Buderus 600 - 24R Installation And Servicing Instructions

7212 2900 - 02/2006 GB (EN) For the installer

Please read thoroughly

Installation and servicing

instructions

Gas wall hung Boiler condensing

Buderus 600 - 11R / 19R / 24R

2 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Subject to technical modifications!

Constant development efforts may result in changes to illustrations, functional steps and technical data.

Updating the documentation

If you have suggestions for improvement or have found discrepancies, please do not hesitate to contact us.

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.

Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006 3

Subject to modifications resulting from technical improvements! Buderus • http://www.buderus-domestic.co.uk

Contents

1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1 Technical specifications . . . . . . . . . . . . . . . . 13

1.2 Dimensions and connections . . . . . . . . . . . . 15

1.3 Boiler assembly - exploded view . . . . . . . . . 16

1.4 Items supplied with unit . . . . . . . . . . . . . . . . 17

1.5 Hanging the boiler . . . . . . . . . . . . . . . . . . . . 17

1.6 Pipe connections . . . . . . . . . . . . . . . . . . . . . 18

1.7 Flue Installation . . . . . . . . . . . . . . . . . . . . . . 21

1.8 Electrical connections . . . . . . . . . . . . . . . . . 27

1.9 External control connections . . . . . . . . . . . . 29

2 Commissioning . . . . . . . . . . . . . . . . . . . . . 30

2.1 Requirements. . . . . . . . . . . . . . . . . . . . . . . . 30

2.2 Preparing the boiler for operation . . . . . . . . 31

3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.1 General directions . . . . . . . . . . . . . . . . . . . . 40

3.2 Preparing the boiler for inspection . . . . . . . . 40

4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1 Clean the heat exchanger, burner and

condensate trap . . . . . . . . . . . . . . . . . . . . . . 41

5 Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.1 Operating codes. . . . . . . . . . . . . . . . . . . . . . 46

5.2 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.3 Checking and replacing parts . . . . . . . . . . . 55

6 Conversion to another type of gas. . . . . . 63

7 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7.1 Short list of spare parts . . . . . . . . . . . . . . . . 65

8 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

8.1 Start-up report . . . . . . . . . . . . . . . . . . . . . . . 66

8.2 Inspection and maintenance reports . . . . . . 68

G. C. Aplliance No. :

Buderus 600 - 11R 41-110-21

Buderus 600 - 19R 41-110-22

Buderus 600 - 24R 41-110-23

Other manuals available for this boiler are:

– user manual.

Preface

These installation and servicing instructions apply to:

Buderus wall-mounted condensing gas boilers

600 - 11R / 19R / 24R.

Model: C

13

, C

33

, C

53

Type: GB II

2H3P

20 mbar, 37 mbar

In this document: NG = 2H-G20-20 mbar

LPG = 3P-G31-37 mbar

Fuse rating: 1.25 Ampere slow blow (on boiler)

Power rating: 230 VAC, 50 Hz, IPX4D

A fuse main supply of 3 amp required (BS. 1362).

The boiler consists of the following components:

– 600 : Gas condensing boiler

– 11, 19, 24 : Maximum output in kW for the different

models

– R : Regular boiler.

Important general instructions for use

Only use the boiler in accordance with its designated

use and the installation and servicing instructions.

Installation, maintenance and repair must be carried out

by competent service engineers (e.g. CORGI regis-

tered). Only use the boiler in conjunction with the acces-

sories and spare parts indicated in the installation and

servicing instructions. Other accessories and consuma-

bles 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,

open vented or sealed water systems.

Adequate arrangements for completely draining the

system by provision of draining cocks must be provided

in the installation pipework.

Subject to technical modifications.

As a result of our policy of constant development, there

may be differences between illustrations, functional

steps and technical data.

BENCHMARK' Log Book

All Buderus gas fired boilers include an installation,

commissioning and service record log book. The details

of the log book will be required in the event of any

warranty work being requested.

Please complete the appropriate sections on completion

of the installation and commissioning.

REMEMBER: Please hand the log book back to the

user.

4 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Regulations and directives

It is a requirement that all gas appliances are installed

and serviced by a CORGI registered installer in accord-

ance with the regulations. Failure to install appliances

correctly could lead to prosecution. It is in your own

interest, and that of safety, to ensure the law is complied

with.

The installation must also be in accordance with the

latest I.E.E (BS.7671) Wiring Regulations, water regula-

tions, the building regulations and the Building Stand-

ards (Scotland) and any relevant requirements of the

local authority.

It is a requirement and in your own interest, and that of

safety that this boiler must be installed by a CORGI

registered installer, in accordance with the relevant

requirements of the current Gas Safety (Installation and

Use) Regulations, The Building Regulations, current

I.E.E. Wiring Regulations and the relevant British

Standard Codes of Practise.

Detailed recommendations are contained in the

following British Standard Codes of Practice:

BS. 5440:1Flues (for gas appliances of rated input not

exceeding 70 kW).

BS. 5440:2Ventilation (for gas appliances of rated input

not exceeding 70 kW).

BS. 5449 Forced circulation hot water systems.

BS. 5546 Installation of gas hot water supplies for

domestic purposes (2nd. family Gases).

BS. 6798 Installation of gas fired hot water boilers of

rated input not exceeding 60 kW.

BS. 6891 Low pressure installation pipes.

IGE/UP/1b Tightness testing and purging domestic

sized gas installations.

Health and & Safety Document No. 635.

The Electricity at Work Regulations, 1989.

The manufacturer's notes must not be taken, in any way,

as overriding statutory obligations.

The design and construction of the Buderus wall-

mounted condensing gas boiler 600 - 11R/19R/24R

conforms to the basic specifications listed in the

European directive governing gas-fired appliances

90/396/EEC, and with respect to EN 625, EN 483 and

EN 677.

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it

should be fitted in accordance with the Institute of Gas

Engineering document IGE/UP/7:1998.

Bathroom Installations

This appliance is rated IPX4D.

The boiler may be installed in any room or internal

space, although particular attention is drawn to the

requirements of the current IEE (BS.7671) Wiring Regu-

lations and, in Scotland, the electrical provisions of the

building regulations applicable in Scotland, with respect

to the installation of the boiler in a room or internal space

containing a bath or shower.

If the appliance is to be installed in a room containing a

bath or shower then, providing water jets are not going

to be used for cleaning purposes (as in communal

baths/showers), the appliance can be installed in

Zone 3, as detailed in BS.7671.

Compartment Installations

A compartment used to enclose the boiler should be

designed and constructed especially for this purpose.

An existing cupboard or compartment may be used,

provided that it is modified for the purpose.

In both cases, details of essential features of cupboard/

compartment design, including airing cupboard installa-

tion, are to conform to the following:

BS 6798 (No cupboard ventilation is required - see 'Air

Supply' for details).

NOTE

Observe the corresponding technical

rules and the building supervisory and

statutory regulations when installing and

operating the system.

WARNING!

Keep the burner-control unit housing

CLOSED when working on water-bearing

components.

NOTE

It is mandatory to inspect 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.

Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006 5

Subject to modifications resulting from technical improvements! Buderus • http://www.buderus-domestic.co.uk

It is not necessary to have a purpose-provided air vent

in the room or internal space in which the boiler is

installed. Neither is it necessary to ventilate a cupboard

or compartment in which the boiler is installed, due to

the low surface temperatures of the boiler casing during

operation; therefore the requirements of BS 6798,

Clause 12, and BS 5440:2 may be disregarded.

The permanent clearances required are:

in front: 8 mm

below: 21 mm

right side: 5 mm

left side: 5 mm

above: 21 mm

The position selected for installation MUST allow

adequate space for servicing in front of the boiler.

See table below:

in front: 350 mm

below: 50 mm

right side: 5 mm

left side: 5 mm

above: 200 mm

For the minimum clearances required for safety and

subsequent service, see the wall mounting template.

In addition, sufficient space may be required to allow

lifting access to the wall mounting plate.

Wall-mounted condensing gas boilers must only be

operated with the combustion air/flue gas systems espe-

cially devised and authorised for this type of boiler.

Observe the relevant standards, regulations and legisla-

tion of the country of final use.

The hydraulic resistance of the boilers is shown in the

graph below.

graph 1

CAUTION!

Use this device for its intended purpose

only.

WARNING!

DANGER!

notes relating to the heating system

water.

Thoroughly flush the system before it is

filled with water. Use only untreated water

or water treatment product such as

Sentinal X100 to fill and top up the

system.

When using water treatment, only prod-

ucts suitable for use with Buderus heat

exchangers are permitted (e.g. Sentinel

X100). Your warranty is at risk if an incor-

rect water treatment product is used in

conjunction with this appliance.

For more information, contact Buderus

Product Support Department.

It is most important that the correct

concentration of the water treatment

product is maintained in accordance with

the manufacturer's instructions.

If the boiler is used in an existing system

any unsuitable additives MUST be

removed by thorough cleaning.

BS.7593:1992 details the steps neces-

sary to clean a domestic central heating

system.

In hard water areas, treatment to prevent

lime scale may be necessary - however,

the use of artificially softened water is

NOT permitted.

Under no circumstances should the boiler

be fired before the system has been

thoroughly flushed.

Do not use water softened in a salt

bedding exchanger.

Do not use anti-freeze or other additives.

The expansion vessel must be of

sufficient size.

When oxygen-permeable pipes are used

(e. g. for floor heating systems) the

system must be separated by means of

heat exchangers. Unsuitable heating

water promotes sludge formation and

corrosion. This may cause malfunctions

and damage in the heat exchanger.

This appliance is not suitable for gravity

central heating nor are they suitable for

the provision of gravity domestic hot

water.

The boiler must be vented.

Drain cocks must be located in accessible

positions, which permits the draining of

the entire system. They should be at least

½" BSP nominal size and be in accord-

ance with BS 2879.

0

50

100

150

200

250

300

350

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3

resistance (mbar)

resistance heat exchanger

flow (m /h)

3

6 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Safe handling of substances

Care should be taken when handling the boiler's insula-

tion, which can cause irritation to the skin.

No asbestos, mercury or CFCs are included in any part

of the boiler and its manufacture.

Open vent system requirements

The system should be vented directly off the boiler flow

pipe, as close to the boiler as possible. The cold feed

entry should be inverted and MUST be positioned

between the pump and the vent, and not more than

150 mm away from the vent connection.

There should be a minimum height, 450 mm, of open

vent above the tank water level. The vertical distance

between the highest point of the system and the

feed/expansion cistern water level MUST not be less

than 1000 mm. The pump must be fitted on the flow side

of the boiler.

A suitable pump is a domestic circulator capable of

providing a maximum 11 °C temperature differential

across the boiler with the whole of the heating circuit

open. With the minimum flow circuit allowed by the

controls the differential must not exceed 25 °C

(see also the graph on page 5).

The vertical distance between the pump and

feed/expansion cistern MUST comply with the pump

manufacturer’s minimum requirements, to avoid cavita-

tion. Should these conditions not apply either lower the

pump position or raise the tank above the minimum

requirements specified by Buderus. The isolation valves

should be fitted as close to the pump as possible.

The system will work more efficiently when the flow

temperature is as low as possible.

NOTE:

notes relating to domestic hot water.

The boiler must not be used for direct hot

water supply.

The hot water storage cylinder must be of

the indirect type.

Primatic cylinders are not recommended

and must not be used on sealed systems.

The hot water cylinder and ancillary

pipework, not forming part of the useful

heating surface, should be lagged to

prevent heat loss and any possible

freezing - particularly where pipes run

through roof spaces and ventilated under-

floor spaces.

The domestic hot water service must be in

accordance with BS 5546 and BS 6700.

fig. 1 Open vent system

22 mm

open vent

Water

level

(cold)

Feed / expansion

tank

450 mm

minimum

1000 mm

minimum

15 mm

cold

feed

150 mm

max.

System

return

System

flow to

pump

Inverted cold

feed entry

Connection

to boilers

Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006 7

Subject to modifications resulting from technical improvements! Buderus • http://www.buderus-domestic.co.uk

Schematic pipework

The boiler does not normally need a bypass but is

required when using 2 port zone valves. Lock shield

valves are required on the radiators in the area where

the thermostat is situated.

Thermostatic radiator valves

An automatic bypass is always required.

To comply with the building regulations that heating

systems utilising the thermostatic radiator valve control

of temperature in individual rooms shall also be fitted

with a room thermostat, controlling the temperature in a

space served by radiators not fitted with such a valve.

Such an arrangement will provide for potentially more

efficient control of the environment and will also avoid

the continuous running of the circulation pump during

programmed heating ON periods - thus saving electrical

energy.

It is, therefore, strongly recommended that, when ther-

mostatic radiator valves are used, space heating

temperature control over a living/dining area or a

hallway having a heating requirement of at least 10% of

the minimum boiler heat output, is achieved using a

room thermostat whilst other rooms are individually

controlled by thermostatic radiator valves.

System examples

fig. 2 Schematic pipework

BOILER

Return

Flow

22 mm

open vent

Elbow

then

tee

15 mm

cold

feed

Radiators

Cylinder

balancing

valve

3 port

valve

Air vent

Alternative

2x2 port

valves

automatic

bypass

NOTE

System examples are to be regarded as

schematic representations only.

8 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Buderus 600 Regular with external 230V connection (Y-plan)

Key to abbreviations:

AB = Automatic Bypass

AV = Air Vent

CB = Connection Block

CBV= Cylinder Balancing Valve

CHF = Central Heating Flow

CHR = Central Heating Return

CT = Cylinder Thermostat

DV = Diverter Valve

FEC = Feed / Expansion Cistern

JB = Junction Box /

RTH Converter

LSV = Lockshield Valve

PL = Permanent Live

PM = Pump

Prog= Programmer

RT = Room Thermostat

TRV = Thermostatic Radiator

Valve

WC = Wiring Centre

fig. 3

fig. 4 Y-plan 230V

Prog

reference room / main living area

other rooms

PL

CT

DVPM

TRV

LSV

Cylinder

radiator radiator

AV

WC

RT

CHF CHR

FEC

JB

CBV

CB

AB

perty rights.

1

3

2

RT

4

5

2

1

C

2

CT

8

7

6

White

Blue

Grey

Orange

Gr / Yel

5

2

7

8

3

L

N

E

230 vac

1

2

3

HW OFF

HW ON

CH ON

L

N

E

Programmer

7

6

4

1

2

3

1

2

3

230 vac

8

2

Brown

Blue

Gr / Yel

1

2

3

L

N

E

Pump

8

2

3

JB / RTH converter

UBA

10

1

TYPE: UBA4001

Max Safetytime 10sec

CE REG nr.63A 05280

DV

PL

1

2

3

4

5

6

7

8

9

10

WC

Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006 9

Subject to modifications resulting from technical improvements! Buderus • http://www.buderus-domestic.co.uk

Buderus 600 Regular with external 230V connection and two port zone valves (S-plan)

Key to abbreviations:

AB = Automatic Bypass

AV = Air Vent

CB = Connection Block

CBV= Cylinder Balancing Valve

CHF = Central Heating Flow

CHR = Central Heating Return

CT = Cylinder thermostat

FEC = Feed / Expansion Cistern

JB = Junction Box /

RTH Converter

LSV = Lockshield Valve

PL = Permanent Live

PM = Pump

Prog= Programmer

RT = Room thermostat

TRV = Thermostatic Radiator

Valve

WC = Wiring Centre

ZV = Two port Zone Valve

fig. 5

fig. 6 S-plan 230V

Prog

reference room / main living area

other rooms

PL

CT

PM

TRV

LSV

Cylinder

radiator radiator

AV

WC

RT

CHF CHR

FEC

JB

CBV

CB

ZV

AB

1

3

2

RT

4

5

2

1

C

2

CT

8

Not used

6

White

Blue

Grey

Orange

Gr / Yel

5

2

1

10

3

L

N

E

230 vac

1

2

3

HW OFF

HW ON

CH ON

L

N

E

Programmer

Not used

6

4

1

2

3

1

2

3

230 vac

10

2

Brown

Blue

Gr / Yel

1

2

3

L

N

E

Pump

10

2

3

JB / RTH converter

1

2

3

4

5

6

7

8

9

10

WC

UBA

10

1

TYPE: UBA 4001

Max Safety time 10 sec

CE REG nr. 63A 05280

ZV

CH

White

Blue

Grey

Orange

Gr / Yel

8

2

1

10

3

ZV

DHW

PL

10 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Sealed system requirements

1. General

The installation must comply with the requirements of

BS. 6798 and BS. 5449.

All components of the system, including the heat

exchanger of the indirect cylinder, must be suitable for a

working pressure of 3 bar and temperature of 110 °C.

Care should be taken in making all connections so that

the risk of leakage is minimised.\

2. Safety valve

A spring loaded safety valve complying with the relevant

requirements of BS. 6759 must be fitted in the flow pipe

as close to the boiler as possible and with no intervening

valve or restriction. The valve should have the following

features:

– A non-adjustable preset lift pressure not exceeding

3 bar;

– A manual testing device;

– Provision for connection of a discharge pipe. The

valve or discharge pipe should be positioned so that

the discharge of water or steam cannot create a

hazard to the occupants of the premises or cause

damage to electrical components and wiring.

3. Pressure gauge

A pressure gauge covering at least the range of 0-4 bar

must be fitted to the system. The gauge should be easily

seen from the filling point and should preferably be

connected at the same point as the expansion vessel.

4. Expansion vessel

A diaphragm type expansion vessel must be connected

to a point close to the inlet side of the pump, the

connecting pipe being not less than 15 mm size and not

incorporating valves of any sort.

The vessel capacity must be adequate to accept the

expansion of the system water when heated to 110 °C.

The charge pressure must not be less than the static

water head above the vessel. The pressure attained in

the system when heated to 110 °C should be at least

0.35 bar less than the lift pressure of the safety valve.

For guidance on vessel sizing refer to table 1.

For further details refer to BS. 5449 and BS. 7074:1 and

the British Gas Corporation publication: "Material and

Installation Specifications for Domestic Central Heating

and Hot Water".

5. Cylinder

The cylinder must be either of the indirect coil type or a

direct cylinder fitted with an immersion calorifier which is

suitable for operating on a gauge of 0.35 bar in excess

of the safety valve setting. Primatic cylinders are not

suitable for sealed systems.

6. Make-up water

provision must be made for replacing water loss from the

system, either:

– from a manually filled make-up vessel with a readily

visible water level. The vessel should be mounted at

least 150 mm above the highest point of the system,

and be connected through a non-return valve to the

system, filled at least 300 mm below the make-up

vessel on the return side of the domestic hot water

cylinder or radiators.

or

– where access to a make-up vessel would be difficult

by pre-pressurisation of the system. Refer to "Filling",

below.

7. Mains Connection

There must be no direct connection to the mains water

supply or to the water storage tank supplying domestic

water, even through a non-return valve, without the

approval of the local water authority.

fig. 7 System fill and make up

Heating return

Hose

return

Non return

valve

Non return

valve

Test cock

Stop cock

Mains

supply

Stop

cock

Temporary hose

SYSTEM FILL

Fill point

Heating return

Auto

air vent

Non

return valve

Stop

valve

Make up

vessel

1000 mm

above the

highest point of

the system

SYSTEM MAKE UP

Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006 11

Subject to modifications resulting from technical improvements! Buderus • http://www.buderus-domestic.co.uk

8. Filling

The system may be filled through a temporary hose

connection from a draw-off tap supplied from a servicing

pipe under mains pressure. Where the mains pressure

is excessive a pressure reducing valve shall be used to

facilitate filling.

The following fittings shall form a permanent part of the

system and shall be fitted in the order stated:

– A stop valve complying with the requirements of

BS. 1010, Part 2 (the hose from the draw-off tap

shall be connected to this fitting);

– A test cock;

– A double check valve of an approved type.

Sizing procedure for expansion vessel

The volume of the expansion vessel (litres) fitted to a

sealed system shall not be less than that given by

table 1, multiplied by a factor of 0.8 (for flow tempera-

tures of less than 80 °C).

Safety valve setting 3.0 bar

Vessel charge and

initial system pressure

0.5 1.0 1.5

bar bar bar

Total water content of

system (litres)

Expansion vessel

volume litres

25 2.1 2.7 3.9

50 4.2 5.4 7.8

75 6.3 8.2 11.7

100 8.3 10.9 15.6

125 10.4 13.6 19.5

150 12.5 16.3 23.4

175 14.6 19.1 27.3

200 16.7 21.8 31.2

225 18.7 24.5 35.1

250 20.8 27.2 39.0

275 22.9 30.0 42.9

300 25.0 32.7 46.8

Multiplying factors for

other system volumes

0.0833 0.109 0.156

Table 1 Expansion vessel volumes

12 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Hazard definitions and abbreviations

Hazard definitions

Abbreviations

AB = Automatic Bypass

AV = Air Vent

CB = Connection Block

CBV = Cylinder Balancing Valve

CH = Central Heating

CHF = Central Heating Flow

CHR = Central Heating Return

CT = Cylinder Thermostat

CWDO= Condensate water drainage outlet

DV = Diverter Valve

E=Earth

FEC = Feed / Expansion Cistern

L=Live

LSV = Lock Shield Valve

MCW = Mains Cold Water

N = Neutal

JB = Junction Box / RTH Converter

PL = Permanent Live

PM = Pump

Prog = Programmer

PRV = Pressure relief valve (safety valve)

RT = Room Thermostat

T=Timer

TRV = Thermostatic Radiator Valve

WC = Wiring Centre

ZV = Two Port Zone Valve

WARNING!

DANGER:

Indicates the presence of hazards that will

cause severe personal injury, death or

substantial property damage.

WARNING!

WARNING:

Indicates the presence of hazards that can

cause severe personal injury, death or

substantial property damage.

CAUTION!

CAUTION:

Indicates presence of hazards that will or

cause minor personal injury or property

damage.

NOTICE:

Indicates special instructions on installation,

operation or maintenance that are important

but not related to personal injury or property

damage.

Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006 13

Subject to modifications resulting from technical improvements! Buderus • http://www.buderus-domestic.co.uk

Installation 1

1 Installation

1.1 Technical specifications

Dimensions Unit

600 Series Buderus wall-mounted condensing gas boiler

11R 19R 24R

Type of gas supply as established in

EN 437 (GB)

GB II

2H3P

20 mbar, 37 mbar

(natural gas

H, propane P)

Rated heating capacity for system

temperature (modulating from 30° to 100°)

Heating curve 75/60 °C

Heating curve 40/30 °C

kW

4.3 - 10.0

4.9 - 11.0

8.6 - 17.4

9.7 - 19.0

8.6 - 22.0

9.7 - 24.0

Seasonal efficiency (SEDBUK) % 90.3 90.3 90.2

Central heating installation

Heating water temperature °C 40 - 80

ΔT at residual head of 200 mbar °C <20

Max. operating overpressure of boiler bar 3.0

Volume heat exchanger heating circuit l 1.0

Pipe connections

Gas (compression fitting) mm Ø 22

CH flow/return mm Ø 22

Condensate water outlet inch G1"

Flue gas values

Condensate water quantity, natural gas,

40/30 °C

l/h 0.7 1.3 1.6

pH value of condensate water approx. 4.1

Flue gas mass-flow rate

Full load

Part-load

g/s

4.9

2.2

8.4

4.3

10.6

4.3

Flue gas temperature, full load

Heating curve 75/60 °C

Heating curve 40/30 °C

°C

75

50

85

55

95

55

Flue gas temperature, part-load

Heating curve 75/60 °C

Heating curve 40/30 °C

°C

65

40

70

45

70

45

CO

2

full load, natural gas

standard test gas G20 % 9.2

CO

2

full load, natural gas

standard test gas LPG % 10.3

Standard emission factor CO mg/kWh <22

Standard emission factor NO

x

mg/kWh <30

Max. pressure drop permitted Pa 35 60 100

14 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Installation1

Flue-gas system

Type of flue gas connection C

13

, C

33

, C

53

Standard diameter of flue gas system mm 60/100

Electrical data

Mains connection voltage V 230

Electrical power consumption

Full/Part load W 40/25 40/25 40/25

Electrical protection rating IPX4D

Boiler dimensions and weight

Height x Width x Depth mm 700 x 460 x 290

Weight (without casing) kg 23.5 23.5 23.5

Casing kg 5.5 5.5 5.5

Dimensions Unit

600 Series Buderus wall-mounted condensing gas boiler

11R 19R 24R

Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006 15

Subject to modifications resulting from technical improvements! Buderus • http://www.buderus-domestic.co.uk

Installation 1

1.2 Dimensions and connections

460 mm

230 mm

50 mm

Ø100 mm

Ø60 mm

290 mm

105 mm

700 mm

604 mm

20 mm

70 mm

82 mm

328 mm

376 mm

25 mm

145 mm

130 mm

CH RETURN

CH FLOW

695 mm

GAS

CWDO

119 mm

8 mm

200 mm

21 mm

8 mm

CH Flow = Ø22 mm copper

CH return = Ø22 mm copper

GAS = Ø22 mm compression fitting

CWDO = Condensate water drainage outlet G1" OUTSIDE

16 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Installation1

1.3 Boiler assembly - exploded view

Regular unit (11R / 19R / 24R)

Legend

1. Casing

2. Door complete

3. Ventilation cover

4. Bracket

5. Concentric adaptor

6. Clip adaptor

7. 100 mm Lipring

8. Fan

9. Seal Fan / Venturi

10. 60 mm Lipring

11. Flue gas pipe

12. Condensate collector

13. Seal flue gas pipe

14. Flue gas thermostat (STL)

15. Condensate trap

16. Air silencer tube

17. 50 mm Lipring

18. Gas valve

19. Rectifier

20. Venturi

21. Gas pipe

22. Gas service valve

23. Pipe return/flow top

24. Pipe connection

25. Clip

26. Return pipe

27. Drain cock

28. Connection return

29. Sensor

30. Flow pipe

31. Connection supply

32. Spring heat exchanger

33. Automatic air vent

34. O-ring heat exchanger

35. Seal heat exchanger

36. Safety sensor

37. O-ring

38. Rearpart heat exchanger

39. Gasket heat exchanger

40. Insulation rearpart heat

exchanger

41. Burner 11 kW

Burner 19-24kW

42. Burner seal

43. Heat exchanger

44. Restrictor baffle

45. Front heat exchanger insulation

46. Frontpart heat exchanger

47. Sight glass

48. Securing latch

49. UBA

50. Power switch

51. Glow ignitor

52. Ionisation electrode

53. Cable fan

54. Cable harness

55. Frame

56. RTH converter 230V

57. Seal ventilation cover

58. Assembly casing block

59. Seal

60. Air seal bush

61. Bracket ionisation electrode &

glow ignitor

62. Syphon seal condensate trap

63. Seal syphon

64. Insulation divider

65. Clip & screw insulation divider

66. Cap

67. Seal ionisation electrode

68. Clip air silencer

69. Gas air supply

70. Valve fan / gas air supply

71. Seal glow ignitor

72. Shield glow ignitor

73. Seal venturi / gasket

74. Seal fan / gas air supply

75. Gas air supply valve

76. Plate screw

77. Casing clip

78. Clip

79. Screw M5

80. Gasket

81. Clip

82. Seal flue gas thermostat

83. Seal condensate pipe

84. Swivel dreg with pinchring

85. Screw

86. Syphon

87. Drain pipe condensate trap / syphon

88. 60 mm Lipring

1

44

42

30

24

38

25

9

31

20

23

78

24

37

3

15

16

17

54

10

7

6

21

13

48

45

25

33

32

34

28

35

51

52

18

53

11

43

41

46

22

78

50

49

4

29

26

27

36

19

40

39

2

47

12

8

14

5

55

56

86

59

63

62

76

72

71

67

79

73

80

68

64

48

70

73

74

69

78

81

29

25

32

35

34

65

82

85

66

83

88

60

84

60

77

58

57

87

Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006 17

Subject to modifications resulting from technical improvements! Buderus • http://www.buderus-domestic.co.uk

Installation 1

1.4 Items supplied with unit

z Check the contents against the packing list to ensure

that no parts are missing.

Key to fig. 1:

item 1: Wall-mounted condensing gas boiler

item 2: Wall bracket

item 3: Technical documents

item 4: CH Flow connection pipe

item 5: CH Return connection pipe

item 6: Gas service valve

item 7: Plastic bag containing the following accessories:

2 x wall fixing-screws

2 x wall plugs

2 x washers

Seals (2 x ¾“)

Square wrench

Initial start-up sticker

Second identification plate

1.5 Hanging the boiler

The boiler is transported in a horizontal position.

z Open the box and remove the four foam supports

(fig. 2, item 1). The casing is not attached to the

boiler.

z Take out the casing (fig. 2, item 2) and put aside

during installation.

z Hang the wall mounting template.

z Drill the necessary holes.

z Take out the wall bracket (fig. 1, item 2) and attach to

the wall using the wall mounting template.

z Take out the condensing gas boiler (fig. 2, item 3)

and hang onto the wall bracket (fig. 3).

z Dispose of packaging.

Fig. 1 Items supplied with unit

1

2

3

7

4

6

5

Fig. 2 Unpacking the box

1

2

3

CAUTION!

Do not carry the boiler by the casing at

any time.

Fig. 3 Installation

18 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Installation1

1.6 Pipe connections

Buderus advises to use copper piping for the first

600 mm, then it is allowed to switch to another approved

pipe material.

z Take the CH flow connection pipe and the CH return

connection pipe out of the box and connect to the

condensing gas boiler (fig. 4, item 1 and 2).

z Connect the central heating system to these pipe

connections according to the relevant standards.

1.6.1 Gas Supply

The gas installation must be installed in accordance with

BS.6891.

The complete installation MUST be tested for gas

tightness and purged as described in IGE/UP/1b.

1.6.2 Gas connection

z A gas service valve is supplied with the unit. Take it

out of the box and connect it to the boiler see fig. 4,

item 3 with approved P.T.F.E.-tape. Connect to gas

supply according to the relevant standards.

1.6.3 Water circulation system

The central heating system should be installed in

accordance with BS.6798 and, in addition, for smallbore

and microbore systems, BS.5449 or EN 12823.

1.6.4 Condensate removal

Positioning and termination of the condensate drain

pipe

The condensate pipe should be run and terminate

internally to the house soil and vent stack or waste pipe.

Alternatively, the condensate can be discharged into the

rainwater system if connected to a foul water draining

system, or into a purpose-made soak away (condensate

absorption point).

All connecting drainage pipework should generally have

a fall of at least 2.5° to the horizontal, or approximately

50 mm per metre of pipe run. If this is can not be

achieved, consider the use of a condens pump.

Fig. 4 Pipe connections

Key to fig. 4:

item 1: CH flow

item 2: CH return

item 3: Gas

item 4: Condensate water drainage outlet (CWDO)

12

4

3

CAUTION!

Ensure that all pipework is routed so as to

minimise any strain on the boiler fittings.

CAUTION!

Pipework from the meter to the boiler

MUST be of adequate size.

Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006 19

Subject to modifications resulting from technical improvements! Buderus • http://www.buderus-domestic.co.uk

Installation 1

If an external pipe run is unavoidable then the run should

be insulated with water proof insulation limited to 3 m in

length. Should this be exceeded then the pipework

diameter should be increased to 32mm and the

pipework insulated using weather proof materials.

It should be noted that the connection of a condensate

pipe to a drain may be subject to local building controls.

Material for condensate

The condensate drainage pipe should be run in a

standard drain pipe material, e.g. PVC (polyvinyl

chloride), PVC-U (unplasticized polyvinyl chloride),

BS (acrylonitrile-butadienestyrene), PP (polypropylene

polyprolene) or PVC-C (cross-linked polyvinyl chloride).

The condensate drain can be attached to the syphon

(fig. 5).

Any internal pipework should be of a diameter to match

the requirements of the condensate exit pipe on the

appliance.

Internal termination to internal stack

The condensate drainage pipe should have a minimum

outside diameter of 1" with no length restriction. It should

incorporate a trap with a 75 mm condensate seal and be

connected to the stack at a point at least 450 mm above

the invert of the stack. The trap built into the boiler will

provide this 75 mm (fig. 6) condensate seal.

WARNING!

Any external run must be insulated with

water proof insulation.

Fig. 5 Condensate outlet

NOTE

Ensure that the condensate trap is filled

with water.

Fig. 6 Internal termination of condensate drainage pipe to

internal stack

No length restriction

Ø22 mm min.

75 mm min. trap

internal soil

and vent stack

invert

Boiler

450 mm min.

20 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 02/2006

Buderus • http://www.buderus-domestic.co.uk Subject to modifications resulting from technical improvements!

Installation1

External termination via internal branch (e.g. sink

waste)

The condensate drainage pipe should have a minimum

outside diameter of 1" with no length restriction. The

connection should preferably be made downstream of

the sink waste trap. If the connection is only possible

upstream, then the air break is needed between the two

traps. This is normally provided by the sink waste pipe

(see fig. 7 and 8).

Condensate absorption point

The condensate drainage pipe should have a minimum

outside diameter of 1" and the external pipe length

should not be more than 3 m. The condensate

absorption point should be sited in a convenient position

as close as possible to the boiler but not in the vicinity of

other services. See fig. 9 for information.

Fig. 7 External termination of condensate drainage pipe

via internal discharge branch (e.g. sink waste) and

condensate syphon

75 mm min. trap

No length restriction

Ø22 mm min.

Open end of pipe

direct into gully,

below ground but

above water level

Boiler

Sink

Fig. 8 External termination of condensate drainage pipe

via internal discharge branch (e.g. sink waste –

proprietary fitting) and condensate syphon

No length

restriction

Boiler

Open end of pipe

direct into gully,

below ground but

above water level

75 mm min. trap

Ø22 mm min.

Sink

Fig. 9 External termination of condensate drainage pipe to

absorption point

Ø100 mm min.

plastic tube

bottom of

tube sealed

limestone

cladding

hole depth

400 mm min.

300 mm min.

25 mm min.

Ground

(either/or)

Two rows of three

12 mm holes at 25 mm centres

50 mm from bottom of tube and

facing away from house

1000 mm min.

Ø22 mm min.

External length of

pipe 3m max.

NOTE

When discharging condensate to an

outside drain caution must be taken to

ensure blockage cannot occur during

freezing conditions. If this is likely to

occur, the use of a syphon trap is

recommended.

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