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

Gas wall hung boiler condensing
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Installation and maintenance
instructions
Buderus 500-24S
7215 3100-00.1TD
Gas wall hung Boiler
condensing
For the installer
Please read thoroughly

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Summary of Contents for Buderus 500-24S

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

  • Page 2: Table Of Contents

    The boiler type consists of the following components: – 500 Gas condensing boiler – 24 Maximum output is 24 kW – S System boiler Other manuals available for this boiler are: – user manual; – service instructions. Buderus 500-24S - Subject to modifications resulting from technical improvements...

  • Page 3: Regulations And Directives

    MUST be removed by be made to the relevant British Standard codes of Prac- thorough cleaning. BS.7593 details the tice. steps necessary to clean a domestic central heating system. Buderus 500-24S - 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 500-24S - 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 6: Installation

    Exhaust-fume temperature, partial load Heating curve 75/60 °C °C Heating curve 40/30 °C °C full load, natural gas standard test gas G20 full load, natural gas standard test gas LPG 10.3 Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 7 Electrical power consumption Full/Partial load/Standby 110/88/4 Electrical protection rating IP X4D Boiler dimensions and weight Height x Width x Depth 780 x 460 x 330 Weight (without casing) Weight (without casing) Buderus 500-24S - Subject to modifications resulting from technical improvements...

  • Page 8: Dimensions, Connections And Assembly

    CH return = Ø 22 mm (compression fitting) CDO = Condensate drainage outlet Ø 21.5 mm The wall-spacing frame may not always be PRV = Pressure relief valve Ø 15 mm (compression fitting) necessary. Buderus 500-24S - 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 500-24S - 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) Initial start-up sticker Second identification plate Pressure Relief Valve compression fitting + brass insert Radiator key Buderus 500-24S - 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 500-24S - 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 500-24S - 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 14: Pipe Connections

    When using plastic pipes, observe the sup- plier’s instructions - especially those referring to recommended jointing techniques and the notes relating to the heating system water on page 3. 7215 3000-05.1TD Fig. 12 Compression fitting Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 15 13) is cor- rectly aligned. 7215 3100-13.1TD Fig. 13 Condensate outlet Any internal pipework should be of a diameter to match the requirements of the condensate exit pipe on the appli- ance. Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 16 (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 500-24S - Subject to modifications resulting from technical improvements...
  • Page 17 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 18: 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 500-24S - Subject to modifications resulting from technical improvements...
  • Page 19 – 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 500-24S - Subject to modifications resulting from technical improvements...
  • Page 20 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 500-24S - Subject to modifications resulting from technical improvements...
  • Page 21 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 500-24S - Subject to modifications resulting from technical improvements...
  • Page 22 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 500-24S - Subject to modifications resulting from technical improvements...
  • Page 23 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 24: 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 25: 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 500-24S - Subject to modifications resulting from technical improvements...
  • Page 26 34, item 1). 7215 3100-34.1TD Fig. 34 Connect cable V Slide the receiver securely into the bracket, supplied with the boiler ( fig. 35). 7215 3100-35.1TD Fig. 35 Place receiver into bracket Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 27 Fig. 37 Room thermostat connection on DBA V Raise and secure the DBA. 1, 2 Room Thermostat HW Tank Sensor V Refit the boiler casing if necessary. 24 VAC 6, 7 3-Way Valve Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 28 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 29: System Examples

    Installation 1.12 System examples NOTE These system schematics are simplified heating schematics showing the main electrical and water connec- tions. Buderus 500-24S with ModuLink 250 RF (or other Buderus controls) 7215 3000-08.1TD Fig. 40 condensing gas boiler 500-24S Caution: cylinder RT/programmer The BCT and BDV are Buderus products.
  • Page 30 = Central Heating Return = Diverter valve = Junction Box = Lock Shield Valve = Permanent Live Prog = Programmer = Room Thermostat = Thermostatic Radiator Valve = Wiring centre Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 31 = Central Heating Return = Junction Box = Lock Shield Valve = Permanent Live Prog = Programmer = Room Thermostat = Thermostatic Radiator Valve = Wiring centre = Two port Zone Valve Buderus 500-24S - Subject to modifications resulting from technical improvements...

  • Page 32: 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 33: Preparing The Boiler For Operation

    1.0 bar then top up the system as described previously. external MCW supply stop valve V Disconnect the filling loop and cap off. double check valve filling loop CH return Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 34 V Remove the condensate trap and fill with water fig. 47 and fig. 48). 7215 3000-14.1TD Disconnect hose from condensate trap Fig. 47 7215 3000-15.1TD Fig. 48 Remove the condensate trap and fill with water Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 35 ('Lo' appears in the display, fig. 51). 7215 3100-51.1TD Fig. 51 DBA display Lo Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 36 54, item 2) three times. The current setting blinks. V Use the keys to adjust to desired setting. Central heating is on. Central heating is off (summer operation). DHW is still available. Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 37 The test pressure of the gas pipe when the gas shut off valve is open may not exceed 150 mbar. Warning: ATTENTION Check the used measuring nipples for gas tightness. Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 38 56, item 2). V Measure the standing gas-supply pressure. V Pull off the tube from the gas test nipple. 7215 3100-56.1TD V Tighten the gas testing nipple screw. Fig. 55 DBA front Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 39 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. 57 Measuring the gas-supply pressure Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 40 61, item 1). correct left turn V Set mains power switch to "0" ( fig. 55, item 1). right turn V Close the gas shut off valve ( fig. 56, item 1). Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 41 62) V Turn the mains power switch to "0" ( fig. 55, item 1). V Loosen the connector-and-socket connection of the ionisation electrode and connect the multimeter in series. Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 42 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 43: 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 44: Maintenance

    V Then remove the connectors of the glow ignitor fig. 66, item 5) and the ionisation electrode fig. 66, item 6). 7215 3100-066.2TD Fig. 66 Remove connectors of the gas air unit Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 45 V Check the seal for damage. Always replace the seal if in doubt. 7215 3100-68.1TD Fig. 69 Remove restrictor baffle Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 46 V Place a new flat seal between the gas pipe and the gas valve ( fig. 72). V Reassemble in reverse order. 7215 3100-085.1TD Fig. 72 Place a new flat seal Buderus 500-24S - Subject to modifications resulting from technical improvements...

  • Page 47: Cleaning The Condensate Trap And Syphon

    V Fill the condensate trap with water and reassemble. V Undo the condensate drain connection ( fig. 73, item 1) and remove the syphon. V Rinse and refit the syphon. 7215 3000-16.1TD Fig. 74 Remove the condensate trap Buderus 500-24S - Subject to modifications resulting from technical improvements...

  • Page 48: 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 500-24S - Subject to modifications resulting from technical improvements...

  • Page 49: Wiring Diagram

    3-WAY VALVE 0 VAC (external Buderus three way valve) 24 VAC 24 VAC HW TANK SENSOR (Buderus product) ROOM THERMOSTAT OR MODULINK 250 RF Flow sensor Safety sensor 7215 3000-18.1TD Buderus 500-24S - Subject to modifications resulting from technical improvements...

  • Page 50: Residual Pump Lift

    This graphic shows the amount of pump lift remaining for the heating system. 1000 7215 3100-74.1TD Fig. 75 Buderus 500-24S series Residual pump lift [mbar] 275 mbar at 900 l/h Flow [l/h] Buderus 500-24S - Subject to modifications resulting from technical improvements...

  • Page 51: Spare Parts List

    Mounting button (set of 10 pc.) 7746900854 Flue gas pipe 78122 – 60 mm seal (top flue gas pipe) 73736 – Flue gas pipe seal 73579 Clips (set of 2x3 pc.) 78156s Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 52 103 1" Seal (set of 5 pc.) 73527s 104 – 105 – – 106 – – – Spring gaspipe (set of 5 pc.) 73531 – LPG kit 24 kW - 28 kW 73734 Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 53 Appendix Exploded view - Single unit (Buderus 500-24S) 7215 3000-019.1TD Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 54 Appendix Notes Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 55 Appendix Notes Buderus 500-24S - Subject to modifications resulting from technical improvements...
  • Page 56 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.

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