Boulter Buderus benchmark 500-24/S Installation And Maintenance Instructions Manual
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Boulter Buderus benchmark 500-24/S Installation And Maintenance Instructions Manual

Wall-mounted condensing gas system boiler
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7215 3000 - 03/2005 GB/IE(EN)
For the installer
Installation and maintenance instructions
Wall-mounted condensing gas system boiler
Buderus 500 - 24/S
Please read thoroughly

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Summary of Contents for Boulter Buderus benchmark 500-24/S

  • Page 1 7215 3000 - 03/2005 GB/IE(EN) For the installer Installation and maintenance instructions Wall-mounted condensing gas system boiler Buderus 500 - 24/S Please read thoroughly...
  • 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-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 3: Table Of Contents

    – service instructions; BENCHMARK' Log Book – wall spacing frame instructions. All Boulter 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 4 An existing cupboard or compartment may be used, provided overriding statutory obligations. that it is modified for the purpose. The design and construction of the Boulter Buderus wall- In both cases, details of essential features of cupboard/ mounted condensing gas system boiler 500-24/S conforms to...
  • Page 5 Wall-mounted condensing gas system boilers must only be The domestic hot water service must be in operated with Boulter Buderus purpose made gas systems, accordance with BS 5546 and BS 6700. which are certified for this type of boiler.
  • Page 6 Abbreviations = Air Vent = Boulter Buderus cylinder thermostat = Boulter Buderus diverter valve = Connection Block = Central Heating = Central Heating Flow = Central Heating Return...

  • Page 7: Installation

    Condensate water outlet Ø mm 21.5 Pressure relief valve (compression fitting) Ø mm 15 (adapter supplied with boiler) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 8 Boiler dimensions and weight Height x Width x Depth 780 x 460 x 330 Weight (without casing) Casing Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 9: Dimensions, Connections And Assembly

    NOTE See wall-mounting template for the necessary clearances. The wall spacing frame may not always be necessary. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 10: Items Supplied With Unit

    Hang the wall mounting template. fig. 2 Installation Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 11: Water Circulation System

    Connect pipes as shown in fig. 4. Ensure that all pipework is routed so as to minimise any strain on the boiler fittings. Boulter Buderus advises to use copper piping for the first 600 mm, then it is allowed to switch to another approved pipe material.
  • 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-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 13 9 External termination of condensate drainage pipe via internal discharge branch (e.g. sink waste) and condensate syphon Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 14 50 mm from bottom of tube and facing away from house fig. 11 External termination of condensate drainage pipe to absorption point Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 15: Flue Installation

    MUST NOT be closer than 25 mm to combustible material. Detailed recommendations on the protection of combustible material are given in BS. 5440- 1:2000. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 16 To ensure optimal operation, the 500 Series appliances must be connected to a Boulter Buderus horizontal or vertical flue terminal. These terminals have been developed specifically for Boulter Buderus condensing gas boilers and have been comprehensively tested for trouble free operation when correctly installed.
  • Page 17 Maximum wall thickness without extensions is 415 mm. Maintain a minimum side clearance of 8 mm (see fig. 14). fig. 16 Vertical flue length Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 18 80/125 flue gas systems, because the flue outlet of the boiler is 60/100. Weathering slates for 60/100 and 80/125 Flat roof, pitched roof. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 19 Fit the horizontal flue turret (fig. 19) onto the appliance flue connector. Flue gas testing point fig. 19 Horizontal flue turret with flue gas testing point Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 20 Outer terminal relative Wall to the outside Face wall face fig. 23 Flue terminal position Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 21: Electrical Connections

    Electrical connections 1.8.1 Mains connection NOTE All Boulter 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 22: Dba Wiring Diagram

    24 VAC HW TANK SENSOR (Boulter Buderus prod.) RTH-CONVERTER OR MODULINK 250 RF Flow sensor Safety sensor Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 23 Boulter Buderus 24V controls; item 1, 2: Boulter Buderus control – a room-temperature control device at 230V connected to item 3, 4: Boulter Buderus cylinder valve the rth-converter (see subsection 1.10.4, S-plan and item: 5, 6, 7: Diverter valve Y-plan);...
  • Page 24 (fig. 28). fig. 28 Place receiver into bracket Remove the boiler's casing. fig. 29 Remove casing Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 25 DBA (see fig. 32, item 1). RTH- converter fig. 32 Room thermostat connection on DBA Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 26 Fix the wire to terminal 1 and 2 of the volt free connection (fig. 33, item 3). Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 27: 1.11 System Examples

    Installation 1.11 System examples NOTE Example systems are to be regarded as schematic representations only. Buderus 500-24S with ModuLink 250 RF or other Boulter Buderus controls Key to abbreviations: Cylinder AV = Air Vent BCT = Boulter Buderus cylinder thermostat...
  • Page 28 Gr/Yel Black lead JB 230 vac Boiler DBA fig. 36 Wiring diagram Y-plan with exernal 230V controls Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 29 Grey Orange Gr/Yel fig. 38 Wiring diagram S-plan with external 230V controls and two port zone valves Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 30: Commissioning

    Follow the steps described in this chapter to properly commis- sion the boiler and fill out the commissioning log book. NOTE If a fault occurs, then refer to the servicing manual or contact Boulter Buderus. Preparing the boiler for operation CAUTION DO NOT operate the condensing gas boiler if large amounts of dust are present, e.g.
  • Page 31 1.0 bar then top up the system as described previously. Disconnect the filling loop and cap off. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 32 43 Disconnect hose from condensate trap fig. 44 Remove the condensate trap and fill with water Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 33 ('Lo' appears in the display, fig. 47). fig. 47 DBA display Lo Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 34 When summer operation is active then the boiler will not operate for central heating until summer operation has been deactivated. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 35 – measuring the working gas-supply pressure (boiler 3.45 Standard (LPG) operating at full power). table 3 Gas injector diameter Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 36 If the required connection pressure is incorrect item 1: Gas valve closed contact your gas supplier. item 2: Gas valve open Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 37 (see fig. 55). fig. 55 DBA with open-end spanner Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 38 The product must be certified as a gasleak- testing agent. Do not allow the product to come into contact with the electrical wiring. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 39 Explain and demonstrate the lighting and shutting down procedures. NOTE Always keep the user manual and installation and servicing instructions available for feed- back. Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 40: Inspection

    Check the pre-pressure of the expansion vessel 3.2.6 Check the hot water cylinder for leakage 3.2.7 Check the programming of the room thermostat Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 41: Maintenance

    Now the front cover of the heat exchanger can be removed by opening the latches (fig. 60, item 1). fig. 62 Remove gas air unit Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 42: Cleaning The Condensate Trap And Syphon

    Undo the condensate drain connection (see fig. 64, item 1) and remove the syphon. Rinse and refit the syphon. fig. 65 Remove the condensate trap Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 43: Appendix

    78121 Burner 73668 60mm seal (bottom flue gas pipe) 73563 Heat exchanger - Gas/air supply seal 73728 Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 44 (set of 5 pc.) Clips (set of 5 pc.) 73653s Receiver bracket 78200 Wall spacing frame 75972 Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 45 Appendix Exploded view Single unit (Buderus 500-24/S) Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...

  • Page 46: Index

    Wobbe index ........35 Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 47 Notes Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk Installation and maintenance instructions for Buderus 500 - 24/S • 03/2005...
  • Page 48 Heating system specialist: Boulter Buderus Ltd. Magnet House 30 Whitehouse Road Ipswich Suffolk, IP1 5JA Telephone: 0044 (0)1473 - 241555 Fax: 0044 (0)1473 - 241321 Sales Boilers: 0044 (0)1473 - 243780 Customer Services (gas): 0044 (0)870 - 421 5933 Technical Product Support (gas): 0044 (0)870 - 421 5944 http://www.boulter-buderus.co.uk...

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