Buderus 500-24C Installation And Maintenance Instructions Manual
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Buderus 500-24C Installation And Maintenance Instructions Manual

Gas wall hung boiler condensing
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See also: User Manual
Installation and maintenance
instructions
Buderus 500-24C
Buderus 500-28C
7215 3100-00.1TD
Gas wall hung Boiler
condensing
For the installer
Please read thoroughly

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Summary of Contents for Buderus 500-24C

  • Page 1 Installation and maintenance Gas wall hung Boiler condensing instructions 7215 3100-00.1TD Buderus 500-24C For the installer Buderus 500-28C Please read thoroughly...

  • Page 2: Table Of Contents

    Gas condensing boiler – 28 Maximum output is 28 kW – C Combination boiler (Integrated domestic hot water supply). Other manuals available for this boiler are: – user manual; – service instructions. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 3: Regulations And Directives

    British Standard codes of Prac- unsuitable additives MUST be removed by tice. thorough cleaning. BS.7593 details the steps necessary to clean a domestic central heating system. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 4 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. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 5: Hazard Definitions And Abbreviations

    = Room Thermostat = ModuLink 250 RF Receiver = Timer = Thermostatic Radiator Valve μ = micro (as μA - micro Amps) = Wiring Centre = Two Port Zone Valve Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 6: Installation

    CH flow/return (compression fitting) ∅ mm MCW inlet / DHW outlet (compression fitting) ∅ mm Condensate-water outlet 21.5 ∅ mm Pressure relief valve (compression fitting) 15 (adapter supplied with boiler) Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 7 Electrical protection rating IP X4D Boiler dimensions and weight Height x Width x Depth 780 x 460 x 330 780 x 460 x 330 Weight (without casing) Weight (without casing) Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 8: Dimensions, Connections And Assembly

    The wall-spacing frame may not always be Gas = Gas connection Ø 22 mm (compression fitting) necessary. CDO = Condensate drainage outlet Ø 21.5 mm PRV = Pressure relief valve Ø 15 mm (compression fitting) Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 9: Boiler Locations And Clearances

    D = left side 5 mm E = above 200 mm 7215 3100-02.1TD In addition, sufficient space may be required to allow lift- ing access to the wall-mounting bracket. Compartment Installations Fig. 2 Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 10: Items Supplied With Unit

    Seals (1 x G½“ - 1“, 2 x ¾“ - 22 mm, 2 x ½“ - 15 mm) 1 x MCW inlet filter Initial start-up sticker Second identification plate Pressure Relief Valve compression fitting + brass insert Radiator key Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 11: Hanging The Boiler

    Fig. 5 Remove casing Note If the boiler isn't connected to the pipework immediately, place caps on the pipe connec- tions. V Connect manifold unions to the boiler using supplied seals. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 12: Install The Wall-Spacing Frame

    The lower wall-spacing bracket is fitted upside down compared to the upper wall-spacing bracket, ie. with the hooks facing down. V Attach this lower wall-spacing bracket to the wall. 7215 3100-07.1TD Fig. 7 Mounting the lower bracket Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 13: Water Circulation System

    Hanging the boiler Water circulation system The central heating system should be installed in accord- ance with BS.6798 and, in addition, for smallbore and microbore systems, BS.5449 or EN 12823. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 14: Pipe Connections

    Compression fitting pressure relief valve outlet V Insert the small piece of pipe ( fig. 11). V Attach the compression fitting ( fig. 12). 7215 3100-11.1TD Fig. 11 Insert pipe Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 15 32 mm. It should be noted that the connection of a condensate pipe to a drain may be subject to local building controls. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 16 7215 3100-14.1TD Fig. 14 Internal termination of condensate drainage pipe to internal stack Boiler Ø21.5 mm min. internal soil and vent stack No length restriction 450 mm min. invert Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 17 (e.g. sink waste) and condensate syphon Sink Boiler No length restriction Ø21.5 mm min. open end of pipe direct into gully, below ground but above water level Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 18 Two rows of three 12 mm holes at 25 mm centres 50 mm from bottom of tube and facing away from house Ground (either/or) 25 mm min. 10. 300 mm min. hole depth 400 mm min. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 19: Flue Installation

    The boiler MUST be installed so that the terminal is exposed to external air. It is important that the position of the terminal allows the free passage of air at all times. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 20 – item 1: Flue turret 60/100; – item 2: Horizontal flue terminal 60/100; 415 mm – item 3: Flue finishing kit. 5 mm 7215 3100-20.1TD Fig. 20 Side flue and rear flue installation Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 21 The total of the bends and extensions must not add up to more than the reduction lenghts of the flue length L. 7215 3100-22.1TD Fig. 22 Vertical flue length Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 22 The total reduction length must never exceed Vertical adaptor (60/100 --> 80/125) is re- the maximum flue length. quired for 80/125 flue gas systems, because the flue outlet of the boiler is 60/100. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 23 Ensure that the flue turret is fully engaged into the top of the boiler. 7215 3100-25.1TD Fig. 25 Horizontal flue turret with flue gas testing point Flue gas testing point Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 24 The assembly will be made easier if a solvent free grease is lightly applied to the male end of the ducts. 7215 3100-28.1TD Fig. 28 Flue length - side Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 25: 1.10 Electrical Connections

    The means of isolation must be accessible to the user after installation (fig. 30, item 1). The electrical connection to the mains supply should be readily accessible and adjacent to the boiler. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 26: 1.11 External Controls

    V Remove the boiler's case ( fig. 5 on page 11). V Remove the securing screw ( fig. 32, item 1). V Lower the boiler control unit (DBA) ( fig. 32, item 2). Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 27 34). The wires are not polarity sensitive. V To refit the cover, slide back on and click into place fig. 34, item 1). 230V 7215 3100-34.1TD Fig. 34 Connect cable Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 28 7215 3100-36.1TD Fig. 36 Hang bracket under boiler V Remove the securing screw ( fig. 32, item 1) and lower the Boiler Control Unit (DBA) ( fig. 32, item 2). Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 29 230V thermostat / programmer etc. Alternatively 230V controls can be powered from a sepa- rate mains supply external to the boiler (i.e. L & N terminals are not used). Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 30 V Remove the securing screw of the DBA and lower the DBA ( fig. 32). V Connect the wire to terminal 1 and 2 of the connection block, marked Room Thermostat ( fig. 37). Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 31: 1.12 System Examples

    1.12 System examples NOTE These system schematics are simplified heating schematics showing the main electrical and water connec- tions. Buderus 500-24C or 500-28C with ModuLink 250 RF (or other Buderus controls) 7215 3100-40.1TD Fig. 40 Condensing gas boiler 500-24C / 28C...
  • Page 32 = Central Heating Return = Domestic Hot Water = Junction Box = Lock Shield Valve = Mains Cold Water = Permanent Live = Room Thermostat = Timer = Thermostatic Radiator Valve Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 33 Installation Buderus 500-24C or 500-28C with external Volt Programmable Room thermostat 7215 3100-42.1TD Fig. 42 Condensing gas boiler 500-24C / 28C radiator reference room / main living area other rooms Key to abbreviations: = Connection Block = Central Heating Flow...

  • Page 34: Commissioning

    Follow the steps described in this chapter to properly commission the boiler and fill out the commissioning log book. NOTE If a fault occurs, then refer to the servicing manual or contact Buderus. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 35: Preparing The Boiler For Operation

    1.0 bar then top up the system as Fig. 45 Connecting filling loop described previously. MCW inlet V Disconnect the filling loop and cap off. stop valve double check valve filling loop CH return Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 36 V Remove the condensate trap and fill with water fig. 47 and fig. 48). 7215 3100-47.1TD Disconnect hose from condensate trap Fig. 47 7215 3100-48.1TD Fig. 48 Remove the condensate trap and fill with water Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 37 ('Lo' appears in the display, fig. 51). 7215 3100-51.1TD Fig. 51 DBA display Lo Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 38 Maximum comfort due to short warm start waiting period for warm water. Not as energy efficient as the cold start and there is more chance of calcification. Tab. 4 Warm start function Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 39 1). Factory setting is 80 °C. Frost protection The boiler has an automatic frost protection. When the CH flow temperature drops below 7 °C then the boiler will start up. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 40 Tab. 5 Gas-supply types Gas injectors ∅ Type of gas [mm] Venturi Buderus 500 tubes Natural gas H (G20) 4.45 4.45 Standard 3.45 3.45 Standard Tab. 6 Gas injector diameter Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 41 V Measure the standing gas-supply pressure. Fig. 56 DBA front V Pull off the tube from the gas test nipple. V Tighten the gas testing nipple screw. V Tighten the gas testing nipple screw. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 42 If the required connection pressure is incor- rect, contact your gas supplier. Ensure that all disturbed joints and connections are checked for gas tightness on completion of tasks. 7215 3100-58.1TD Fig. 58 Measuring the gas-supply pressure Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 43 62, item 1). correct left turn V Set mains power switch to "0" ( fig. 56, item 1). right turn V Close the gas shut off valve ( fig. 57, item 1). Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 44 63) V Turn the mains power switch to "0" ( fig. 56, item 1). V Loosen the connector-and-socket connection of the ionisation electrode and connect the multimeter in series. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 45 V Explain and demonstrate the lighting and shutting down procedures. NOTE Always keep the user manual and installation and servicing instructions with the boiler for future reference. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 46: Inspection

    Check the burner 3.2.4 Check the functioning and safety of the flue gas exhaust 3.2.5 Check the pre-pressure of the expansion vessel 3.2.6 Check the programming of the room ther- mostat Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 47: Maintenance

    V Then remove the connectors of the glow ignitor fig. 67, item 5) and the ionisation electrode fig. 67, item 6). 7215 3100-066.2TD Fig. 67 Remove connectors of the gas air unit Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 48 V Check the seal for damage. Always replace the seal if in doubt. 7215 3100-68.1TD Fig. 70 Remove restrictor baffle Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 49 V Place a new flat seal between the gas pipe and the gas valve ( fig. 73). V Reassemble in reverse order. 7215 3100-085.1TD Fig. 73 Place a new flat seal Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 50: Cleaning The Condensate Trap And Syphon

    V Fill the condensate trap with water and reassemble. V Undo the condensate drain connection ( fig. 74, item 1) and remove the syphon. V Rinse and refit the syphon. 7215 3100-70.1TD Fig. 75 Remove the condensate trap Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 51: Cleaning Or Replacing The Plate Heat Exchanger

    V Open a hot water faucet to rinse and purge the system. V Close the hot water faucet and reconnect the boiler to the mains supply. 7215 3100-72.1TD Fig. 77 Remove plate heat exchanger Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 52: Appendix

    Reset is carried out. above 130 °C. This code appears after the reset The contacts of the flow sensor or safety button is pressed for 5 seconds. sensor are broken. Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 53: Wiring Diagram

    0 VAC use for 500-24C and 28C) 24 VAC 24 VAC HW TANK SENSOR (do not use for 500-24C and 28C) ROOM THERMOSTAT OR MODULINK 250 RF Flow sensor Safety sensor Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 54: Residual Pump Lift

    This graphic shows the amount of pump lift remaining for the heating system. 1000 7215 3100-74.1TD Fig. 78 Buderus 500-24C and 500-28C series Residual pump lift [mbar] 275 mbar at 900 l/h Flow [l/h] Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 55: Spare Parts List

    Flue gas pipe 78122 Mounting button 7746900854 60 mm seal (top flue gas pipe) 73736 Plate heat exchanger 78144 Flue gas pipe seal 73579 O-ring (set of 10 pc.) 78158s Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 56 101 Spring Hydroframe 78164s (set of 5 pc.) 102 ½" Seal (set of 10 pc.) 15033s 103 1" Seal (set of 5 pc.) 73527s 104 Connection set combi 73784 105 – – Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...

  • Page 57: Buderus 500-24C

    Appendix Exploded view Combi unit (Buderus 500-24C, 500-28C) 7215 3100-075.3TD Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 58 Notes Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 59 Notes Buderus 500-24C/28C - Subject to modifications resulting from technical improvements...
  • Page 60 Buderus Cotswold Way, Warndon, Worcester WR4 9SW Customer Services: 0870 - 421 5933 Technical Product Support: 0870 - 421 5944 Fax: 01905 - 753 130 www.buderus.co.uk In the UK and IE, Buderus is a brand name of Bosch Thermotechnology Ltd.

This manual is also suitable for:

500-28c

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