Buderus 800 User Manual
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Buderus 800 User Manual

Wall-mounted condensing gas boiler
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Users manual

Buderus 800 - 24/29/43/60 and
Buderus 800 - 24T25/29T25 H/V
Wall-mounted
condensing gas boiler
For the user
Please read thoroughly
before operating the unit

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Summary of Contents for Buderus 800

  • Page 1: Users Manual

    Users manual Wall-mounted condensing gas boiler Buderus 800 - 24/29/43/60 and For the user Buderus 800 - 24T25/29T25 H/V Please read thoroughly before operating the unit...

  • Page 2: Table Of Contents

    Updating the documentation If you have suggestions for improvement or have found discrepancies, please do not hesitate to contact us. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 3: Regulations And Directives

    800 – 24T25 /29T25 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. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 4 In both cases, details of essential features of cupboard/ compartment design, including airing cupboard installation, are to conform to the following: (No cupboard ventilation is required - see 'Air BS 6798 Supply' for details). Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 5 Unsuitable heating water promotes sludge formation and corrosion. This may cause malfunctions and damage in the heat exchanger. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 6: Installation

    115 mm 335 mm (4 ") (13 ") (6") 420 mm (16 ") 46 (1 ") (3") (12 ") (2 ") (8 ") (3") 431 mm (17") Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 7 CH flow boiler flow line 28 mm dia. CWDO condensate water drain 32 mm dia. Minimum side clearance required for all boilers is 100 mm (4") Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 8: Boiler Assembly - Exploded View

    650 Filling-, draining valve 560 Pressure relief valve 470 Control uba 660 RTH converter 570 Non return valve R 1/4'' 480 Temperature / pressure gauge 580 Pump Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 9: Flue Installation

    Balanced flue terminal position If this could occur the appliance MUST be turned off (with the owners permission), and labelled as unsafe until corrective action can be taken. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 10 Concentric bend 90° NE 83715 Concentric bend 45° NE 83716 24-43 kW adaptor plate NE 79061 60 kW adaptor plate NE 79064 table 3 Additional flue parts Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 11: Items Supplied With Unit

     Fit the wall bracket. fig. 5 Removing the casing Removing the casing:  Open the cover of the control panel (fig. 5, item 1). Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 12: Water Circulation System

    In single-circuit systems the required minimum amount of circulation water can be provided e.g. by means of an bypass valve. A bypass valve is not needed when a hydraulic shunt is installed. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 13 Fit the supplied service valve in the gas feed line. Connect the pipe free of tension (fig. 7). Fit a gas service valve with a size of R¾ on type 800 – 1.7.4 Hot water connection On type 800 –...
  • Page 14 The condensate water from the exhaust flue flows via the gas boiler and into the boiler's odour trap (syphon, see fig. 10). Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 15: Flue Installation

    See subsection 1.3.3 for the maximum horizontal straight length of each type boiler. Full instructions for fitting this flue are in Section 1.8.2: "Installation of the horizontal flue“ on page 16. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 16 Use the wall-mounting template to help you Terminal Flue mark the position of the side flue opening assembly Turret Maximum 595 mm Outer Wall fig. 15 Standard flue Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 17 The guard must give a clearance of at least 50 mm to the outside around the terminal and be fixed with corrosion re- wall face sistant screws. fig. 18 Flue terminal position Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 18: Electrical Connections

    The electrical supply for both the boiler and the system must be taken from the same fused spur outlet. WARNING! Do not connect 230V to the connection block on the UBA. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 19 Installation 1.9.2 Wiring Diagram WARNING! Do not connect 230V to the connection block on the UBA. fig. 20 Wiring diagram Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 20 (see subsection 1.9.5). – A room-temperature control device at 230V connected to the RTH converter (see subsection 1.9.6); – ON/OFF temperature controller, volt free (see subsection 1.9.7); Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 21  Open the flap at the front of the boiler unit and insert the twin plug connector of the service tool into the sockets provided (fig. 23, item 1). fig. 23 Service-tool connection Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 22: System Examples

    = Room Thermostat TRV = Thermostatic radiator valve WC = Wiring Centre radiator radiator = Two port Zone Valve other rooms reference room / main living area Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 23: Initial Start-Up

     Fill the system to a pressure of 1.0 to 1.2 bar (fig. 26, item 1). Max. water pressure is 2.0 bar.  Shut both stop valves and disconnect the filling loop. fig. 26 Pressure display Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 24 Filling the syphon with water possible escapes. The product must be certified as a gas leak-testing agent. DO NOT allow the product to come into contact with electrical wiring. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 25 IGE/UP/1b. Ensuring all safety requirments are met. fig. 29 Purging the gas supply pipe (Honeywell gas units) fig. 30 Purging the gas supply pipe (SIT gas units) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 26: Start-Up Work

    800-29 (29T25 H/V) 3.90 23.00 Natural gas H 6.40 29.30 800-43 4.85 27.40 800-60 Natural gas H 8.00 36.40 table 5 Gas and air injector diameters Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 27  Use the controller (fig. 31, item 3) to set the desired domestic hot water temperature in accordance with table 7. table 7 Domestic hot water temperature Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 28  Connect 3-m long extension cable (fig. 32, item 2) for the hot water sensor to the plug and fit sensor in the reservoir. fig. 32 Hot water sensor FW for external storage-type water heater Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 29  Pull off the measuring hose and tighten up the screw plug on the test nipple. fig. 35 Measuring the gas distribution pressure (Honeywell gas units) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 30 "1".  When the burner has fired after approx. 30 seconds, press the service button (fig. 37) until "Y" is shown on the display. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 31 The agent must be certified as a gas leak test agent. Do not apply the agent to electrical connection ca- bles. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 32  When the display shows "7" and the service button is pressed, the display turns to "c". Press the reset button until "r" is shown on the dis- play.  Close the cover. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 33  Explain and demonstrate the function of time and temperature controls, radiator valves etc., for the economic use of the system. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 34: Inspection

    43 Visual inspection for signs of corrosion For further information, please refer to subsection 7.2 "Inspection and service reports" on page 68 and fill out Benchmark. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 35: Maintenance

     Pull off the plug of the fan (fig. 45, item 1).  Turn and pull out the safety retainer of the fan (fig. 45, item 2). fig. 45 Removing the fan Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 36 24 VAC (fig. 47, item 5). fig. 47 Removing the cover and condensate plate  Pull out the baffle plate (fig. 48). fig. 48 Baffle plate Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 37 (fig. 51) and check that the condensate water bypass is not obstructed. fig. 51 Checking the operation of the condensate water bypass Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 38  Visual inspection to see if there is a white sealing cap on the condensate water bypass (fig. 52). fig. 52 Condensate water bypass sealing cap Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 39: Servicing

    800 Series runs in hot water mode Normal hot water mode Reset (after reset button has been pressed for 5 sec. UBA is reset to the switch-on condition) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 40: Fault Codes

    (no circulation) Replace pump if necessary (see subsection 5.3.7 and subsection 5.3.8) Water pressure is too low in the installation Top up the system (see subsection 2.1.1) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 41 Check for a dirty heat exchanger and clean if necessary (see subsection 4.1) Flue gas retarder faulty or missing Check if the flue gas retarder is installed in the heat exchanger Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 42 (see subsection 5.3.9 and subsection 5.3.10) A short or bad connection in the cable harness Check the cable harness and/or connector of the sensor (see subsection 5.3.12) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 43 – Check the cabling on the ionisation electrode – Press reset. If fault code remains than try to temporarily connect a different UBA (see subsection 5.3.5) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 44 20 mbar for natural gas Earthing cable may be faulty Check the earthing cable connections (yellow/green wire) Ionisation electrode may be faulty Check the cabling on the ionisation electrode Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 45 – Check if for example induction fields interfere with the regulating device – Check if the are any peaks in the electrical network caused by maybe windmills or a power generator Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 46 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 Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 47 – Check the wiring between the regulating device and the UBA (see subsection 5.3.18) – Check all the wiring – Check the UBA and replace if necessary (see subsection 5.3.5) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 48: Checking And Replacing Parts

    24VA C - max 6 VA If defective, fit new fuse (1.25 AT). 24VA C  Connect system to mains power supply. fig. 55 Checking the fuses Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 49  Reconnect all plug-in cables to their correct sockets.  Fit the casing.  Connect system to mains power supply. fig. 57 Replacing the UBA  Move mains power switch to “I”. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 50  Pivot the lower end of the fan forward (fig. 60, item 2) and take it out downwards and forwards (fig. 60, item 3).  Replace the fan  Reassemble in reverse order. fig. 60 Removing the fan Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 51 62 Replacing the modulating pump  Connect cables in correct order inside terminal box, close terminal box and screw shut. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 52 (see page 53). If there is any mismatch, the sensor is defective.  If the sensor is working correctly, plug it in once more. fig. 64 Checking the flow/return sensors fig. 65 Checking the safety sensors Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 53 5,594 1,084 4,656 1,940 3,893 1,817 table 10 Resistance values (indicative values) of the sensors R (Ω) 5,000 10,000 15,000 fig. 68 Boiler temperature sensor diagram Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 54  If the cables are in order, plug them in. fig. 71 Checking the cable to the flow/return sensors  Connect system to mains power supply.  Set the mains switch to “I”. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 55 Servicing fig. 72 Checking the cable to the safety sensor fig. 73 Checking the cable to the burner thermostat Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 56  If the hot surface ignitor is working correctly, plug it in once more.  Connect system to mains power supply. fig. 76 Checking the hot surface ignitor Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 57  Check that the hoses are correctly fitted to P1. Hose connection: P1 + , to T-piece gas-valve assembly. fig. 78 Checking the hose connection between the gas-air injector and gas-valve assembly (Honeywell gas units) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 58 Blue plug-in lead: fig. 80, item 1 ; White plug-in lead: fig. 80, item 2. fig. 80 Checking the wiring connections on the gas-valve assembly (HONEYWELL assembly illustrated to provide example) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 59 With the system running, check for leaks at all joints likely to have been affected by the fitting of replacement parts. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 60  Loosen all cables. Note order of cable terminals.  Attach cables, in the right order, to the new room- temperature control device.  Carry out the corresponding adjustment settings on room-temperature control device. Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 61 Open the maintenance isolating valves and then fill the 800 Series and purge the system of air. fig. 86 Replacing the valve core on the 800 – 24/24T25/29/43/60 Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 62 NOTE The device itself is fitted with an additional condensation-water bypass (located on the fume exhaust outlet). fig. 88 Function diagram of condensation-water bypass Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 63: Appendix

    Stand-by heat losses in hot water mode in 24 hours at WW (DHW) = 60 °C [kWh] – approx. 1.6 – approx. 1.6 – – temp Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 64 IP4X (C Power consumption full load partial load Boiler dimensions and weight Height [mm] 1250 1250 Width [mm] Depth [mm] Weight without casing [kg] Weight casing [kg] Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 65: Residual Pump Lift For Wall-Hung Gas Boilers

    (in heating mode only) T=20K T=20K T=20K 1000 1200 1400 1600 1800 2000 2200 2400 2600 1000 1200 1400 1600 1800 2000 Flow [l/h] Flow [l/h] Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 66: Short List Of Spare Parts

    (800-24 only) Swivel nut for pump 15020s Burner plaque assembly (incl. gas/air Return pipe 73122 73010 distribution plate) (800-29 only) Filling-, draining valve 38452 RTH converter 78079 Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 67: Reports

    (see chapter 2.2.8 on page 33) 12.Instruct the user, hand over the documentation (see chapter 2.2.9 on page 33) 13.Confirm commissioning (see Benchmark) Confirmation of professional commissioning (Company stamp, signature) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!

  • Page 68: Inspection And Service Reports

    (see documentation supplied with control unit) 14.Final check of inspection tasks, with record kept of measurement readings and test results 15.Confirm servicing work Confirmation of professional servicing work (Company stamp, signature) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 69 ––––––––––––––––––– –––––––––––––––––– –––––––––––––––––– –––––––––––––––––– –––––––––––––––––– –––––––––––––––––– mbar mbar mbar mbar mbar ––––––––––––––––– ––––––––––––––––– ––––––––––––––––– ––––––––––––––––– ––––––––––––––––– mbar mbar mbar mbar mbar ––––––––––––––––– ––––––––––––––––– ––––––––––––––––– ––––––––––––––––– ––––––––––––––––– Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 70 ______________ % (see chapter 2.2.4 on page 30) 3. Confirm servicing work: confirmation of servicing carried out by a Gas Safe registered installer (company stamp, signature) Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 71 ______________ Pa ______________ Pa ______________ Pa ______________Pa _____________ Pa _______________ % _______________% ______________ % ______________ % ______________ % _______________ % _______________% ______________ % ______________ % ______________ % Wall-mounted condensing gas boiler Buderus 800 - Subject to modifications resulting from technical improvements!
  • Page 72 D-35576 Wetzlar www.buderus.de info@buderus.de Buderus Cotswold Way, Warndon, Worcester WR4 9SW, Customer service: 0844 892 9700 Technical support: 0844 892 3004 Fax: 01905 753130 United Kingdom www.buderus-commercial.co.uk In the UK and IE, Buderus is a brand name of Bosch Thermotechnology Ltd.

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800-24800-24t25 h800-24t25 v800-29800-29t25 h800-29t25 v ... Show all

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