Related Manuals for Boulter Buderus Benchmark 600-28C
Summary of Contents for Boulter Buderus Benchmark 600-28C
- Page 1 7212 7900 - 01/2004 GB/IR(EN) For trade use Installation and servicing instructions Wall-mounted condensing gas boiler 600 - 28C Please read thoroughly before installing or 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! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and servicing instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 3: Table Of Contents
BENCHMARK' Log Book Buderus 600 - 28C 47-110-02 All Boulter Buderus gas fired boilers now include an installa- tion, commissioning and service record log book. The details of the log book will be required in the event of any warranty work being requested. - Page 4 Defects and faults must be eliminated immediately. CAUTION Use this device for its intended purpose only. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 5 When using water treatment, only products dishwasher appliances. suitable for use with Boulter Buderus heat When connecting to suitable showers, exchangers are permitted (e.g. Sentinel X100). ensure that: Your warranty is at risk if an incorrect water a.
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Page 6: Installation
Air supply Ø 80 or Ø 125 mm socket Condensate drain Ø 30 mm Safety valve R¾" (¾"-½" adaptor supplied with boiler) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 7: Boiler Assembly - Exploded View
85. Insulation casing 56. BC10 mount 66. Connection assembly 76. Return pipe 86. RCC connection box Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 8: Flue Installation
L. Horizontally from a terminal on the wall 300 mm (12") M. Adjacent to opening Table 1 Balanced flue terminal position Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... - Page 9 NE 83706 Vertical flue turret adaptor 80/125 to 60/100 Table 3 Additional flue parts Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 10: Items Supplied With Unit
Attach the manifold assembly (accessory) to the wall (fig. 5, item 1). fig. 5 Installation Attach the pipes. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 11: Water Circulation System
Connect to gas supply according to relevant standards, installing a screw-threaded gas shutoff valve (accessory) to the gas supply system. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... - Page 12 It should be noted that the connection of a condensate pipe to a drain may be subject to local building controls. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 13 12 External termination of condensate drainage pipe via internal discharge branch (e.g. sink waste – proprietary fitting) and condensate siphon Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 14: Flue Installation
Flue installation absorption point The only flue systems that may be used are those supplied by Boulter Buderus. The flue system must be installed in accord- ance with the requirements of BS5440:1. 2000. Standard 100 mm flue systems The standard concentric flue system provides for a max. hori- zontal straight length of upto 12.0 m for 60/100 flue connection... - Page 15 19 Flue terminal position Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 16: Electrical Connections
The electrical supply for both the boiler and the system must be taken from the same fused spur outlet. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 17: 1.10 Wiring Diagram
Installation 1.10 Wiring Diagram Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... - Page 18 1.10.4 Modulating room thermostat connection Open the connection box (see fig. 23). fig. 23 Connection box cover Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 19 7-8 blue to this position. Do not use this connection. Do not use this connection. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 20 Note that example systems are to be regarded as schematic representations only. fig. 26 System example Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 21: Initial Start-Up
Adjust the knobs for central heating (fig. 28, item 1) and domestic hot water (fig. 28, item 2) to '0'. fig. 28 Control panel Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... - Page 22 31 Connecting temporary hose Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 23 Open the CH return stop valve to drain the system. hose Stop Stop valve valve Drain Drain fig. 34 Draining the system Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 24 This LED indicates that the burner is on. fig. 37 Emergency operation is active. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 25 0 min to 60 min. (F 0..F60) and 24 hours (F1d). Confirm the selection by pressing the service button (fig. 38, item 1). Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 26 Check the used measuring nipples for gas 22.8 tightness. 24.0 Table 6 Heating capacity in percentages Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 27 If the difference between the two is greater than 5 mbar then the pressure in the gas pipe is too great. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 28 Ensure that all disturbed joints and connections are checked for gas tightness on completion of tasks. fig. 43 Measuring the gas-supply pressure Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 29 Turn the boiler on by setting the mains power switch to "1". fig. 46 Idjust gas/air ratio CAUTION Check the test nipples for gas tightness. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 30 47 Measuring the ionisation current Set mains power switch to "1" (fig. 41, item 1). Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 31 Explain and demonstrate the lighting and shutting down procedures. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 32: Inspection
Finalize the inspection by filling out and signing the inspec- tion protocol on page 66. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 33: Maintenance
(see fig. 50, item 1). fig. 50 Loosen gas connection Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... - Page 34 Chek the seal for damage. Always replace the seal when in doubt. Reassemble in reverse order. fig. 53 Remove flue gas retarder Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 35: Cleaning The Syphon
Sign maintenance report Sign the maintenance report (see subsection 7.2: "Mainte- nance report" on page 66). Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 36: Servicing
– The LED comes on shortly after the electricity is switched fig. 57 UBA 3 pos. 1: red indicator LED Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 37: Operating Codes
Reset (when the reset button is pressed on the BC10, the boiler will attempt to fire up) Table 9 BC10 operating codes (after pressing the service button) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 38: Fault Codes
If not replace bi-sensor (see subsection 5.3.8, subsection 5.3.9, subsection 5.3.10) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... - Page 39 Fan wiring or connections faulty Check the fan wiring and connections (see subsection 5.3.3) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 40 If not replace bi-sensor (see subsection 5.3.8, subsection 5.3.9, subsection 5.3.10) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 41 UBA might be faulty Check the UBA by temporarily connecting a different UBA (see subsection 5.3.2) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 42 – Press reset. If fault code remains than try to temporarily connect a different UBA (see subsection 5.3.2) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 43 Try to reset the boiler by pressing the reset button for 2 seconds Check if UBA 3 is fitted tightly onto the boiler (see subsection 5.3.2). KIM may be defect If this is the case then contact the Boulter Buderus service department. Code Meaning Blinking fault code: Mains supply interrupted...
- Page 44 UBA may be defective Press reset. If fault code remains then try to temporarily connect a different UBA (see subsection 5.3.2) KIM may be defective action Call the service department of Boulter Buderus Code Meaning Blinking fault code: Gas valve assembly error...
- Page 45 – Check all the wiring – Check the UBA and replace when necessary (see subsection 5.3.2) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 46: Checking And Replacing Parts
Install the new flue gas sensor in reverse order. fig. 60 Remove UBA 3 Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... - Page 47 Connect system to mains power supply. fig. 62 Remove UBA 3 Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 48 Loosen the swivel nut (fig. 65, item 2) Remove the suction tube (fig. 65, item 3). fig. 65 Remove suction tube Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 49 67 Remove fan Remove the gas valve (fig. 68). fig. 68 Remove gas valve Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 50 Replace with a new fuse (2.5 AT) if necessary. Reassemble in reverse order. fig. 71 Checking the fuse Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 51 Fill the 600 - 28C and purge the system of air. fig. 73 Replacing the pump Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 52 75 Measure resistance of bi-sensor Disconnect the return sensor (see fig. 76). fig. 76 Disconnect return sensor Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 53 1.458 6.754 1.255 5.594 1.084 4.656 3.893 Table 11 Resistance values of the sensors Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 54 (see fig. 81, fig. 82, fig. 83 and fig. 83). fig. 81 Measure resistance of bi-sensor fig. 82 Measure resistance of return sensor Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 55 Fill the system and purge the system of air (see subsection 2.1.1). fig. 85 Disconnect plug return sensor Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 56 Remount the UBA 3 and connect the boiler to the mains power supply. fig. 88 Measuring resistance of hot surface ignitor Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 57 Remove the ionisation electrode (see fig. 91, item 1). fig. 91 Remove ionisation electrode Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 58 94 Checking the three-way valve for correct operation turns to the central heating position. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 59 Some remaining water may come out. fig. 97 Remove the internal mechanism of three-way valve Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 60 This is not a serviceable part and any fault identified with this component, contact Boulter Buderus. fig. 99 KIM connections Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 61: Appendix
Adjustable hot water temperature °C 30 - 60 Minimum connection pressure Maximum connection pressure Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... - Page 62 Height x Width x Depth 850 x 480 x 370 Weight (without casing) Casing Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 63 600 - 28C series 247 mbar at 900 l/h 1000 Flow [l/h] Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
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Page 64: Short List Of Spare Parts
Connection blue 73775 Seal heat exchanger / gas/air supply 73728 Connection turquoise 73772 73639 Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 65: Reports
13. Confirm initial start-up Confirmation of initial start-up by qualified service technician (Company stamp, signature) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... -
Page 66: Inspection And Maintenance Reports
15. Confirm inspection carried out by qualified service engineer and fill out the Benchmark Company stamp / Date / Signature) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004... - Page 67 _____________ mbar _____________ mbar _____________ mbar _____________ mbar _____________ mbar _____________ mbar _____________ mbar Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 68 Confirm servicing work Confirmation of servicing carried out by qualified technician Company stamp, signature) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 69 ____________________ ____________________ ____________________ ____________________ _______________ µA _______________ µA _______________ µA _______________ µA _______________ µA Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 70 Notes Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 71 Notes Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-boilers.com Installation and maintenance instructions for wall-mounted condensing gas boiler 600 - 28C • 01/2004...
- Page 72 Heating system specialist: Boulter Buderus Ltd. Magnet House Whitehouse Road Ipswich Suffolk, IP1 5JA http://www.boulter-boilers.com...