable loom or the affected part thereof step 9 Check tacho cable of fan see box 73 step 10 Is the tacho cable in full working order Yes No step 11 Replace the cable loom or the affected part thereof step 12 Check to ensure that the mains voltage at the earthed grounded plug is between 195V and 253V AC We reserve the right to make technical modifications Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 box 42 gt step 4 step 3 box 42 step 7 gt step 6 box 42 gt step 10 step 9 gt box 41 step 12 box 42 step 4 step 3 box 42 step 9 gt step 6 box 41 gt step 8 box 42 step 12 step 11 box 42
61. he tap flow rate is correctly adjusted see box 180 Is the tap flow rate correctly adjusted Correctly adjust the tap flow rate see box 180 Is an internal 3 way valve fitted Check the movement of the servomotor of the Boulter Buderus 24V AC external 3 way valve see box 211 Does the servomotor of the Boulter Buderus 24V AC external 3 way valve move correctly Check the movement of the servomotor of the internal 3 way valve see box 181 Does the servomotor of the internal 3 way valve move correctly Check to ensure that the the Boulter Buderus 24V AC external 3 way valve has been fitted correctly see box 227 Has the Boulter Buderus 24V AC external 3 way valve been fitted correctly Fit the Boulter Buderus 24V AC external 3 way valve in the correct way see box 227 Check the drive mechanism of the internal 3 way valve see box 195 Is the drive mechanism of the internal 3 way valve working correctly Replace the drive mechanism of the internal 3 way valve see box 198 Check the circulation for debris see box 97 Is there any debris in the pump Clean the pump see box 97 The following components must be checked for soiling and or damage combustion air inlet pipework heat exchanger flue gas pipework Are the above mentioned components clean and free of damage Clean and or replace the corresponding components Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued
62. his purpose Take the boiler out of operation and close the gas tap see box 43 44 46 or 47 Remove the power supply plug of the glow ignitor see box 131 Remove the plug of the ionisation electrode see box 144 Remove the power supply plug of the gas valve union nut and air silencer tube see box 77 Pull out both fan plugs item 1 We reserve the right to make technical modifications Turn the gas air unit clockwise by about 10 as 0 ee eel Ca 2a va p ED A Remove the gas air unit along with the burner Loosen both screws item 1 Remove the burner Boulter Buderus Ltd http www boulter buderus co uk 68 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Fit the new burner to the gas air unit Note that a new seal Install the new sight glass Use a new seal when doing so must be fitted between the burner and gas air unit Put the boiler into operation see box 51 54 or 55 Take the boiler out of operation see box 43 44 or 47 Remove the heat exchanger gas air seal Check the heat exchanger gas air seal for signs of ageing Replace the heat exchanger gas air seal if required Refit all components following the above procedure in reverse order Open
63. iler Flue gas connection Type of flue gas connection model C13 C33 x C530 C730 Flue gas pipe combustion air inlet mm 60 100 accessory We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 6 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Buderus Flue gas readings Condensate water quantity natural gas 40 30 C Exhaust fume mass flow rate Full load Part load Exhaust fume temperature full load Heating curve 75 60 C Heating curve 40 30 C Exhaust fume temperature partial load Heating curve 75 60 C Heating curve 40 30 C CO full load natural gas standard test gas G20 CO full load natural gas standard test gas G31 propane Standard emission factor NO Standard emission factor CO Flow pressure available for use Electrical specifications Mains connection voltage Electrical protection rating Electrical power consumption standby Electrical power consumption partial load Electrical power consumption full load Dimensions and weight of boiler height x width x depth Weight without casing Weight with casing Gas Category of gas as per EN 437 for GB Gas injector natural gas H G20 Gas injector propane P G31 Venturi article number Natural gas H Propane P Other items Pump Pump over run time Heating system default adjustments External cylinder Plate heat exchanger EC
64. ing electrodes of the multimeter too far into the holes of the plug and socket connection Remove the casing and place the boiler out of operation see box 47 43 or 44 Boulter Buderus Ltd http www boulter buderus co uk 41 Set the multimeter to VAC Minimum value 250 V AC Disconnect the 230V AC plug item 1 from the fan Attach the multimeter to the two outer contacts blue and brown of the fan connection plug Start system at full load see box 54 55 or 13 Check whether with operating code iL active there is a voltage of 230 V AC at the two outer contacts blue and brown of the plug Take the electrical system of the boiler out of operation see box 43 and 44 Insert the fan connection plug Refit the casing and place the boiler into operation see box 51 53 54 or 55 DANGER OF FATAL ACCIDENT A due to electric shock CAUTION A To prevent damage do not insert the measuring electrodes of the multimeter too far into the holes of the plug and socket connection Take the boiler out of service and tip the DBA control panel forwards see box 43 44 47 or 63 We reserve the right to make technical modifications Disconnect the 230V AC plug item 1 from the fan Set multimeter to measure resistance Check the power supply cable of the fan for
65. ing the service button reset button A button and v button item 2 3 5 6 and 7 and the display item 4 box 12 to 14 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 11 step 1 cH Current CH flow temperature in C See also box 20 step 2 Keep the V button pressed step 3 OO current DHW flow rate in litres per minute step 4 Continue with Normal Operation menu Yes step6 No step 5 step 5 Release the V button gt step 1 step 6 Keep the A button pressed step 7 OH Operating code See also box 20 step 4 In this case The boiler is ready for operation No current heat requirement step 1 24 Current CH flow temperature in C See also box 20 step 2 Activate service mode Yes step 3 No gt step 1 step 3 Press the button once step 4 24 As soon as the spanner symbol on the left hand side of the display and the flame appear the boiler will run for 30 minutes in service mode The maximum CH flow temperature as configured in the Settings menu applies in this case step 5 Briefly press the A button step 6 Partial load service mode L a is activated Check the gas air ratio and ionisation current Adjust the gas air ratio as re
66. ipework 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 ben A Chimar BENCHMARK Log Book All Boulter Buderus gas fired boilers now include an installa tion commissioning and service record log book The details of the log book will be required in the event of any warranty work being requested Please complete the appropriate sections on completion of the installation and commissioning REMEMBER Please hand the log book back to the user Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 3 It is a requirement that all gas appliances are installed and serviced by a CORGI registered installer in accordance with the regulations Failure to service 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 serviced by a CORGI registered installer in accordance with the relevant requirements of the current Gas Safety Installation and Use Regulations The Building Regulations current E E Wiring Regulations a
67. isation electrode see box 144 Remove the power supply plug of the gas valve union nut and air silencer tube see box 77 Pull out both fan plugs see box 78 item 1 a Remove the gas air unit along with the burner see box 247 and 248 Remove the heat exchanger gas air seal see box 251 Remove the restrictor baffle item 1 F A V eL ge Lm UT cca Remove the stop spring on the top left hand side of the heat exchanger by turning it towards the arrow 1 z AY Open the four clip fastenings item 1 Clean the heat exchanger with a brush and compressed air or with TAB2 In the event of serious restriction continue with box 261 ieee ee Lee Remove the stop spring on the bottom right hand side of the heat exchanger by turning it towards the arrow We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 70 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 a Hi Bi 0 ie m xl ol i a J WI a Cis gt a cs Ses ie 10 2 Na a oe Pull the heat exchanger towards the arrow to remove
68. item 1 on the gas valve Remove the gas valve item 2 We reserve the right to make technical modifications Remove the Venturi item 1 Fit the Venturi to the new fan W Fit the gas valve to the new fan When doing so ensure that the gas injector item 1 is correctly fitted Fit the fan to the boiler Remember to fit the new flat rubber sealing ring Supplied when doing so Fit the air silencer tube to the fan Fit the gas supply pipe to the gas valve Ensure when doing so that the flat rubber sealing ring is correctly fitted Insert the power supply plug into the gas valve then insert the power supply plug and tacho cable plug into the fan Open the gas cock and place the electrical system of the boiler into operation see box 59 54 or 55 Carry out a gas leak check Check the tightness of all components that were loosened in the course of component removal Use an authorised foam type leak detection product for this purpose If you detect a gas leak refer to box 46 43 or 44 Remedy the cause of the gas leak Open the gas cock place the electrical system of the boiler into operation and fit the casing see box 59 54 55 or 51 Boulter Buderus Ltd http www boulter buderus co uk 44 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02
69. lations and legislation of the country or region of final use A CAUTION Use this boiler for its intended purpose only A 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 sys tem For more information about Sentinel call 0151 420 9563 When using water treatment only products suitable for use with Boulter Buderus heat exchangers are permit ted e g Sentinel X100 Your warranty is at risk if an incorrect water treatment product is used in conjunc tion with this appliance For more information contact Boulter Buderus Techni cal Product Support Department Itis 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 unsuita ble additives MUST be removed by thorough cleaning BS 7593 1992 details the steps necessary to clean a domestic central heating system In hard water areas treatment to prevent lime scale may be necessary however the use of artificially sof tened 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 Only plastic pipework containing a polymeric barrier should be used It is allowed to use copper for the
70. ler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Display indication Display Reset Key to display code Other symptoms Diagnosis code y Play required ymp g Fault No box 27 cP The flow sensor has detected a temperature increase in 1 the heating system water of over 5 C sec Fault No box 29 JH The tacho signal from the fan has failed during the 1 operating phase Fault Yes No heating operation and no hot water box 29 The tacho signal from the fan is not present during the pre 2 operative or operating phase Fault Yes No heating operation and no hot water box 30 No current of air after a certain time 2 Fault Yes No heating operation and no hot water box 31 The fan runs too slowly or too fast 2 WA Fault Yes No heating operation and no hot water box 32 nU The flow sensor and safety sensor have detected a 2 NAN CH flow temperature of over 105 C Fault Yes No heating operation and no hot water box 33 The sensor test has failed 2 Fault Yes No heating operation and no hot water box 34 A The contacts of the flow sensor and safety sensor are 2 in shorted to each other or there is a short circuit to earth NYIN ground or the flow or safety sensor has detected a CH flow temperature of above 130 C WALL Fault Yes No heating operation and no hot water box 35 NU BI The contacts of the flow sensor or safety sensor are 2 ISAAA broken Fault No box 36 HH During the ignition phase the
71. low temperature to a higher setting see box 14 box 42 step 19 Is the CH flow temperature of the boiler sufficient to heat the building Yes step 21 No gt step 20 step 20 Install a larger boiler box 42 step 21 Is there a hot water supply Yes step 22 No gt box 41 step 22 Is an internal 3 way valve fitted Yes step 23 No step 34 step 23 Check the movement of the servomotor of the internal 3 way valve see box 181 step 24 Does the servomotor of the internal 3 way valve move correctly Yes step 25 No gt step 28 step 25 Check the drive mechanism of the internal 3 way valve see box 195 step 26 Is the drive mechanism working correctly Yes box 42 No step 27 step 27 Replace the drive mechanism of the internal 3 way valve see box 198 box 42 step 28 Check the actuation of the servomotor of the internal 3 way valve see box 185 step 29 Does the servomotor of the internal 3 way valve start up correctly Yes step 30 No step 31 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 25 step 30 Replace the servomotor of the internal 3 way valve see box 190 box 42 step 31 Check the power supply cable of the internal 3 way valve see box 191 step 32 Is the power supply cable of the internal 3 way
72. lt has been rectified step 60 Has the malfunction been repaired Yes step 61 No step 62 step 61 The cause of the fault lies in the flue gas system Take the boiler out of operation box 42 step 62 Switch the boiler off and then on again at the operating switch step 63 Is the error code still displayed Yes step 64 No box 42 step 64 Has an error hH reoccurred Yes step 66 No gt step 65 step 65 Interpret the display code with box 20 and deal with the fault step 66 Has the entire table box 36 been covered Yes box 41 No step 1 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 34 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 step 1 step 2 step 3 step 4 step 5 step 6 step 7 step 8 step 9 step 10 step 11 step 12 step 13 step 14 step 15 step 16 step 17 step 1 step 2 step 3 step 4 step 5 step 6 We reserve the right to make technical modifications The system has detected an ionisation current before burner startup Locking boiler fault code Is the ionisation current displayed Yes step2 No step 1 Disconnect the plug and socket connection see box 144 Is the ionisation current still displayed Yes step 12 No box 41 Check the plug and socket connection between the ionisation electrode and cable loom see box 144 Ye
73. lue gas STL fit the DBA control panel attach the casing and place the boiler into operation see box 51 54 or 55 Take the boiler out of operation see box 43 44 or 47 Remove both plugs of the flue gas STL see box 121 Twist the flue gas STL anticlockwise to remove Fit the new flue gas STL Use a new seal when doing so Insert both plugs at the flue gas STL and place the boiler into operation see box 51 54 or 55 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 51 DANGER OF FATAL ACCIDENT A due to electric shock Take the boiler out of operation see box 43 44 or 47 N Z A Pull out the plug of the glow ignitor item 1 Set the multimeter to measure AC voltage Minimum measuring range 230V AC Put the boiler into partial load or full load operation see box 13 Check to see whether with the operating code OL 110 230 V AC is measured at the plug Take the boiler out of operation see box 43 Connect the plug of the glow ignitor Put the boiler into operation see box 54 55 or 51 We reserve the right to make technical modifications DANGER OF FATAL ACCIDENT A due to electric shock Take the boiler out of operation see box 43 44 or 47 Remove the plug of the glow ignitor see box 131
74. make technical modifications Fit the gas injector to the new gas valve Fit the new gas valve to the fan Fit the fan to the boiler insert the air silencer tube into the fan fit the gas supply pipe to the gas valve and insert the plugs into the fan and gas valve Fit the air silencer tube to the fan A CAUTION When attaching the gas supply pipe to the gas valve ensure that the flat rubber seal is fitted correctly between the gas supply pipe and gas valve Fit the gas supply pipe to the gas valve Insert the power supply plug into the gas valve then insert the power supply plug and tacho cable plug into the fan Open the gas cock and place the boiler into full load operation see box 59 54 55 or 13 Carry out a gas leak check Check the tightness of all components that were loosened during removal of the gas valve Use an authorised foam type leak detection product for this purpose Remedy the cause of the gas leak Put the boiler into operation see box 51 54 or 55 Take the boiler out of service and tip the DBA control panel forwards see box 43 44 or 47 or 63 Loosen the six screws and remove the rear section see box 70 Room Controller LOG Room Controller Arsis 3LO OQ 7 6 m 7 Kere Hot water tank sensor 24 VAC 3 way valve Bridge the two contacts terminal 1 and 2 Boulter Buderus Ltd http www boulter buderus co uk
75. moothly This is done by gradually pushing the spring fully home by hand and allowing the spring to return gradually to its home position Refit the servomotor following the above procedure in reverse order Put the boiler into operation see box 51 54 or 55 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 60 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 a Fit the new drive mechanism on the internal 3 way valve Ensure that the flat side faces upwards Connect the servomotor of the 3 way valve by following the above procedure in reverse order Fill the heating system vent it of air and place the boiler into operation see box 52 to 58 Take the boiler out of operation and drain the heating system see box 48 to 51 Disconnect the cable from the main switch see box 54 Pull the spring off the flow NTC sensor lead item 1 Pull out the flow NTC sensor plug item 2 Pull the main switch cable out of the nut item 3 We reserve the right to make technical modifications Pull the plug item 1 out of the pump Loosen the four screws item 3 on the pump Remove the return pipe with spring item 4 Remove the pipe to the expansion vessel with spring item 5 Pull out the pump item 2 Boulter Buderus Ltd http www b
76. mportant but not related to personal injury or property damage Abbreviations AV Air Vent BCT Boulter Buderus cylinder thermostat BDV Boulter 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 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 5 Buderus Unit 500 24 S 500 24 C 500 28 C Hot water capacity combination boilers kW 5 7 28 5 6 0 24 0 5 7 28 5 with external tank Rated thermal load for CH kW 5 7 23 0 5 7 23 0 5 7 23 0 Rated thermal load for preparing DHW kW 5 7 28 5 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 5 3 22 0 Heating curve 40 30 C kW 6 0 24 0 6 0 24 0 6 0 24 0 Seasonal efficiency SEDBUK for natural gas 90 3 90 3 90 3
77. n pressure measuring nipple item 1 Connect a long hose item 2 to the gas connection pressure measurement nipple and then run this hose out of the building Leave the gas cock open until no further air escapes from the hose see box 59 Close the gas cock see box 46 Remove the hose from the gas connection pressure measurement nipple Tighten the screw on the gas connection pressure measurement nipple Open the gas tap see box 59 Use a detection product to check the gas connection pressure measurement nipple for leaks Use an authorised foam type leak detection product for this purpose Fit the casing and place the boiler into operation see box 51 54 or 55 Take the boiler out of operation and drain the heating system see box 48 to 50 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 67 Twist the automatic air vent in the direction of the arrow to remove Fit the new automatic air vent by following the above procedure in reverse order Fill the heating system vent it of air and place the boiler into operation see box 52 to 58 DANGER OF FATAL ACCIDENT A due to electric shock A DANGER OF FATAL ACCIDENT All work on gas supply pipes and gas fitting components must be carried out by a company registered and authorised for t
78. nction box fitted correctly Yes step4 No step 3 Correctly attach the switch live to terminal 1 and Neutral to terminal 2 on the 230V connector se box 286 Disconnect black leads from terminals 1 amp 2 on the back of the DBA and test for continuity between ine Tyo box 43 leads No continuity check S L and N connections are made correctly and that there is 230v between the two Replace RTH converter Junction box Continuity reconnect the cables to terminals 1 amp 2 and check the connections between the terminals and the DBA drve the right to make technical modifications Boulter Buderus Ltd http www bduiter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Operating step number Explanation of this subject starts in this box The following boxes can be relevant as well We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 10 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 orion box 10 Operation General points E E E aF The central boiler can be run from the DBA control panel item 1 item 1 Mains switch 0 1 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 You can navigate through the menu structure of the central boiler us
79. nd 3 We reserve the right to make technical modifications Insert the power supply plug of the Boulter Buderus 24V AC external 3 way valve Put the boiler into operation see box 51 54 or 55 Take the boiler out of operation see box 43 44 or 47 Remove the power supply plug of the servomotor of the Boulter Buderus 24V AC external 3 way valve see box 213 Remove the servomotor of the Boulter Buderus 24V AC external 3 way valve To release the servomotor press the release catch item 1 and twist the servomotor DANGER OF DAMAGE TO THE SYSTEM A Before removing the servomotor check to see if the Boulter Buderus 24V AC external 3 way valve is in its heating mode position and wait for the boiler display code UH to appear This prevents sudden pressure surges occurring in the heating circuit while the removal operation is taking place and the resultant accidental opening of the pressure relief valve Fit the new servomotor by following the above procedure in reverse order Put the boiler into operation see box 51 54 or 55 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 63 CAUTION J To prevent damage do not insert the measuring electrodes of the multimeter too far into the holes of the plug and socket connection Take the boiler out of operation see box 43 o
80. nd the relevant British Standard Codes of Practise Detailed recommendations are contained in the following British Standard Codes of Practice BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW BS 5449 Forced circulation hot water systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd family Gases BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 60 kW BS 6891 Low pressure installation pipes 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 Boulter Buderus wall mounted condensing gas boiler conforms to the basic spec ifications 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 Is WARNING Keep the burner control unit housing CLOSED when working on water bearing components NOTE It is mandatory
81. o operation see box 54 and 55 Set the multimeter to measure AC voltage Minimum measuring range 40V AC Use the Settings menu on the boiler DBA control panel to adjust the temperature to 60 C see box 14 or 18 Open a hot water tap Check to see if during operating code OC at plug in contacts 1 and 3 24 V AC is detected between plug in contacts 1 and 3 Close the hot water tap Check to see if during operating code OH 24 VAC is detected at plug in contacts 1 and 2 We reserve the right to make technical modifications Insert the power supply plug of the 3 way valve Put the boiler into operation see box 51 or 61 Take the boiler out of operation see box 43 44 or 47 Remove the power supply plug of the servomotor see box 186 Remove the servomotor see box 182 Fit the new servomotor by following the above procedure in reverse order Put the boiler into operation see box 51 54 or 55 DANGER OF FATAL ACCIDENT A due to electric shock A CAUTION To prevent damage do not insert the measuring electrodes of the multimeter too far into the holes of the plug and socket connection Take the boiler out of operation and remove the DBA control panel see box 43 44 47 63 or 70 Remove the power supply plug of the servomotor of the 3 way valve see box 186 oo0oo0oo0
82. o0000000000000 Ooo 300 mV Set multimeter to measure resistance Check the power supply cable of the 3 way valve for breaks The electrical resistance measured at each individual wire must be approximately 0 Q Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 59 Take the boiler out of operation and drain the heating system see box 48 to 51 Remove the servomotor of the 3 way valve see box 182 Check the power supply cable of the 3 way valve for internal short circuits The level of electrical resistance measured between two wires chosen at random must be infinitely high Remove the stop spring item 1 by pulling it in the Insert the power supply plug of the 3 way valve fit the direction of the arrow DBA control panel and place the boiler into operation see box 51 54 or 55 Take the boiler out of operation see box 43 44 or 47 Remove the servomotor of the 3 way valve see box 182 Remove the drive mechanism item 1 of the 3 way valve CAUTION A Note that water will squirt out when the drive mechanism is removed Have a bucket and a supply of dry cloths to hand Check to ensure that the drive mechanism of the 3 way valve is running s
83. ode and earth ground The electrical resistance ionisation electrode and earth ground must be infinitely between the ionisation electrode cable and earth ground high must be infinitely high We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 54 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Connect the plug of the ionisation electrode Refit the DBA control panel by following the above 1 2 procedure in reverse order and place the boiler into S ay operation see box 51 54 or 55 Take the boiler out of operation see box 43 44 or 47 Remove the plug of the ionisation electrode see box 144 3 4 SS Wee Check the ionisation electrode for signs of wear item 2 damage item 3 or soiling item 4 Replace the ionisation electrode if required Fit the ionisation electrode Connect the plug of the ionisation electrode Put the boiler into operation see box 51 54 or 55 Remove the mounting plate item 2 Detach the ionisation electrode item 3 Check to ensure that the earth ground lead of the ionisation circuit item 1 has been correctly fitted Set multimeter to measure resistance Take a reading at the ionisation electrode to check whether there is a possible break in the electrode cable The electrical resistance of the ionisation electrode cable mu
84. of the boiler see box 61 Remove the drive mechanism on the internal 3 way valve see box 200 CAUTION A Note that water will squirt out when the internal 3 way valve is removed Have a bucket and a supply of dry cloths to hand We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 62 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 CAUTION A To prevent damage do not insert the measuring electrodes of the multimeter too far into the holes of the plug and socket connection Take the boiler out of operation see box 43 44 or 47 SS Ix XS A EN lg TRL LN Yl AN Remove the power supply plug of the servomotor of the Boulter Buderus 24V AC external 3 way valve Put the boiler into operation see box 51 54 or 55 Plug in contacts Purpose Plug in contacts of Boulter on DBA control Buderus 24V AC panel external 3 way valve 2 24V AC 3 OV AC 6 Set the multimeter to measure AC voltage Minimum measuring range 40V AC Open a hot water tap Adjust the hot water in the Settings menu on the DBA control panel of the boiler to 60 C see box 61 Check to see if during operating code HL 24VAC is detected at plug in contacts 2 and 6 Close the hot water tap Check to see if during operating code HH 24 VAC is detected at plug in contacts 2 a
85. oulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 61 Remove all pipes beneath the boiler A CAUTION Replace the housing of the 3 way valve Note that water will squirt out when the internal 3 way valve is removed Have a bucket and a supply of dry cloths to hand Refit all components following the above procedure in Loosen the gas pipe at the gas valve reverse order Remove the two screws item 1 Fill the heating system vent it of air and place the boiler Remove the complete hydraulic assembly into operation see box 52 to 58 Remove the four M8 nuts item 2 Remove the five screws item 3 Remove the plastic block H3 Put the boiler into operation see box 54 and 55 Adjust the hot water in the Settings menu on the DBA control panel of the boiler to 60 C see box 61 Open a hot water tap Check to see if the servomotor of the Boulter Buderus 24V AC external 3 way valve during the operating code UL rotates from the setting for heating mode position 1 to the position for hot water mode position 2 Close the hot water tap Loosen the screw in the plastic block item 2 Check to see if the servomotor runs back again Remove the pressure relief valve item 1 see box 276 Adjust the hot water in the Settings menu on the DBA or 277 control panel
86. quired See box 233 and box 143 step 7 Exit partial load service mode Yes step 8 No gt step 6 step 8 Press the G button once step 9 Briefly press the A button step10 Full load service mode H is activated Check the working gas input pressure or analyse the exhaust gas accordingly box 230 step11 Exit full load service mode Yes step 12 No gt step 10 step12 Press the button once or wait for service mode to expire after 30 minutes step13 Service mode is deactivated step 1 step 1 24 Current CH flow temperature in C See also box 17 step 2 Open Settings menu Yes step3 No gt step 1 step 3 Press the m button once step 4 step 4 Is boiler a combination boiler with warm start Yes step5 No step 9 step 5 F rt rl I Configured hot water mode As soon as F rit is displayed you can verify the current hot water mode or adjust it as required See also box 18 step 6 Adjust configured hot water mode Yes step 7 No gt step 8 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 12 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 step 7 step 8 step 9 step 10 step 11 step 12 step 13 step 14 step15 step 16 step 17 step 18 step 19 step 20 step
87. r 44 Remove the power supply plug of the servomotor of the Boulter Buderus 24V AC external 3 way valve see box 213 Remove the connection of the power supply cable of the Boulter Buderus 24V AC external 3 way valve at the boiler Set multimeter to measure resistance Check the power supply cable of the Boulter Buderus 24V AC external 3 way valve for breaks The electrical resistance measured at each individual wire must be approximately 0 Q Check the power supply cable of the Boulter Buderus 24V AC external 3 way valve for internal short circuits The level of electrical resistance measured between two wires chosen at random must be infinitely high Insert the power supply plug of the Boulter Buderus 24V AC external 3 way valve Connect the power supply cable of the Boulter Buderus 24V AC external 3 way valve at the boiler Put the boiler into operation see box 54 or 55 Take the boiler out of operation see box 43 or 44 Remove the servomotor of the Boulter Buderus 24V AC external 3 way valve see box 218 Check to ensure that the drive mechanism of the Boulter Buderus 24V AC external 3 way valve is running smoothly This is done by gradually pushing the spring fully home by hand and allowing the spring to return gradually to its home position Refit the servomotor following the above procedure in reverse order Put the boiler into operation see box 54 or 55 We reserve the
88. r 55 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 40 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Press the menu button item 1 on the DBA control panel of the boiler fron 1 Configure the menu as required see box 14 DANGER OF FATAL ACCIDENT A due to electric shock Take the boiler out of operation see box 43 44 or 47 Remove the casing from the boiler see box 47 Loosen the cap screw on the DBA control panel item 1 Tip the DBA control panel forwards item 2 We reserve the right to make technical modifications Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 A Q ooooooo0 y Oo o c BEA ee _ le ooooooogonogoon p pi J i E Os o D q O O Remove the rear section of the DBA control panel see box 70 Remove the fuse from the fuse holder Check the fuse with a multimeter If the fuse possesses infinitely high electrical resistance it is defective Replace the defective fuse with a new 2 5 AT slow blow reserve fuse Refit the DBA control panel following the above procedure in reverse order Refit the casing and place the boiler into operation see box 51 53 54 or 55 DANGER OF FATAL ACCIDENT A due to electric shock CAUTION A To prevent damage do not insert the measur
89. r setting see operating instructions step 5 Check to see if the heating requirement TH indicator lights up on the display see box 11 step 6 Does the heating requirement TH indicator light up Yes step 11 No step 7 step 7 Check the Boulter Buderus controls or ON OFF controller as per box 177 step 8 Is the Boulter Buderus controls or ON OFF controller working correctly Yes step 9 No step 10 step 9 Replace the thermostat cable box 42 step 10 Replace the Boulter Buderus controls or ON OFF controller box 42 step 11 Check to ensure that the CH flow temperature at the DBA control panel or on the Boulter Buderus controls or ON OFF controller is adjusted to a high enough setting as per box 14 and box 61 step 12 Is the CH flow temperature adjusted to a high enough setting Yes step 13 No step 15 step 13 Are enough thermostatic valves open on the radiators convectors etc Yes step 16 No step 14 step 14 Open more thermostatic valves on the radiators convectors etc box 42 step 15 Adjust the CH flow temperature as per box 14 and box 61 Ensure that the Boulter Buderus controls or box 42 ON OFF controller are calling for a heating demand step 16 Check to ensure that the CH flow temperature is correctly adjusted see box 14 step 17 Is the CH flow temperature adjusted to a high enough setting Yes step 19 No gt step 18 step 18 Adjust the CH f
90. requirement from the room temperature controller Yes No The symbol TJ lights up The glow ignitor is activated for seven seconds OL mT HL The fan runs at 49 of capacity The pump is started up Ignition phase The gas valve is opened Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Yes gt step 62 gt step 23 gt step 18 gt step 25 gt step 28 gt step 26 gt step 46 step 27 gt step 62 step 24 gt step 32 step 72 gt step 39 gt step 34 gt step 35 gt step 32 gt step 29 gt step 38 gt step 46 step 19 Boulter Buderus Ltd http www boulter buderus co uk 15 step49 Does the ionisation current exceed 1 4 pA microamperes within 5 seconds Yes step 50 No step 72 step50 H The boiler is in heating mode The symbol 6 lights up The startup load on the boiler is 49 for the first 13 seconds for the purposes of flow monitoring It is then increased or decreased step51 Is there a heating requirement from the room temperature controller Yes step 52 No step 57 step52 Is the heat system flow temperature 6 C higher than the target setting Yes step 53 The target setting is entered at the DBA control panel if room temperature adjustment is required No gt step 50 step53
91. rks DO NOT operate electrical switches of any kind including telephones plug in devices and doorbells Shut off the gas supply at the main valve Open doors and windows Warn other occupants of the building but DO NOT use the house intercom or doorbells Contact the gas supplier from a telephone located outside the building f you detect an audible gas leak evacuate the building immediately prevent other persons from entering and notify the police and fire service immediately from a telephone OUTSIDE the building Is WARNING DANGER OF FATAL ACCIDENT due to electric shock CAUTION A General information on maintenance work USER INSTRUCTIONS Instructions for optimum usage correct adjustment of the boiler and other useful information A CAUTION Use eye protection inhalation protection hearing gloves shoes etc on the right time Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 9 This document consists of various sections These in turn contain subsections boxes in the form of text or tables Subsections boxes inside text and tables are identified by a small grey box Each subsection box is assigned its own identification number These subsections boxes are divided into operating steps If an operating step involves the taking of a yes no decision the right hand side of the table in
92. rvice mode operation The differential pressure Pgas Pair must be 5 Pa 5 Pa as indicated by the measuring device 10 to 0 Pa Boulter Buderus Ltd http www boulter buderus co uk 66 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Use the adjustment screw to readjust the gas air ratio if necessary item 1 NOTE The adjustment screw 4mm Allen screw is located behind the screw on cover Take the boiler out of operation and close the gas tap see box 43 44 or 46 Remove the pressure gauge Tighten the screw on the burner pressure measurement nipple Open the gas cock and place the boiler into full load operation see box 59 54 55 and 13 Wait for the boiler to start Use a detection product to check the burner pressure measurement nipple for leaks Use an authorised foam type leak detection product for this purpose Take the boiler out of operation see box 43 or 44 Fit the casing and place the boiler into operation see box 51 54 or 55 DANGER OF FATAL ACCIDENT J All work on gas supply pipes and gas fitting components must be carried out by a company registered and authorised for this purpose Take the boiler out of operation and close the gas tap see box 43 44 46 or 47 We reserve the right to make technical modifications Loosen by two turns the screw on the gas connectio
93. ry cloths to Set multimeter to measure resistance hand Detach the cables of the DHW temperature sensor item 3 Pull out the plug of the safety sensor item 1 and 4 from the DBA control panel Detach the stop spring of the safety sensor by pulling in Measure the resistance of the cable of the DHW the direction of the arrow item 2 temperature sensor and check it for short circuits and breaks See box 112 Fit the cables of the DHW temperature sensor to the DBA control panel item 3 and 4 Remove the safety sensor item 3 Insert the cables of the corresponding DHW temperature or outside air temperature sensor Fit the DBA control panel and place the boiler into operation see box 54 55 or 51 Take the boiler out of operation drain the heating system and pull out the plug of the corresponding sensor see box 43 44 47 45 47 49 or 50 A CAUTION Note that water will squirt out when the sensor is removed Have a bucket and a supply of dry cloths to hand Detach the stop spring of the flow NTC sensor by pulling in the direction of the arrow Remove the flow NTC sensor Fit the corresponding new sensor Fill the heating system vent it of air and place the boiler into operation see box 52 to 58 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 50 Servicing manual Gas condensing boiler Buderus 500 24 S 500
94. s Is the plug and socket connection in full working order step 7 No gt step 6 Correctly insert the plug into its socket step 11 Check the cable of the ionisation electrode see box 151 Is the wiring in order Yes step 10 No step 9 Replace the cable loom or the affected part thereof step 13 Check the ionisation electrode see box 149 or box 155 box 42 Is the ionisation electrode working correctly Yes step 14 No step 12 Replace the ionisation electrode see box 155 box 42 Switch the boiler off and then on again at the operating switch The following components should be checked for soiling damage and or correct installation syphon see box 256 flue gas pipework Check the pressure control valve see box 85 Is the pressure control valve working correctly Yes box 41 No step 17 Replace or clean the pressure control valve see box 85 box 42 An ionisation current has been measured as soon as the burner shuts down Locking boiler fault code Connect a digital pressure gauge see box 233 and 234 Open the gas cock and place the boiler into full load operation see box 59 or box 13 Deactivate the heat requirement as per flue gas test box 13 and check to see if the burner remains under pressure after the heat requirement symbol on the DBA control panel goes out Is the burner still under pressure Yes step4 No step 3 Check the ionisation
95. sensor Set multimeter to measure resistance and check the earth ground connection of the safety Measure the resistance of the safety sensor sensor This must be infinitely high The measured resistance of the flow NTC sensor is virtually identical to that of the safety sensor We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 48 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Use a digital contact type thermometer to measure the temperature in the vicinity of the corresponding sensor Compare the resistance readings with the values listed in box 111 Replace the corresponding sensor if the reading fluctuates by more than 10 with respect to the reference value e g infinitely high resistance in the event of a line break or resistance of 0 Q in the case of a short circuit Reinsert the plug Refit the casing and place the boiler into operation see box 51 53 54 or 55 Resistance readings approximate values for the sensor Temperature Resistancein Temperature Resistancein in C Q in C Q 0 29 490 5 23 462 55 3 271 10 18 787 60 2 760 15 15 136 65 2 339 20 12 268 70 1 990 25 10 000 75 1 700 30 8 197 80 1 458 35 6 754 85 1 255 40 5 594 90 1 084 45 4 656 95 940 50 3 893 100 817 Key to terms
96. serve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 16 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Display indication Key to display indication a Service mode 6 lonisation signal flame monitoring rei Hot water mode ECO setting or hot water requirement Hot water mode warm start setting or hot water requirement a Standby hot water mode to warm start TH Heating mode or heating requirement TH Summer operation no heating mode hot water only Displa Factory Pr y Key to display reading Unit Range default readings setting AY Current CH flow temperature C 40 BO Button Display Key to display settin Unit Range Setting y play g g x6 724 Service mode La Service mode partial load 25 1x Ho Service mode full load 100 1x End service mode or wait for 30 minutes _ ay erate e Hot water supply to ECO mms UENS 1 Only applies to combi boilers F I Hot water mode to warm start DHW temperature C 40 60 TH Heating mode ON Pry Heating mode a TH Heating mode OFF 7 oo N CH flow temperature C 30 80 flashing When it appears on the display at a system boiler please connect a link between terminal 3 and 4 on the back side of the DBA control panel hot water cylinder sensor or make sure that the hot water cylinder sensor is fitted securely
97. st be approximately 0 Q We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 55 Take the boiler out of operation see box 43 44 or 47 Check to ensure that the power supply plug item 1 has been inserted correctly into the gas valve Put the boiler into operation see box 51 54 or 55 Take the boiler out of operation see box 43 44 or 47 i Run the boiler at full load see box 54 55 and box 13 step 14 Set the multimeter to measure DC voltage Minimum measuring range 40V DC Check to see if the gas valve has been activated During operating code HL or somewhat later 20 24V DC must be detectable at both the centre and upper contacts item 1 and 2 Put the boiler into operation see box 51 54 or 55 Take the boiler out of operation and remove the DBA control panel see box 43 44 47 63 or 70 Set multimeter to measure resistance Check the power supply cable of the gas valve for breaks The electrical resistance measured at each individual wire must be approximately 0 Q Check the power supply cable of the gas valve for internal short circuits The level of electrical resistance measured between two
98. syphon see box 256 combustion air inlet pipework air silencer pipework seal between the Venturi and fan Venturi see box 86 gas injector see box 83 item 1 fan connection between the fan and burner burner heat exchanger system of flue gas pipe and air inlet pipeworks pressure control valve see box 85 earth ground lead of ionisation circuit see box 160 step 48 Are the above mentioned components clean free of damage and or correctly intalled Yes step 50 No step 49 step 49 Clean replace and or correctly install the components concerned step 62 step 50 Measure the ionisation current see box 143 step 51 Is the ionisation current in order Yes step 62 No step 52 step 52 Check the plug and socket connection between the ionisation electrode and cable loom see box 144 step 53 Is the plug and socket connection in full working order Yes step 55 No step 54 step 54 Correctly insert the plug into its socket gt step 62 step 55 Check the cable of the ionisation electrode see box 151 step 56 Is the wiring in order Yes step 58 No step 57 step 57 Replace the cable loom or the affected part thereof step 62 step 58 Check the ionisation electrode and replace as required see box 155 step 62 step 59 Temporarily disconnect the flue gas pipework from the top of the boiler Run the boiler at low mode see box 13 Check to see if the fau
99. system has detected an 1 insufficient ionisation current IAL Fault Yes No heating operation and no hot water box 36 H After four startup attempts the system has detected an 2 insufficient ionisation current Fault Yes No heating operation and no hot water box 37 The system has detected an ionisation current before 2 burner startup Fault Yes No heating operation and no hot water box 38 An ionisation current has been measured as soon as the 2 burner shuts down Fi Fault No aL The flame goes out during the operating phase 1 Fault Yes No heating operation and no hot water box 39 The power supply was shut off during a crucial breakdown 2 Operating phase Display test during startup phase The code is displayed for a maximum of 1 second tia Fault Yes No heating operation and no hot water box 41 PAN The DBA control panel is defective 2 tT Fault Yes No heating operation and no hot water box 40 CAT The contacts of the gas valve have been broken 2 ait Fault Yes No heating operation and no hot water box 41 vA The DBA control panel is defective 2 Ha Fault Yes No heating operation and no hot water box 40 De AL The contacts of the gas valve have been broken 2 cat Fault Yes No heating operation and no hot water box 41 a The DBA control panel is defective 2 1 This error code may deactivate again automatically after a specific time without reset Heating and hot water are now available once more 2 In the event o
100. t to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 21 step 30 Is there any indication on the DBA control panel display Yes step 33 No gt step 31 step 31 Replace the pump see box 101 step 32 step 32 Replace fuse again see box 62 step 33 step 33 Turn the operating switch on the DBA control panel of the boiler to position 0 OFF see box 43 step 34 Connect the power supply plug of the fan in reverse step 35 Turn the operating switch on the DBA control panel of the boiler to position 1 ON see box 55 step 36 Is there any indication on the DBA control panel display Yes box 42 No gt step 37 step 37 Replace fan see box 76 step 38 step 38 Replace fuse again see box 62 box 42 No or insufficient hot water radiators convectors etc may be heated without current heat requirement step 1 Set the operating switch on the boiler DBA control panel to position O OFF see box 43 and set the other DBA control panel operating switch to position 1 ON see box 55 step 2 Open a hot water tap step 3 Check that the hot water pipe directly beneath the external storage type water heater warms up step 4 Does the pipe warm up to approx 60 C Yes step5 No gt step 39 step 5 The cause of this fault does not lie with
101. tep 13 Deal with restriction box 42 Check to see if there is a second fan in the flue gas pipe or air inlet system Is a second fan fitted es gt step 15 No step 16 Take second fan out of service gt box 42 Check to see if the fan impeller has come loose at the motor spindle see box 76 step 17 Has the fan come loose step 18 Replace fan see box 76 Has the malfunction been repaired es gt step 18 No step 19 Yes box 42 No box 41 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 0 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C e Issued 02 2005 io The flow NTC sensor has detected a temperature of over 105 C UA Locking boiler fault code step 1 Check the flow rate in the heating circuit step 2 Are all servicing valves and thermostat valves closed Yes step 4 No step 3 step 3 Check all servicing valves and thermostat valves for correct functioning step 4 Open all servicing valves and thermostat valves step 5 Has the malfunction been repaired Yes box 42 No box 41 Ray The sensor test has failed UE Locking boiler fault code TAY TINS step 1 Check the flow NTC sensor and safety sensor and their wiring for short circuits see box 104 to 115 and box 287 step 2 Are the flow NTC sensor and safety sensor along with their
102. tep 16 Is there any indication on the DBA control panel display Yes box 42 No step 17 step 17 Turn the operating switch on the DBA control panel of the boiler to position 0 OFF see box 43 step 18 Disconnect the following boiler components from the electrical power supply pump see box 92 fan see box 71 item 1 step 19 Check the fuse again for correct functioning Use a multimeter to check the fuse on the inside of the DBA control panel see box 62 step 20 Is the fuse working correctly Yes step 22 No step 21 step 21 Replace fuse again see box 62 step 22 Turn the operating switch on the DBA control panel of the boiler to position 1 ON see box 55 step 23 Is there any indication on the DBA control panel display Yes step 27 No step 24 step 24 Use a multimeter to check the power supply cables of the pump box 95 the fan box 69 and the glow ignitor box 137 for signs of short circuiting step 25 Are the cables in order Yes step 27 No gt step 26 step 26 Replace the cable harness or the affected part thereof Replace fuse again see box 62 rene step 27 Turn the operating switch on the DBA control panel of the boiler to position 0 OFF see box 43 step 28 Connect the power supply plug of the pump in reverse step 29 Turn the operating switch on the DBA control panel of the boiler to position 1 ON see box 55 We reserve the righ
103. tep 45 step 46 We reserve the right to make technical modifications Check the power supply cable of the glow ignitor see box 137 Is the power supply cable in full working order Replace the cable loom or the affected part thereof Check the electrical resistance of the glow ignitor see box 134 Is the electrical resistance of the glow ignitor in order Replace the glow ignitor see box 140 Place the boiler in full load operation see box 13 and check whether the glow ignitor activates with the operating code OL rv Do Does the glow ignitor activate with the operating code O Connect a digital pressure gauge see box 233 and 234 Open the gas cock and place the boiler into operation see box 59 or box 13 Check whether the gas valve opens with the operating code OL Does the gas valve open with the operating code UL Check the plug and socket connection on the gas valve see box 161 Is the plug and socket connection in full working order Reconnect the plug and socket connection at the gas valve Check whether the gas valve receives power with the operating code UL see box 164 Does the gas valve receive power Replace the gas valve see box 174 Check the power supply cable of the gas valve see box 167 Is the wiring in order Replace the cable loom or the affected part thereof Check whether the incoming gas supply is of sufficient cap
104. ter radiators convectors etc may be heated without current heat requirement Applies to boilers with hot water supply hot water available no heating operation Applies to boilers without hot water supply no heating operation Applies to boilers with hot water supply hot water available no heating operation The heating circuit is warmed up without a heat requirement Pump over run time Heating system factory default setting 5 minutes for details of hot water and service mode see box 5 The target room temperature may not be reached Heat request but no respons of the boiler Recycling phase The fan runs for 15 seconds at about 60 of maximum speed Extraction of residual fumes in boiler The target room temperature may not be reached The target room temperature may not be reached No heating operation and no hot water 1 This error code may deactivate again automatically after a specific time without reset Heating and hot water are now available once more 2 In the event of this malfunction the pump is started up and remains in continuous operation in order to minimise the possibility of the heating system freezing up We reserve the right to make technical modifications 18 Diagnosis box 21 box 21 box 22 box 23 box 24 box 22 box 25 box 285 box 26 box 27 box 28 box 27 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boi
105. the boiler but with the mains water supply Check to see if the MCW inlet and DHW outlet have been incorrectly connected to the external storage type water heater step 6 Are the pipes connected correctly Yes step 8 No step 7 step 7 Connect the pipeworks correctly box 42 step 8 Close the shut off valve in the MCW inlet and open a hot water tap at random to see if water is still flowing step9 Is this the case Yes step 10 No step 11 step 10 The cause is a defective thermostat controlled mixer tap a thermostat controlled mixer valve or a short box 42 circuit between the hot and cold water circuits step 11 Check to see if any other external part of the drinking water system is a possible cause step 12 Are such items detected Yes step 13 No box 42 step 13 Place the affected components out of service box 42 step 14 Check to ensure that the pre adjusted setting corresponds to the hot water bu box 14 supply to ensure that the DHW temperature is adjusted to a high enough setting see box 61 to see if the hot water supply has been shut off by the control system ModuLink 250 RF a step 15 Are the adjustment settings in order Yes step 17 No gt step 16 step 16 Adjust the settings box 42 step 17 Check to see if the hot water mode indicator r l or F amp T lights up on the display see box 11 step 18 Does the hot water mode in
106. the gas cock and place the boiler into full load operation see box 59 54 55 and 13 Carry out a gas leak check Check the tightness of all components that were loosened in the course of removal of the burner Use an authorised foam type leak detection product for this purpose Remedy the cause of the gas leak Open the gas cock and place the boiler into operation Remove the condensate trap item 1 and syphon see box 59 54 55 or 51 item 2 Clean the condensate trap and syphon Take the boiler out of operation see box 43 44 or 47 Fit the new or cleaned syphon Put the boiler into operation see box 51 54 or 55 Loosen both screws item 1 Remove the sight glass along with the seals We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 69 DANGER OF FATAL ACCIDENT A due to electric shock DANGER OF FATAL ACCIDENT J All work on gas supply pipes and gas fitting components must be carried out by a company registered and authorised for this purpose Take the boiler out of operation close the gas cock and drain the heating system see box 46 or 48 to 50 LD yyy CCC ie Remove the power supply plug of the glow ignitor f see box 131 J DD Dy Remove the plug of the ion
107. ting system see box 48 to 50 Remove the stop spring item 2 of the pressure relief valve Remove the pressure relief valve item 1 in the direction of the arrow Use a screwdriver to lever out the turbine flowmeter hs DANGER OF FATAL ACCIDENT Release the pressure relief valve from the section of due to electric shock condendsate outlet pipework by pulling in the direction of Take the boiler out of operation and remove the DBA the arrow control panel see box 43 44 47 63 or 70 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 73 UOOOOUOQ0000000000 O00000 ii UU mi E ennai Disconnect the five plugs harness item 1 JP1 JP2 JP4 and JP3 from the DBA control panel Remove the DBA control panel Fit the new DBA control panel following the above procedure in reverse order CAUTION A Please ensure that the new DBA control panel is fitted with the correct KIM see box 284 The coloured stripe on the new KIM should match that of the old KIM Otherwise refit the old KIM to the new DBA control panel Fit the casing and place the boiler into operation see box 51 54 or 55 We reserve the right to make technical modifi
108. tion pressure measuring nipple item 1 Fit the pressure gauge to the gas connection pressure measurement nipple item 2 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 65 Open the gas tap see box 59 Put all other gas fired devices e g gas ovens and stoves etc out of use Check to see if static gas input pressure does not rise slowly for 2 minutes Run all other gas fired appliances e g gas ovens and stoves etc at full capacity but do not operate the boiler The static gas input pressure must be for natural gas minimum 20 mbar and for propane minimum 37 mbar Open the gas cock and place the boiler into service mode see box 59 54 55 or 13 Press the service button twice Capacity during service mode is at A Hi 100 max heating capacity Wait for 1 minute until the boiler starts at full load Measure the working gas pressure at the appliance Measure the difference between the static and working gas input pressure The working pressure may be for natural gas minimum 17 mbar and for propane minimum 30 mbar Take the boiler out of operation and close the gas tap see box 43 44 or 46 Remove the pressure gauge Tighten the screw on the gas connection pressure measurement nipple Open the gas tap see box 59 Use a dete
109. to clean and service the system once a year This includes an inspection of the entire system to see if it is in full working order Defects and faults must be eliminated immediately NOTE When instructions aren t followed warranty expires NOTE Condensing boilers work more efficient if the CH flow return temperature is as low as possible J We reserve the right to make technical modifications 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 Scot land 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 or serviced 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 or serviced in Zone 3 as detailed in BS 7671 Compartment Installations A compartment used to enclose the boiler should be designed and constructed especially for this purpose An existing c
110. uce the DHW flow rate turn the flow regulator in direction Adjust the flow rate of hot water at one of taps where the a user is likely to require hot water at an ideal temperature SA EN Bi Factory default setting see factory settings in the FAD installation instruction This assumes a cold water input temperature of 10 C N Put the boiler into operation see box 54 and 55 Use the Settings menu on the boiler DBA control panel to adjust the temperature to 60 C see box 14 or 18 Take the boiler out of operation see box 48 44 or 47 Open a hot water tap Check to see if the servomotor of the internal 3 way valve during operating code UL rotates through a full revolution Close the hot water tap Check to see if the servomotor runs back again We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 58 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Fit the servomotor to the 3 way valve Insert the stop spring Adjust the DBA control panel see box 61 Fit casing see box 51 CAUTION A To prevent damage do not insert the measuring electrodes of the multimeter too far into the holes of the plug and socket connection Take the boiler out of operation see box 43 44 or 47 Pull out the power supply plug of the servomotor Put the boiler int
111. ump during locking fault code d 7 7 We reserve the right to make technical modifications 46 Insert the power supply plug of the pump Fit casing see box 51 DANGER OF FATAL ACCIDENT A due to electric shock Take the boiler out of serve and tip the DBA control panel forwards see box 43 44 47 or 63 Loosen the six screws and remove the rear section see box 70 Remove the power supply plug of the pump see box 92 Check the power supply cable of the pump for breaks The electrical resistance measured at each individual wire must be approximately 0 Q Check the power supply cable of the pump for internal short circuits The level of electrical resistance measured between two wires chosen at random must be infinitely high Fit the power supply plug of the pump fit the DBA control panel and place the boiler into operation see box 53 54 or 55 Take the boiler out of operation and drain the heating system see box 43 44 47 45 49 or 50 Boulter Buderus Ltd http www boulter buderus co uk Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Loosen the four Allen screws on the pump Loosen the union nuts item 1 at the top and side of the Remove the top section of the pump pump Remove the pump A CAUTION Fit new flat sealing rings when
112. upboard or compartment may be used provided that it is modified for the purpose In both cases details of essential features of cupboard compartment design including airing cupboard installation are to conform to the following BS 6798 No cupboard ventilation is required see Air Supply for details It is not necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed due to the low surface tempera tures 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 8mm 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 8mm left side 8mm 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 Boulter Buderus purpose made gas systems which are certified for this type of boiler Boulter Buderus Ltd http www boulter buderus co uk 4 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 Observe the relevant standards regu
113. valve in good condition Yes box 41 No gt step 33 step 33 Replace the cable loom or the affected part thereof box 42 step 34 Check the movement of the servomotor of the Boulter Buderus 24V AC external 3 way valve see box 211 step 35 Does the servomotor of the Boulter Buderus 24V AC external 3 way valve operate correctly Yes step 36 No gt step 39 step 36 Check to ensure that the the Boulter Buderus 24V AC external 3 way valve has been fitted correctly see box 227 step 37 Has the Boulter Buderus 24V AC external 3 way valve been fitted correctly Yes step 45 No gt step 38 step 38 Install the Boulter Buderus 24V AC external 3 way valve correctly see box 227 box 42 step 39 Check to ensure that the Boulter Buderus 24V AC external 3 way valve is actuated correctly see box 212 and box 228 step 40 Does the Boulter Buderus 24V AC external 3 way valve actuate correctly Yes step 41 No step 42 step 41 Replace the servomotor of the Boulter Buderus 24V AC external 3 way valve see box 217 box 42 step 42 Check the wiring of the Boulter Buderus 24V AC external 3 way valve see box 220 step 43 Is the wiring of the Boulter Buderus 24V AC external 3 way valve in correct condition Yes step 47 No step 44 step 44 Replace the wiring of the Boulter Buderus 24V AC external 3 way valve box 42 step 45 Check the drive mechanism of the Boulter Buderus 24V AC external 3 way valve
114. wires must be infinitely high Insert the gas valve plug Fit the DBA control panel and place the boiler into operation see box 51 54 or 55 Take the boiler out of operation see box 43 44 or 47 Remove the power supply plug of the gas valve see box 168 We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 56 Servicing manual Gas condensing boiler Buderus 500 24 S 500 24 C and 500 28 C Issued 02 2005 eer N we 180 250 Q Ge a Set multimeter to measure resistance Take a reading at the coils to check the internal electrical resistance of the two gas valve coils The electrical resistance between the middle and lower contact must be approx 70 110 Q item 1 The electrical resistance between the middle and upper contact must be approx 180 250 Q item 2 Fit the power supply plug to the gas valve Put the boiler into operation see box 51 54 or 55 DANGER OF FATAL ACCIDENT A All work on gas pipework and gas fitting components must be carried out by a company registered and authorised for this purpose Take the boiler out of operation and close the gas tap see box 43 44 46 or 47 Remove the fan see box 77 78 79 or 80 Rial Pull the gas injector item 1 out of the gas valve We reserve the right to
115. wiring in correct working order Yes box 41 No step 3 step3 Replace the flow NTC sensor safety sensor cable loom or corresponding component of the cable loom box 42 see box 116 Kip The contacts of the flow NTC sensor and safety sensor are shorted to each other or ig there is a short circuit to earth ground or the flow or safety sensor has detected a AN CH flow temperature of above 130 C Locking boiler fault code step 1 Are the servicing valves open Yes step3 No step 2 step 2 Open the servicing valves see box 53 step 3 Is the pressure of the heating system water at least 1 bar Yes step5 No step 4 step 4 Fill and vent the heating system see box 52 step 5 Are enough thermostatic valves open on the radiators convectors etc Yes step 7 No gt step 6 step 6 Open more thermostatic valves on the radiators convectors etc box 42 step 7 Check the flow NTC sensor and safety sensor see box 104 step 8 Are the flow NTC sensor and safety sensor functioning correctly Yes step 10 No step 9 step 9 Replace the flow NTC sensor or safety sensor see box 116 step 10 Check the cables of the flow NTC sensor and safety sensor see box 112 step 11 Are the cables in order Yes step 13 No step 12 step 12 Replace the cable loom or the affected part thereof box 42 step 13 Check the pump see box 89 to 100 step 14 Is the pump working correctly Yes
116. x 164 step 5 Is the cable correctly connected and free of damage Yes step7 No gt step 6 step 6 Replace the cable loom or the affected part thereof box 42 step 7 Measure the resistance of the gas valve coils see box 171 step 8 Is the resistance correct Yes box 41 No step 9 step 9 Replace the gas valve see box 174 box 42 Bad electrical contacts circuit board or EEPROM KIM of DBA control panel defective step 1 Check the contacts on the circuit board of the DBA control panel by pushing fully home the plug and socket connections on the board check and deal with any other contact problems with plug and socket connections step 2 Switch the boiler off and then on again at the operating switch step 3 Is same fault warning message still displayed Yes step4 No gt step 8 step 4 Check the plug and socket connection on the EEPROM KIM see box 284 step 5 Has the DBA control panel been replaced Yes step7 No gt step 6 step 6 Replace the DBA control panel see box 281 step 2 step 7 Contact Boulter Buderus see on the back of this manual step 8 Has anew fault occurred Yes step9 No gt box 42 step 9 Interpret the fault code now displayed in box 20 and deal with the malfunction We reserve the right to make technical modifications Boulter Buderus Ltd http www boulter buderus co uk 36 Servicing manual Gas condensing boiler Buderus 500 2

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