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Buderus 800-24 Installation And Servicing Instructions

Wall hung condensing
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7212 3900 - 02/2006 GB(EN)
For trade use

Installation and servicing

instructions
Gas wall hung Boiler condensing
Buderus 800 - 24/29/43/60 and
Buderus 800 - 24T25/29T25 H/V
Please read thoroughly before installation and servicing

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Summary of Contents for Buderus 800-24

  • Page 1: Installation And Servicing

    7212 3900 - 02/2006 GB(EN) For trade use Installation and servicing instructions Gas wall hung Boiler condensing Buderus 800 - 24/29/43/60 and Buderus 800 - 24T25/29T25 H/V Please read thoroughly before installation and servicing...
  • Page 2 If you have suggestions for improvement or have found discrepancies, please do not hesitate to contact us. Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 3: Table Of Contents

    Installation....... 6 Buderus wall-mounted condensing gas boilers Dimensions, connections and assembly ..6 800 –...

  • Page 4: Regulations And Directives

    BENCHMARK' Log Book : Please hand the log book back to the user. All Buderus gas fired boilers now include an installation, commissioning and service record log book. The details of the log book will be required in the event of any warranty work being requested.
  • Page 5 Sentinal X100 to fill and top up the system. When using water treatment, only products CAUTION suitable for use with Buderus heat exchangers Provision must be made to accomodate the are permitted (eg Sentinel X100). Your expansion of DHW contained within the...

  • Page 6: Installation

    (3") (12 ") (2 ") (8 ") (3") 431 mm (17") Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 7 Minimum side clearance required for all boilers is 100 mm (4") Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 8: Boiler Assembly - Exploded View

    570 Non return valve R 1/4'' 480 Temperature / pressure gauge 580 Pump Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 9: Flue Installation

    M. Adjacent to opening action can be taken. Table 1 Balanced flue terminal position Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 10 Air supply and flue gas exhaust in a closed installation To ensure optimal operation, the 800 Series appliances must be connected to a Buderus wall-mounted or roof-mounted flue terminal. These terminals have been developed specifically for the 800 Series condensing gas boilers and have been comprehensively tested.

  • Page 11: Items Supplied With Unit

    Do not remove the polystyrene foam bottom slab protecting the 5: screw fittings for connecting the boiler (heating system) connection nozzles. During installation the gas boiler and the gas service valve ½" (800-24/29/43) flue gas adapter must be protected to prevent site dirt from gas service valve ¾" (800-60) entering, e.g.

  • Page 12: Water Circulation System

    The complete installation MUST be tested for gas tightness and purged as described in IGE/UP/1b. fig. 7 Gas connection Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 13 Hot water connection horizontal boilers (type 800 – 24T25H / 800 – 29T25H) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 14 12 Remove sealing cap on condensate water bypass (applies only to boiler connection pieces made of plastic) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 15: Flue Installation

    Installation Flue installation The only flue systems that may be used are those supplied by Buderus. The flue system must be installed in accordance with the requirements of BS5440:1. 2000. Standard 125 mm flue systems See subsection 1.3.3 for the maximum horizontal straight length of each type boiler.
  • Page 16 18 Flue terminal position Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 17: Electrical Connections

    Electrical connections 1.9.1 Mains connection NOTE All Buderus boilers require a permanent live. A mains supply of 230 V - 50Hz is required. External controls are suitable for volt free or 230 V installation. Wiring to the boiler MUST be in accordance with the current I.E.E.
  • Page 18 Do not connect 230V to the connection block on the UBA. fig. 20 Wiring diagram Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 19 The wall-mounted condensing gas boiler can be fitted with the following control devices: fig. 21 Connecting a three-way valve of an external storage-type – Buderus programmable room thermostat water heater (see subsection 1.9.5). – A room-temperature control device at 230V connected to the RTH converter (see subsection 1.9.6);...
  • Page 20 (fig. 23, item 1). fig. 23 Service-tool connection Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 21: System Examples

    WC = Wiring Centre other rooms reference room / main living area Buderus 800 with external 230V connection and two port zone valves Key to abbreviations : Cylinder = Air Vent = Connection Block CHF = Central Heating Flow...

  • Page 22: Initial Start-Up

    Place hose on the draining tule. Turn to drain the system. Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 23 IGE/UP/1b. Ensuring all safety requirments are met. fig. 29 Purging the gas supply pipe (Honeywell gas units) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 24: Start-Up Work

    Natural gas H 8.00 36.40 Table 5 Gas and air injector diameters Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 25 Factory setting = 80 °C (controller poition 10). Table 6 Flow temperature Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 26 96.3 94.8 95.8 – 95.2 – 94.7 Table 9 Capacity losses Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 27 (fig. 35, item 2 or fig. 36, item 2). fig. 34 Chimney sweeper switch Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 28 – in accordance with the CO content. fig. 37 Service button Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 29 40 Flue gas measuring point Set the chimney sweeper switch to "0". Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 30 Press the reset button until "r" is shown on the display. Close the cover. Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 31 Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 32: Inspection

    64 and fill out the Benchmark. Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 33: Maintenance

    Turn and pull out the safety retainer of the fan (fig. 45, item 2). fig. 45 Removing the fan Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 34 Pull out the baffle plate (fig. 48). fig. 48 Baffle plate Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 35 24 VAC fig. 51 Checking the operation of the condensate water bypass Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 36 (fig. 52). fig. 52 Condensate water bypass sealing cap Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 37: Servicing

    Reset (after reset button has been pressed for 5 sec. UBA is reset to the switch-on condition) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 38: Fault Codes

    Water pressure is too low in the installation Top up the system (see subsection 2.1.1) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 39 Check if the flue gas retarder is installed in the heat exchanger Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 40 Check the cable harness and/or connector of the sensor (see subsection 5.3.12) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 41 – Press reset. If fault code remains than try to temporarily connect a different UBA (see subsection 5.3.5) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 42 Ionisation electrode may be faulty Check the cabling on the ionisation electrode Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 43 – Check if the are any peaks in the electrical network caused by maybe windmills or a power generator Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 44 KIM error Possible Action cause Kim connected incorrectly or KIM defective Check the KIM connector and fan connector (see subsection 5.3.21). If the connectors are fine then contact Buderus Code Meaning Gas valve assembly error Possible Action cause Wiring to the gas valve incorrect, or loose wiring –...
  • Page 45 Kim connected incorrectly or KIM defective – Check the KIM connector and fan connector (see subsection 5.3.21). If the connectors are fine then contact Buderus Problem: No DHW , despite the system being operational – Set chimney sweep switch to "0"...

  • Page 46: Checking And Replacing Parts

    Connect system to mains power supply. fig. 55 Checking the fuses Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 47 Move mains power switch to “I”. fig. 57 Replacing the UBA Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 48 Replace the fan Reassemble in reverse order. fig. 60 Removing the fan Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 49 Fill the 800 Series and purge the system of air. fig. 63 Cable modulating pump Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 50 65 Checking the safety sensors fig. 66 Checking the mains-water sensor Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 51: Close Maintenance Isolating Valves

    40,000 50,000 60,000 70,000 80,000 fig. 69 Outside temperature sensor diagram Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 52 71 Checking the cable to the flow/return sensors fig. 72 Checking the cable to the safety sensor Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 53 Reconnect cable lugs and plug in once more. fig. 75 Replacing the burner thermostat Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 54 78 Checking the hose connection between the gas-air injector and gas-valve assembly (Honeywell gas units) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 55 If the gas-valve assembly activation system is in order, plug the cable in once more. Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 56: Note Order Of Cable Terminals

    Connect system to mains power supply. fig. 83 Checking the wiring connection to the KIM Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 57 85 Checking the three-way valve for correct activation Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 58 (located on the fume exhaust outlet). fig. 88 Function diagram of condensation-water bypass Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 59: Appendix

    = 60 °C [kWh] – approx. 1.6 – approx. 1.6 – – temp Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 60 Width [mm] Depth [mm] Weight without casing [kg] Weight casing [kg] Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 61: Residual Pump Lift For Wall-Hung Gas Boilers

    2600 1000 1200 1400 1600 1800 2000 Flow [l/h] Flow [l/h] Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 62: Short List Of Spare Parts

    Burner seal (800-24 only) 73475 15022s (set of 10 pieces) Burner seal (800-29 only) 73441 Pump power cable complete with Gas/air distribution plate (800-24 only) 73217 73319 connector Gas/air distribution plate (800-29 only) 73208 Ring (set of 5 pieces) 73480s...

  • Page 63: Reports

    Confirm commissioning (see Benchmark) Confirmation of professional commissioning (Company stamp, signature) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...

  • Page 64: Inspection And Service Reports

    Confirm servicing work Confirmation of professional servicing work (Company stamp, signature) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 65 ––––––––––––––––– mbar mbar mbar mbar mbar ––––––––––––––––– ––––––––––––––––– ––––––––––––––––– ––––––––––––––––– ––––––––––––––––– Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 66 CORGI registered installer (company stamp, signature) Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 67 ______________ % _______________ % _______________% ______________ % ______________ % ______________ % Subject to modifications resulting from technical improvements ! Buderus • http://buderus-domestic.co.uk Installation and servicing instructions condensing gas boiler 800 - 24/29/43/60 and 800 - 24T25/29T25 H/V • edition 02/2006...
  • Page 68 Fax: 01905 - 456 445 / 455 394 Returns: Tel: 01905 - 752 531 Fax: 01905 - 455 392 Spares: Tel: 01905 - 752 576 Fax: 01905 - 754 620 www.buderus-domestic.co.uk Buderus is a trading name of BBT Thermotechnology UK Ltd.

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