201001221723430.63030586_g115installationmanual0304.pdf

7/27/2019 201001221723430.63030586_G115InstallationManual0304.pdf

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Please read these instructions carefully.

6303 0586 03/2004 US/CA For installers

Boiler Installation and

Maintenance Manual

Oil and Gas fired Cast Iron BoilerLogano G115 US


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We reserve the right to make any changes due to technical modifications!

Boiler Installation and Maintenance Manual Logano G115 US Issue 03/2004

Buderus Heiztechnik GmbH http://www.heiztechnik.buderus.de

Inhaltsverzeichnis

1 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Regarding this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Suitable Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 Guideline of Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.4 Observe the following Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4.1 In Case of Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.4.2 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4.3 Boiler Room Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5 Tools, Materials and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Technical Data less Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.2.1 General Operating Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2.2 Requirements for Boiler Room and Surroundings . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2.3 Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2.4 Fuel Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2.5 Requirements for Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.6 Conditions Pertaining to Piping and Water Quality. . . . . . . . . . . . . . . . . . . . . . . 11

4 Packaging and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Moving the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.1 Reducing Boiler Weight for Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.2 Lifting and Carrying the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.3 Moving the Boiler with Boiler Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 Placing the Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.1 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.2 Reversing the Burner Door Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.3 Installation of Boiler Feet (Components of B-Kit) . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.4 Placement of the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7 Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.1 Installation of Venting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.1.1 For Oil-Fired, Direct Vent Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.1.2 For Chimney Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.2 Installation of Water Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.2.1 B-Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.2.2 Installation of Boiler Drain (B-Kit Component) . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.2.3 Installation of System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.3 Filling and Checking for Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.4 Burner Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.5 Installation of Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.6 Aquastat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.7 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247.7.1 Control System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.7.2 Installation of Temperature Sensor and Burner Cable . . . . . . . . . . . . . . . . . . . . . 26

7.7.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.7.4 Strain Relief Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

7.8 Jacket Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


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Inhaltsverzeichnis

8 Placing the Boiler in Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.1 Setting the Initial System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.2 Checking Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.3 Check Position of Flue Baffle Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8.4 Get System Ready for Proper Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8.5 Start-up of Control and Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8.6 Guidelines Regarding Burner Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308.7 Adjusting Stack Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

8.7.1 Adjusting Flue Baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8.7.2 Removing Flue Baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8.7.3 Removing Blocking Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8.8 Testing of the Manual Reset High Limit (STB) of Logamatic controls. . . . . . . . . . . . . . . 32

8.9 Install Front Jacket Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8.10 Detailed Start-up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

9 Taking the Boiler out of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9.1 Normal Boiler Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9.2 Emergency Shut-down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

10 Boiler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10.1 Why do Maintenance? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10.2 Prepare Boiler for Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10.3 Boiler Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3610.3.1 Cleaning the Boiler with Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

10.3.2 Wet Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10.4 Testing System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10.5 Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

10.6 Inspection and Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

11 Restoring Sytem Lock-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

12 Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

13 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

14 SP30D and Burner Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

15 Table of Key Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55


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Safety Considerations1

1 Safety Considerations

1.1 Regarding this Manual

This document contains important information regardingsafe and proper installation, operation and maintenanceof the boiler.

The G115 is designated as a hot water heating boiler.

The Installation and Maintenance Instructions aredirected to the installing contractor who has professionalknowledge regarding boiler installation andmaintenance.

1.2 Suitable Applications

The boiler can only be used for hot water space heatingapplications for single and multi family homes.

Use the rating plate information to size the boiler( Chapter 3, page 7) for the application.

1.3 Guideline of Notices

Two levels of danger are identified by the followingwarning labels:

Cross notice

Designated by means of a narrow , referral to a noticein another document .

1.4 Observe the following Symbols

The local and state codes and regulations must beobserved during the installation of the boiler:

The local building code requirements regardingplacement, combustion air and venting and chimneysystem must be followed.

Follow applicable electrical code requirements.

Follow the regulations of the local gas utility if theboiler is to be operated with a gas burner.

Follow the local code and standards regarding safeboiler operation.

1.4.1 In Case of Smoke

1.4.2 Installation Guidelines

WARNING!

DANGER

Denotes a possible severely dangerous

situation where, without proper caution,bodily injury or loss of life may result.

CAUTION!

DANGER OF INJURY/SYSTEM DAMAGE

Denotes a possible dangerous situationthat can lead to mild to moderate bodilyinjury or physical damage.

APPLICATION NOTICE

Application comment for optimum use ofequipment and adjustment as well asuseful information.

NOTICE

Use only original Buderus spare parts forreplacement purposes. Buderus can not

be held liable for damage caused by nonBuderus parts.

WARNING!

DANGER

due to explosion of flammable gases!

z No open fire! Do not smoke!

z Avoid formation of sparks! Do nottouch any electric switch, phone,electric plug or bell!

z Shut off main gas supply.

z Open windows and doors!

z Notify all occupants!

z Leave the building!

z Immediately call your gas supplier,heating contractor or fire departmentfrom a phone outside the building!

WARNING!

DANGER

due to explosion of flammable gases.

z Work only on gas components whenyou have a license to do so.


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Safety Considerations 1

5




1.4.3 Boiler Room Guidelines

1.5 Tools, Materials and Accessories

For the installation and maintenance of the boiler youwill need typical tools used in the trade. In addition, thefollowing components are useful:

Boiler cart with rope or Buderus boiler cart.

Wood blocking. Cleaning brushes and/or chemical cleaning agents

for a wet cleaning.

1.6 Disposal

z Please dispose of any trash in an environmental

friendly fashion.

z Please discard properly of any heating systemrelated components.

DANGER!

DANGER

due to electricity.

z One is only allowed to work onelectrical components, if one is certifiedfor such work.

zPrior to opening the control: shut downthe power supply and pad lock againstaccidental reactivation.

z Observe all applicable installationguidelines.

WARNING!

DANGER

due to poisoning.Insufficient combustion air can result indangerous operation if all combustion air is

taken from indoors.

z Please observe that combustion airopenings are not reduced in size orclosed.

z If this problem has not been corrected,one can not operate the boiler.

z Make the end-user aware of theseguidelines and their potential danger.

WARNING!

FIRE DANGER

due to flammable or liquid materialsz Make sure that flammable and liquid

materials are not in the close vicinity ofthe boiler.


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PRODUCT DESCRIPTION2

2 PRODUCT DESCRIPTION

The G115 boiler is a low temperature boiler for oil or gasfiring for outdoor reset operation or as a cold start boiler.

The boiler consists of:

optional Logamatic control boiler jacket

boiler block with insulation

customized burner

The optional Logamatic control manages most controlfunctions in a heating system.

As an alternative, a Honeywell aquastat can be used forboiler control.

The boiler jacket serves to reduce energy loss and as a

noise reducing agent.The boiler block transfers the heat generated by theburner to the boiler water. The insulation reduces thestand-by losses.

Customized burner

The boiler must be equipped with a customized burnerfor operation. Please observe the technical data of theboiler when selecting a burner ( Chapter 3.1, page 7).

Fig. 1 Boiler less burner

1 Control panel

2 Boiler jacket

3 Boiler block with insulation

4 Burner door cover

1

2

3

4

CAUTION!

SYSTEM DAMAGE

due to improper burner.

z Use only burners recommended byBuderus as is discussed in ourtechnical documents.


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TECHNICAL INFORMATION 3

7




3 TECHNICAL INFORMATION

3.1 Technical Data less Burner

Select your suitable burner based on this information.

Fig. 2 Dimensions and connections (measurements in inches)

4

3/8"

57

/8"

121/4"

23 5/8"

39 5/8"

30 3/8"

10 3/8"

1 3/4"

20"

2 7/8"

25 1/4"

3 1/4"2 7/8"

8 7/8"

8 7/8"5/8" 1"

1" NPT Rp3/4"

Rp11/4"

EL

5"

RK

VK

LLK

FL

Connections (Measurements see following tables):

VK = Boiler supply

RK = Boiler return

EL = Boiler drain (Connection for drain valve)

Keep plugs in place in remaining 3 top rear tappings.

Boiler model 115/21 115/28 115/34

Number of sections 3 4 5

Heating Capacity (Gross Output) Btu/hr 74,000 98,000 120,000

Net IBR Btu/hr 64,000 85,000 104,000

Boiler water content Gal 8.7 10.8 12.9

Fireside volume cu.ft. 1.20 1.75 2.21

Oil firing rate GPH .60 .80 1.0

Fireside pressure drop psi 0.00058 0.00145

Permissible max. supply temperature1 F 230

Allowable operating pressure psi 58

Maximum Reset High Limit for temperature

sensor and overheat thermostat (STB)

s 40

Table. 1 Technical data less burner

1 High limit (overheat thermostat STB)

Permissible maximum supply temperature = High limit (STB) 32 Fe.g.: High limit (STB) = 212 F, maximum permissble supply temperature = 21232 = 180 FSelect the your high limit (STB setting) according your local codes and requirements.


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TECHNICAL INFORMATION3

3.2 Operating Conditions

By maintaining the operating requirements listed on thefollowing page, one can expect long and trouble freeoperation of the boiler. Proper and timely maintenance

procedures must be followed.

Boiler model 115/21 115/28 115/34

Total boiler length (L) Inch 22 7/8 27 7/8 32 5/8

Boiler block length (LK) Inch 21 1/8 25 3/4 30 1/2

Combustion chamber length Inch 16 20 1/2 25 1/4

Firebox diameter Inch 10 5/8

Burner door thickness Inch 3 5/8

Distance between boiler feet (FL) Inch 10 3/8 16 1/8 20 7/8

Dry weight1 Lbs 330 403 476

Table. 2 Dimensions, Weight and other Data

1 Weight incl. packaging material approx. 68 % more.

CAUTION!

SYSTEM DAMAGE

In case one does not follow theseoperating requirements it can lead topremature failures. Major deviations cancause permanent damage to the boiler.

z Follow the instructions on the ratinglabel and those in the manual.


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9




3.2.1 General Operating Requirements

3.2.2 Requirements for Boiler Room and Surroundings

Operating conditions

Minimum boiler

temperature

Boiler Shut-down Mixed temperature Heating

Circuit w/ mixing valve 1Minimum

return temperature

Systems controlled by R2017 controls for outdoor reset operation

No requirements

Operating conditions are met

with R2107 control 2

Automatic with Logamatic

R2107

No requirement, yet beneficial

with low temperature boiler with130/113 F system design

Necessary with:

radiant floor applications

Systems with large water

content > 115 gal/100,000

Btu/hr)

No requirement, except with

modulating burner

Oil firing: 113 F

Gas firing: 130 F

Systems controlled by aquastats or R2109

150 F 3 Possible, provided the boiler

operates after total shut-down

for at least 3 hours intermittently

to avoid condensate build-up.

Necessary Necessary for

Systems \with very large

water content

>115 gal/100,000 Btu/hr:

130 F Firing with modulating

burners: 130 F

Table. 3 General Operating Requirements

1 A heating circuit equipped with a motorized mixing valve improves the controllability of that sub-system and is specifically recommended when

requiring different water temperatures for optimum control.

2 In case the control system has no in fluence over the flow in a heating circuit (for instance using the Pumplogic feature of the R2107), then one

should achieve a minimum supply temperature of 122 F within 10 minutes after burner start-up by means of reducing (or interrupting) the water

flow through the boiler.

3 Minimum setting on the adjustable high limit or aquastat: During burner operation one should achieve the minimum boiler temperature within 10

minutes after burner start-up by means of flow reduction and one should maintain this temperature.

Operating Conditions Comments - Detailed Information

Boiler room temperature +40 to +104 F

Relative humidity max. 90 % No condensate or dampness in boiler room.

Dust No excessive amounts of dust should be present in the boiler room, e. g.:

no sheet rock or construction dust.

The available combustion air can not contain dust or other particles/ use of

an air filter might be needed, e. g.:

Combustion air from nearby streets with high dust levels.

Combustion air from nearby production facilities such as chemical plants &

shops.

Airborn particulates.

Hydrohalogen contamination Combustion air must be free of hydro halogen components.

Eliminate any chemical compound such as paints, lacquers, thinners,cleaning agents. If not possible, provide fresh outside air for combustion.

Please observe the following:

Product information of Buderus catalog.

Also observe guidelines in K3 chapter of Buderus catalog.

Fans, removing air from boiler

room.

Avoid forced air removal by mechanical means during boiler operation.

bath room exhaust fans

dryer

airconditioning equipment

Table. 4 Boiler room and surroundings


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TECHNICAL INFORMATION3

3.2.3 Combustion Air Requirements

3.2.4 Fuel Conditions

Animals The boiler room and specially the air inlet openings for combustion air must be

kept free from animals entering by means of grills.

Fire protection Maintain proper clearances to combustible materials as required per local code.

Maintain a minimum distance of 16". Do not store flammable materials near the

boiler.

Flood zone conditions Separate the fuel supply and electrical power supply from the boiler during floodconditions. Replace the boiler components such as insulation, electrical and con-

trol components afterwards.


Table. 4 Boiler room and surroundings

Operating Conditions Boiler capacity (combine total boiler

capacity for multiple units)

Cross area required

Two air inlet openings from

outside: one top, one near

bottom

< 170,000 Btu/hr At least 43 square inch

> 170,000 Btu/hr At least 43 square inch and plus 2.5 square inch per

10,000 Btu/hr,

if the output is higher than 170,000 Btu/hr.Table. 5 Observe your local codes and requirements to combustion air requirements


Permissible fuels w/ customs

burners

The G115 boiler can be operated with the following fuels.:

Please select the proper burner based on desired fuel.When using oil of an extreme poor quality (kinematic viscosity

> 0.0093 sq in/sec (> 45.5 s Sayboldt) at 68 F), use a shortened mainte-

nance cycle. Boiler service and cleaning should be performed twice a year

then.

Natural gas based on burner specifications.

Propane based on burners specs.

Biogas, methane, waste gas subject to the operating conditions below.

Contaminations All fuels shall be free of contaminants (such as dust, particulates, liquids) that

could cause damage to the nozzles or oil lines.

Biogas

methane

waste gas

Following operating conditions must be maintained:

Constant boiler temperature of at least 167 F.

No boiler shut-down.

Minimum return temperature of at least 140 F.

Regular service and cleaning, for instance a chemical cleaning and follow-up

surface treatment.

Table. 6 Fuel


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11




3.2.5 Requirements for Power Supply

3.2.6 Conditions Pertaining to Piping and Water Quality


Main power supply 110 120 V Observe the acceptable voltage range for the burner.Provide proper ground to

boiler for equipment and personal protection.

High amp protection 10 A

Frequency 60 Hz AC voltage

Protection Ground all equipment per local code.

Table. 7 Power supply


Operating pressure (over

pressure)

15 58 psi Maximum pressure is 30 psi based on furnished relief valve.

Allowable test pressure 45 75 psi

Adjustable temperature limit

TR

122 194 F Adjustable high limit range under normal operating conditions

Manual reset high limit 212 248 F Suitable range for manual reset high limit of 212 to 248 F.

Water quality Initial fill water and make-up water should be potable water type quality. A pH ran-

ge of 8.2 to 9.5 is desired.

Table. 8 Piping and water quality


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Packaging and Components4

4 Packaging and Components

z Check the packaging for consealed damage.

z Check the packaging for completeness. Contactyour wholesaler in case of missing parts.

1 B-Kit packaging is supplied inside the combustion chamber.

2 Honeywell aquastat is supplied with customized burner if so

ordered.

Component Qty Packaging

Boiler block 1 1 Pallet

Boiler jacket, installed on

boiler

Burner door and burner door

cover installed on boiler block

B-Kit-components:

Supply manifold

(11/4" NPT)

30 psi relief valve

(") boiler drain

Pressure/temperature

gauge (1" NPT R1)

conversion nipple (parallel

to NPT)

90- elbow (1" NPT)

90- elbow (" NPT)

Burner mounting studs and

washers

Screw in feet

1 1 Plastic

packaging with

boiler1

Control panel,

alternative aquastat21 1 cardboard

box (ordered

separately)

Technical documents 1 Plastic

packaging w/

boiler

Table. 9 Packaging and components


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Moving the Boiler 5

13




5 Moving the Boiler

This chapter describes how to move the boiler.

5.1 Reducing Boiler Weight for Transport

One can reduce boiler weight by removing the frontpanel and burner door itself.

z Remove the screws holding the front panel in place.

z Lift up the front panel slightly and remove.

z Open burner door by removing the two burner doorbolts.

z Lift burner door from hinges.

CAUTION!

SYSTEM DAMAGE

due to bumps.

z Protect the boiler from bumps andrough treatment.

NOTICE

z Protect the boiler connections fromdamage and dirt, when the boiler is notinstalled immediately.

NOTICE

Please dispose of the packaging in an

environmental fashion.

Fig. 3 Removing the front panel

Fig. 4 Removal of burner door

NOTICE

Protect the burner door and the burnertube from damage and dirt, when burnerdoor is removed from the boiler.


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Moving the Boiler5

5.2 Lifting and Carrying the Boiler

The boiler can be picked up at the hand grips locatedalong the lower jacket panels.

5.3 Moving the Boiler with Boiler CartYou can order a Buderus kuli cart from your localwholesaler.

z Lift up the boiler from the rear side by using movingequipment (e. g. Buderus kuli cart or other dolly).

z Secure the boiler to the cart.

z Move the boiler to the job location.

Fig. 5 Lifting and carrying the boiler

NOTICE

The boiler is secured to the pallet with twobolts.

z Remove the bolts from pallet beforelifting the boiler.

DANGER!

NOTICE BODILY DANGER

due to carrying of heavy loads.

z Lift and carry the boiler with at least twopeople at the designated hand grippositions.

Fig. 6 Moving the boiler with a Buderus kuli cart

DANGER!

BODILY DANGER

if the product is not properly secured to thecart.

z Use proper moving equipment such asthe Buderus kuli cart or other dolly.

z Secure the boiler to the cart and movethe boiler to the job location.

NOTICE

By tipping the cart, you can install the boilerfeet ( Chapter 6.3, page 17).


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Placing the Boiler 6

15


Boiler Installation and Service Manual Logano G115 US Issue 03/2004


6 Placing the Boiler

This chapter discusses how to place the boiler in theboiler room.

6.1 Clearances

Position the boiler while observing the clearances in( Fig. 7). Access to the boiler is reduced whenreducing these clearances.

The boiler foundation must be level and sufficientlystrong.

The burner door is factory installed right swinging. Youcan reverse the door swing in the field.

CAUTION!

SYSTEM DAMAGE

due to freezing temperatures.

z Place the boiler in a frost free room.

Fig. 7 Clearance dimensions for G115 boilers

Measure Distance

A Recommended 51 1/8"

minimum 39 3/8"

B Recommended 27 1/2"

minimum 15 3/4"

C Recommended 15 3/4"

minimum 3 7/8"

LK see Chapter 3 for Technical Data

Table. 10 Recommended and minimum clearances

(Measurement in Inches)

NOTICE

Smaller clearances must abide with stateand local code. The boiler is approved for6" side clearances. A minimum distance tocombustible materials must be maintainedof 18" per NFPA 31 code requirements.

NOTICEObserve required distances to othercomponents such as water piping, ventingand other components.


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Placing the Boiler6

6.2 Reversing the Burner Door Swing

The burner door hinges are factory installed on the right

hand- the burner door swings to the right. You canadjust the hinges so that the burner door swings to theleft in the field.

Note: the front panel must first be removed.

(

Chapter 5.1, page 13).z Remove burner door ( Chapter 5.1, page 13).

z Remove hex head bolts of burner door hinges andremove hinges.

z Install the hinges on the left side of the boiler with thehex head bolts.

z Remove the eyelets from the burner door byremoving the hex head bolts.

zLocate and secure with hex head bolts these eyeletsto the left side of the burner door.

z Hang the burner door on the hinges.

z Check to make sure that the flue baffle plates arehorizontally in the boiler ( Chapter 8.3, page 29).

z Secure the burner door with the burner door bolts.Make sure to tighten the burner door bolts evenlywith about 7.5 ft-lbs torque.

Fig. 8 Reversing burner door (on boiler block)

1 Hex head bolts for hinges

2 Door hinges

121 2

Fig. 9 Reversing burner door (on burner door)

1 Hex head bolts for door eyelets

2 Door eylet

3 Burner door

4 Door hinges

5 Flue baffles

1

2

3

4

5

NOTICE

When reversing the swing of the burner

door, make sure to remove the burnercable and oil line from the burner first.


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Placing the Boiler 6

17




6.3 Installation of Boiler Feet (Components of B-Kit)

You can level the boiler using the screw-in boiler feet, so

that air can not collect in the boiler.

Requirement: remove front panel from boiler( Chapter 5.1, page 13).

z Tip the boiler slightly using the boiler cart( Chapter 5.3, page 14) or put a piece of woodunder one side.

z Screw in the boiler feet 1/4" to 3/8".

z Level the boiler.

6.4 Placement of the Boiler

z Bring the boiler to its final location.

z Put a level on the boiler and adjust boiler feet to levelthe boiler.

Fig. 10 Installation of boiler feet

1Boiler rail

2 Boiler feet

12

NOTICE

When installing a G115 boiler on top of ahorizontal Buderus DHW indirect tank, donot use the boiler feet on the boiler, butrather use the feet to level the tank.

Fig. 11 Leveling the boiler

NOTICE

Protect the boiler connections from dustand debris, if the boiler will not be

connected right away.


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Boiler Installation7

7 Boiler Installation

This chapter describes how the individual componentsmust be installed on the boiler. These components are:

Flue connection

Water connections

Electrical connections Burner installation (field installation)

Fuel line connection

7.1 Installation of Venting System

7.1.1 For Oil-Fired, Direct Vent Applications

Follow instructions in the G115 Direct Vent Manual,supplied with the direct oil burner options.

7.1.2 For Chimney Venting

Connect boiler with 5 vent pipe to vertical chimney anduse vent material approved by local codes for oil-firedboilers. If codes net present, refer to:

NFPA 31, Installation of Oil-Burning Equipment.

NFPA 211, Standard for Chimneys, Fireplaces,Vents and Solid Fuel Burning Appliances.

In Canada, refer to CSA B139, Installation Code forOil-Burning Equipment.

NFPA 211 requires chimney to be lined prior toconnecting boiler.

Instecting and cleaning existing chimney

z Inspect existing chimney prior to installing new boiler.

z Clean and remove any blockage from chimney.

z Repair or replace defect pipes or liner.

z Repair chimney with mortar and joints if necessary.

Down Drafts

NOTICE

z To avoid down drafts, extend chimneyat least 3 feet above location of roof

penetration and at least 2 feet aboveany roof portion within 10 feet.


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Boiler Installation 7

19




Minimum clearances to combustibles for vent pipe

Minimum recommended chimney size

Minimum recommended chimney size: 8" x 8" (6 " x 6" inside liner) or 6" round with 15 ft minimum height.Use 5" chimney liner when relining existing chimney.

Vent pipe installation

z Slide 5" vent pipe on flue connection and secure with2 screws using pre-drilled holes in boiler breeching.

z Slope vent pipe at least " per foot up towardschimney.

z Connect breeching above the bottom of chimney toavoid blockage. Avoid extending breeching too farinto chimney.

z Install thimble or slip joint at connection point to allowremoval for cleaning.

After burner start-up, set breeching draft to -.01 to -.02inches WC using draft guage. (Over fire pressure can beslightly positive). When necessary, install barometriccontrol in breeching, to relieve excessive draft or tocomply with applicable codes. Always positionbarometric control blade vertically. Set proper openingusing draft gauge.

Vent Pipe TypMinimum

clearances

Double-wall L 6"

Single-wall L 18"

Table. 11 Minimum clearances to combustibles for vent pipe

Fig. 12 Securing the flue connection

1 Flue connector2 Boiler vent collar

12

NOTICE

Avoid long horizontal runs, excessivenumber of elbows and tees.

WARNING!

DANGER

Do not use barometric control and seal allvent joints if:

z excessive resistance to flow ofcombustion gases can be expected.

z actual chimney diameter and/or heightis less than recommended. Installationof a CO detector is recommended inthis case. Positive over fire pressureoperation of boiler will establish draft inventing system.


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7.2 Installation of Water Connections

7.2.1 B-Kit Installation

Use the B-kit components located in the boiler fire box tofinalize the boiler supply connection.

z Use the 1-1/4" BSP x NPT conversion nipple at thesupply connection. Identify the section with thelonger thread length is threaded BSP (straightthread). The threads on this side also have no taper.(NPT side has taper).

z Using high quality Teflon and/or pipe dope, insert thelonger threaded end into the boiler supply connection

(VK).

z Install 90 degree elbow 1" NPT on conversionnipple. Orient in desired direction.

z Install supply manifold into 90 degree elbow. Youcan orient this manifold in three different directions(Fig. 14).

z Install pressure/temperature gauge.

CAUTION!

SYSTEM DAMAGE

due to leaking connections.

z Install the piping connections to theboiler without having undue stress onthe near boiler piping.

Fig. 13 Measuring thread length on 1-1/4" conversion nipple

R

1"(Europe)

1

"NPT(USA)

1"1"

VK

1"

Fig. 14 B-Kit Installation

1 90 degree 1" NPT elbow

2 Supply manifold

3 Pressure/temperature gauge4 Relief valve

5 90 degree " NPT street elbow

1

2

3

4

5

NOTICEThe pressure relief valve can only beinstalled after the hydrostatic test( Chapter 7.3, page 21).

Use the supplied " street 90 to ensurethat the relief valve discharge is installedhorizontally.

NOTICE

We recommend, specially in older, largevolume systems, to install a dirt filter in thereturn connection to the boiler to reducewaterside debris build-up.


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21




7.2.2 Installation of Boiler Drain (B-Kit Component)

z Install the " boiler drain (B-kit component) into theEL tapping.

7.2.3 Installation of System Components

Use the adjacent diagram as an aid during theinstallation of near boiler components.

Additional installation samples are found in Chapter 12, page 43.

7.3 Filling and Checking for Water Leaks

The boiler must be tested hydrostatically for leaks.Check the entire system for leaks prior to placing thesystem in operation to prevent leaks during operation.

Perform the hydrostatic at 1.5 times the expectedoperating pressure and in accordance with local coderequirements:

Fig. 15 Boiler drain installation

ELRK

NOTICE

Install a fill connection in the supply pipingto the boiler.

Fig. 16 Installation diagram

12

3 4 5 6 3

3

8

7

9

3

Return

Boiler drain

VK

RK

10 Supply

Fill valve

Legend for Fig. 161 Relief valve

2 Pressure/temperature gauge

3 Ball valve

4 Air eliminator

5 System pump

6 Back flow preventer

7 Expansion tank

8 Automatic feet valve

9 Flow check

10 Purge station

Fig. 17 Pressure and temperature gauge

CAUTION!

SYSTEM DAMAGE

Be careful not to expose the system to

excessive test pressures during thehydrostatic test as it can damagepressure, control and safety components.

z Make sure that all pressure, controland safety components are NOTinstalled during the hydrostatic test.


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z Plug relief valve connection ( Fig. 14, page 20)and all boiler openings with plugs. (Not supplied).

z Close the ball valve to the expansion tank.

z Open automatic feed valve.

z Fill the boiler slowly with the feed valve.

z Open the automatic air eliminator to allow air toescape.

z Slowly fill the heating system. Monitor the pressuregauge.

z Check all water connections for leaks.

z Vent the heating system by opening and bleedingradiators. Open purge valve slowly and allow air toescape.

z When water pressure drops during the fill, open upthe fill valve more.

z When no leaks are found, remove plug, drain waterand install relief valve (Fig. 14, page 20).

Maximum

operating pressure

Maximum

test pressure

30 psi (based on supplied

relief valve)

45 psi

58 psi (based on 50 psi relief

valve)

75 psi


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23




7.4 Burner Mounting

Install only burners that have been tested and approved

by Buderus Hydronic Systems, Inc. for use on a G115boiler. ( Chapter 3, page 7).

z Burner mounting studs and washers are includedwith the G115 B-kit. Install the studs into the burnerdoor.

z Install the correct burner into the G115 boiler. Checkpump pressure, air setting, turbulator setting andflange position. Refer to burner specificationsincluded with KP burner package.

z Put the washers on the studs and secure burner toboiler using furnished nuts.

z Follow burner manufacturers recommendationregarding installation, fine tuning and maintenanceprocedures.

7.5 Installation of Oil Line

Install the fuel line in accordance with local code. Werecommend the use of an oil filter near the burner in

addition to an oil filter near the oil tank.

z Visually inspect the fuel line for leaks, replace whennecessary.

z Install a shut-off in the oil line.

z Connect the oil line without undue strain.

z Check the fuel supply line for leaks and correct.

CAUTION!

SYSTEM DAMAGE

due to incorrect burner.

z Use only burners approved for use withBuderus G115 boilers.

Fig. 18 Burner stud mounting locations on G115 burner door

4 3/8"

5 7/8"

NOTICE

The burner KP kit, supplied by BuderusHydronic Systems, Inc. contains acustomized, pre-set oil burner, a Taco 007

or Grundfos circulator and pump flanges, aHoneywell L8148A aquastat and a flexibleoil line.

NOTICE

Observe for fine tuning of the burner boththe draft conditions of the chimney and burner manufacturers documentation.


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7.6 Aquastat Installation

A Honeywell aquastat controls the boiler supply

temperature when not using a Buderus Logamaticcontrol.

z Install the Honeywell aquastat into the brass boilerwell. Make sure the capillary is fully inserted in the

well. Do not kink capillary tubing.Refer to Chapter 8, page 28 regarding placing theboiler in operation.

7.7 Electrical Connections

This section only applies to G115 boilers equipped with

a Buderus Logamatic control.

z Remove rear top cover. Remove first rear sheetmetal screws.

z Remove top cover plate. The electrical wiring will runthrough this race way.

Fig. 19 Installation of aquastat

1 Capillary

1

WARNING!

DANGER

due to electrical currents.

z All electrical work must be performedby a qualified electrician.

z Before opening the control: Shut offelectrical supply and prevent fromaccidental reactivation.

z Observe all installation instructions.

Fig. 20 Removal of top rear cover and top cover plate


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25




7.7.1 Control System Installation

z Slide plastic front tabs of control panel in the ovalshaped openings.

z Slide the control panel forward.

z Push forward on plastic snap tabs in rear of control toengage them into the top panels square knock-outs.

z Remove top cover of control panel. Remove coverscrews.

z Secure control to top cover using small sheet metalscrews.

Fig. 21 Installation of control

1 Plastic snap tabs

2 Plastic front tabs

3 Oval knock-outs

4 Square knock-outs

1

3

4

2

Fig. 22 Removal of top cover

1 Top cover screws

2 Sheet metal screws

1

2


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7.7.2 Installation of Temperature Sensor and Burner Cable

z Route the capillary tubing carefully and avoid kinking.Route capillaries and sensor wiring to the immersionwell.

z Strap excess tubing and wiring together and place ontop of insulation.

z Burner wiring can be routed down towards the frontof the boiler. If burner is supplied with a wiringharness, route harnesss between jacket panels and

boiler insulation.z Install burner wiring per wiring instructions included

with Logamatic control or refer to diagrams locatedon pages 51 to 53.

z Bring the sensor bundle to the installed chrome welland slide bundle into the well. The plastic holding clipwill slide back.

z Insert all sensing elements fully into the well andsecure tubing with furnished metal holding clip.

7.7.3 Electrical Connections

Install a power supply point near the boiler inaccordance with local and state code.

Fig. 23 Routing and connecting of capillary, sensor and

electrical wiring

1 Cable raceway opening in top front cover

2 Capillary tubing and sensor wiring.

3 Well location.

4 Burner cable/wiring

1

3

2

4

CAUTION!

SYSTEM DAMAGE

Be careful not to kink or have the capillarytubes come in contact with sharpsurfaces.

z Route the capillary tubing carefully and

avoid kinking. Route capillaries andsensor wiring to the immersion well.

Fig. 24 Installation of sensor bundle

1 Chrome immersion well

2 Plastic holding clip

3 Tension clip

4 Metal holding clip

1

1

2

3

4

NOTICE

Every G115 boiler has a factory installedimmersion well for use with a Honeywellaquastat.

z When installing a Logamatic control,you must replace the installed brass

well with the chrome well supplied withthe Logamatic control.

NOTICE

Make sure all sensing elements are allfully inserted into the well and make good

contact with well inner surface. Make sureto use the tension clip in the middle ofsensing elements.


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27




z Route all electrical wiring through the top cover raceway and install wiring per electrical schematics inLogamatic manuals.

7.7.4 Strain Relief Installation

Secure all electrical wiring near the Logamatic using thefurnished plastic cable ties.

z Install cable ties with the tab facing up into the rear ofthe Logamatic (step 1).

z Slide cable ties down and lock them in (step 2).

z Push cable ties in (step 3).z Push hinging tab down to secure cable (step 4).

7.8 Jacket Panel Installation

z Put control top cover back and secure.

z Install rear top panel on boiler.

WARNING!

FIRE HAZARD

Electrical wiring can be damaged by hot

boiler parts.

z Make sure that all tubing and wiringcomponents are all placed on top ofthe boiler insulation.

Fig. 25 Secure wiring with cable ties

Fig. 26 Installation of rear top cover

1 Control top cover

2 Rear top panel

2

1


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Placing the Boiler in Operation8

8 Placing the Boiler in Operation

This chapter describes the initial start-up procedure forthe G115 boiler irrespective of the employed controlsystem.

z Please fill out the start-up protocol during thisprocess ( Chapter 8.10, page 33).

Further information regarding boiler room lay-out andclearances, combustion air requirements and ventingsystem as well as boiler operational requirements referback to Chapter 3.2, page 8.

8.1 Setting the Initial System PressureSet the system for regular operation during the initialstart-up procedure.

z

Add additional make-up water until the desiredpressure is achieved; at least 12 - 15 psi, but no morethan 30 psi. (Actual settings are dependent on thepressure rating of the relief valve).

z Vent the system during the initial fill.

8.2 Checking Relief Valve

z Make sure nobody is near the discharge of the reliefvalve.

z Lift up on the relief valve.

The relief valve has to open and relief water andpressure. Replace the relief valve immediately if it doesnot discharge. A defective relief valve can causedamage to the system.

CAUTION!

Boiler DAMAGE

due to excessive dust and aircontamination.

z Do not operate the boiler under highdust conditions, such as sheet rockdust and construction dust. Make sure

to provide clean combustion air if theboiler needs to operate under suchconditions,

z Install an airfilter, or other means toensure clean combustion air. Dust canoriginate from within duringconstruction, but also from outsidewhen the installation is in close vicinityof chemical plants, shop or dustyoutside conditions.

Fig. 27 Pressure and temperature gauge

CAUTION!

SYSTEM DAMAGE

due to material stresses as a result oftemperature differences.

z Use cold water for the initial fill. Limit

the fill water temperature to 100 Fmaximum.


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Placing the Boiler in Operation 8

29




8.3 Check Position of Flue Baffle Plates

Check to make sure that the flue baffle plates are in

horizontal position before the initial start-up process.

z Open the burner door by removing the two burnerdoor bolts.

z Pull the baffle plates slightly out of the boiler.

z Bring the baffles in a fully horizontal position andpush back into the boiler.

z Close the burner door and torque door bolts evenlywith 90 lbs-inch torque using hex-head bolts.

8.4 Get System Ready for ProperOperation

z Open fuel shut-off valve.

z Turn on main system disconnect switch.

8.5 Start-up of Control and Burner

Follow the burner start-up procedure per burnermanufacturer' recommendations. Follow the

instructions furnished with the burner.

Turn on the main switch of the Logamatic control toactivate the heating system. The burner comes on whenthe control is switched to manual mode. Follow theinstructions in the Service Manual of the control.

z Select "manual" operation.

z Set the desired adjustable limit temperature on the

control.z Turn control on (Position I).

Fig. 28 Opening of the burner door

1 Flue baffles in secondary passages

1

Fig. 29 Switching control panel (Logamatic 2000 series

controls)

1 Adjustable high limit dial

2 Main control switch

I 0

2

1


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8.6 Guidelines Regarding Burner Start-up

Allow the burner to operate for 15 to 20 minutes prior to

performing combustion test.

Earlier combustion tests can lead to erroneous readingsdue to burning off of the sealing rope. We recommendto check the burner after a few weeks of operation.

Necessary instruments:

CO2 measuring equipment

Draft measuring equipment

Oil pressure gauge

Stack thermometer

Smoke tester

z Measure the over fire pressure at the measuring porton the burner door.

z Measure the breeching draft in the vent connectortwo vent pipe diameters away from the ventconnections. (Only on chimney vent models: refer toDirect Vent Manual for proper test location).

8.7 Adjusting Stack Temperatures

Refer to ( Chapter 3, page 7) for approximate stacktemperatures.

When you determine that the stack temperature is toolow, and condensate formation might take place in thechimney, the stack temperature can be increased by thefollowing steps:

Adjust the flue baffles

Remove the flue baffles

Remove flue blocking plates

z Shut-off the boiler ( Chapter 9.1, page 34).

NOTICE

Improper burner adjustments can lead toimproper combustion and sooting of theboiler. Burner lock-outs can also occur asa result.

z Always check the combustion with thefollowing instruments.

z Never check and/or adjust burneroperation by eye sight.

Fig. 30 Pressure test port on burner door

1 Pressure test port

1


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31




8.7.1 Adjusting Flue Baffles

Adjust or remove the flue baffles always in pairs.

z Open burner door by removing the two hex headbolts.

z Pull the flue baffles slightly out of the flue passages.

z Rotate flue baffles inward and slide back into the fluepassages.

z Close burner door and secure with burner door bolts(ca. 90 Lbs/inch). Tighten bolts evenly.

z Measure the stack temperature again.

8.7.2 Removing Flue Baffles

To further increase the stack temperature, remove bothflue baffles.


z Remove flue baffles from the front.

z Close burner door and secure with burner door bolts(ca. 90 Lbs/inch). Tighten bolts evenly.


WARNING!

EXPOSION DANGER

due to leaking gases.

z Shut-off main valve when, in order toopen the burner door, the gas line mustbe disconnected from the burner. Allowthe remaining gas to disperse into the

air. Do not smoke or generate a spark.

CAUTION!

Combustion Hazard

due to contact with hot boiler surfaces.

z Wear thermal protection gloves or use aset of pliers.

Fig. 31 Adjusting flue baffles

Fig. 32 Removing flue baffles


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8.7.3 Removing Blocking Plates

When the stack temperature after removal of flue bafflesis still too low, you can also remove the front sectionblocking plates to increase the stack temperature.


zRemove blocking plates by removing set screw fromthe front section.


8.8 Testing of the Manual Reset High Limit (STB) of Logamatic controls

The manual reset high limit will permanently interruptburner operation once its limit (230 F) is exceeded. To

restore operation, it is required to reset this control andlower the water temperature well below its fixed setting.

z Refer to Logamatic Service Manual to checkoperation of manual reset high limit.

8.9 Install Front Jacket Parts

z Hang boiler front panel into slots of boiler sidepanels.

z Secure front panel with the two screws into the sidepanels.

Fig. 33 Removing blocking plates

Fig. 34 Installation of boiler front panel


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33




8.10 Detailed Start-up Procedure

z Check off performed start-up steps, sign and date.

Start-up Procedure Page Value Measured Comments

1. Filling of system and check for leaks 21

__________ psi

2. Set operating pressure

vent heating system

check operation of relief valve

pre-set expansion tank pressure ( see expansion tank manufacturer'

instructions)

28

__________ psi

3. Check combustion air and venting system

4. Check position of flue baffles 29

5. Turn on control ( Refer to control Service Manual) 29

6. Turn on burner ( Refer to burner manual) 29

7. Measure stack temperature (Adjust if needed) 30

__________ F

8. Check manual reset high limit (STB) 32

9. Adjust control settings based on requirements ( Refer to control Service

Manual))

10. Inform end user and hand over instructions

Confirm start-up procedure

Company stamp/signature/date

NOTICEz Always inform your customer

regarding proper fuel source andrecord in Operating Manual.


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Taking the Boiler out of Operation9

9 Taking the Boiler out of Operation

9.1 Normal Boiler Shut-down

z With Buderus Logamatic controls: Turn the mainswitch to "0" position. This shuts off power tocomponents wired directly to the control panel.

z With Honeywell aquastat control: Shut off mainheating system switch. (Position "OFF") This shutsoff power to all components wired through thisswitch.

z Further shut-down procedure: refer to aquastatdocumentation.

z Shut off fuel supply by closing main valve.

9.2 Emergency Shut-down

Please explain suitable system operation duringemergency conditions, such as fire:

z Shut off fuel supply by closing main valve.

z Shut down the heating system electrically eitherusing the main emergency switch or the suitableelectrical breaker.

Abb. 35 Shutting down heating system (Logamatic 2000)

1 ON/OFF switch

I 0

1

Fig. 36 Heating system shut-down (with aquastat)

CAUTION!

SYSTEM DAMAGE

due to freezing.

When the system is shut off, the systemcould potentially freeze up.

z Keep the system operational as longas possible.

z Protect the system against freeze-upby draining the entire system at itslowest point.


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Boiler Maintenance 10

35




10 Boiler Maintenance

10.1 Why do Maintenance?

Regular maintenance is required for the followingreasons:

To maintain high efficiency operation and minimizefuel usage.

To sustain reliable operation.

To maintain clean combustion and reduce pollutantemissions.

Please offer your customer an annual service andmaintenance plan. You can review the service andmaintenance protocol regarding precise description ofsuitable services ( Chapter 10.6, page 39).

10.2 Prepare Boiler for Cleaning

z Shut down the heating system ( Chapter 9.1,page 34).

z Remove boiler front panel and possibly burner cover( Chapter 5.1, page 13).

z Disconnect electrical supply to burner.

NOTICE

Spare parts can be ordered by contacting

your Buderus wholesaler.

WARNING!

DANGER

due to electricity.

z Prior to opening control panel: Shutdown electricity supply and padlock

shut to protect against accidentaloperation.

WARNING!

DANGER

due to explosion of flammable fumes.

z Perform service work on gascomponents only, when one has thenecessary certification.


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Boiler Installation and Maintenance Manual Logano G115 US Issue03/2004


Boiler Maintenance10

10.3 Boiler Cleaning

The boiler can be cleaned using boiler brushes and/or

with a wet cleaning. Boiler brushes are available fromyour Buderus wholesaler.


10.3.1 Cleaning the Boiler with Brushes

z Record the position of the flue baffles so they can beplaced back in their original position.

z Remove blue baffles from passages.

z Clean flue fire baffles using a hard bristled brush.

z Brush out flue passages by rotating the round brush.

z Clean the combustion chamber with a flat brush.

Remove the loosened debris from combustionchamber, flue passages and breaching connectionareas.

z Insert the flue baffles into the boiler in their originalposition.

z Check burner door sealing rope. Replace damagedor hardened sealing rope.

z Close burner door by tightening the burner door bolts(Torque to 90 Lbs-in ). Torque burner door evenly forproper door closure.

CAUTION!

COMBUSTION DANGER

Due to contact with hot boiler parts.

z Wear thermal protection gloves or usea set of pliers.

Fig. 37 Opening of burner door

1 Flue baffles in secondary flue passages

1

Fig. 38 Brushing our of flue passages

Fig. 39 Brushing out the combustion chamber

NOTICE

Burner door sealing rope is availablethrough your local Buderus wholesaler.


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37




10.3.2 Wet Cleaning

Use for the wet cleaning a suitable cleaning agentdesigned to dissolve the internal build-up or clean thesoot.

Following the wet cleaning, proceed with the brushingsteps outlined in ( Chapter 10.3.1, page 36).

z Cover control with plastic to prevent water damage.

z Spray heating surfaces evenly with cleaning agent.

z Close burner door and turn on heating system.

z Heat the boiler to a minimum temperature of 160 F.

z Turn the system off.z Brush out heating surfaces.

10.4 Testing System Pressure

The system pressure should be 15 to 30 psi for a closedsystem.

z Check system pressure.

z When the pressure gauge shows less than 12 - 15psi, the pressure is too low.

NOTICE

Observe and follow recommendations ofthe cleaning agent' manufacturer. Undercertain conditions you may need to deviatefrom the guidelines below.

Fig. 40 Pressure/temperature gauge to display system

pressure and supply temperature

CAREFUL!

SYSTEM DAMAGE

due to frequent make-up water.

When you add frequently make-up waterto the system, this can lead to corrosionand lime build-up in the system.

z Make sure that the heating system is

equipped with automatic airelimination.

z Verify that the system has no leaks and

check the expansion tank for properoperation.


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z Add make-up water through the automatic feedvalve.

z Vent system.

z Check system working pressure.

10.5 Testing Relief Valve

Check the functioning of the relief valve every 1 to 3years as required per local code.

z Make sure nobody is near the discharge of the reliefvalve.

z Lift up on the relief valve.

The relief valve must open and discharge water. If thevalve does not discharge, replace the valve andrecheck. If the defective valve is not replaced, it canlead to damage to certain system components due toexcessive high pressures.

CAREFUL!

SYSTEM DAMAGE

due to material stresses as a result of

temperature differences.

z Add only additional make-up waterwhen the system is cold (Temperaturegauge reading should not exceed

100 F).


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39




10.6 Inspection and Maintenance Procedure

z Sign off and date performed service work. This service and maintenance protocol can also becopied for further use.

Service work Page Date: ______ Date: ______ Date: ______

1. Check general status of system

2. Do visual performance test on system

3. Check fuel and water components for:

Leaks during operation

Hydrostatic water test

Visual corrosion

Exterior system changes

4. Check flue passages for soot, shut off system 35

5. Check burner operation ( See burner manual)

6. Check combustion air inlets and vent system

7. Check system pressure, relief valve and expansion tank 37

8. Check DHW tank anode status ( See DHW tank manual)

9. Check control settings ( See manual)

10. Final check, record combustion test results

Confirm service work

Sign/date Sign/date Sign/date


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Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Sign/date Sign/date Sign/date Sign/date Sign/date Sign/date Sign/date

NOTICE

When you find conditions during theannual service/maintenance work thatrequire attention, please perform thenecessary remedial steps.


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41




Maintenance Procedure page Date: ______ Date: ______ Date: ______

1. Take the boiler out off operation 35

2. Remove blue baffles from passages and clean flue fire baffles 35

3. Clean flue passages and the combustion chamber,Insert the flue baffles into the boiler in their original position

35

4. Check burner door sealing rope. Replace damaged or hardened

sealing rope. Close burner door by tightening the burner door bolts.

36

5. Take the boiler in operation 29

6. Final check at the system after maintenance and service inspection

7. Check boiler in operation

Confirm service and maintenance work

Sign/date Sign/date Sign/date

Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______

1.

2.

3.

4.

5.

6.

7.

Sign/date Sign/date Sign/date Sign/date Sign/date Sign/date Sign/date
http://../G0000501_03G00043/Kundenunterlagen/FM_bedingt_neu%20aktuell/BKap08_de1.pdfhttp://../G0000501_03G00043/Kundenunterlagen/FM_bedingt_neu%20aktuell/BKap08_de1.pdf


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Installation and Maintenance Manual Logano G115 US Issue 03/2004


Restoring Sytem Lock-outs11

11 Restoring Sytem Lock-outs

One can identify two different types of lock-outs

burner lock-outs.

control and system lock-outs.

A lock-out light will typically be lit on the burner ( seeburner manual) during its lock-out. Press the burnerreset button once to restart the burner. Call your servicecompany immediately if the burner locks out again. DoNOT continue to reset the burner.

Error conditions on the control or in the system are typi-cally displayed on the control display, if so equipped.Further information can be found in the control

Service Manual.

Correct burner lock-outs

z Remove burner cover, when the burner is so equip-

ped. Press the burner reset buttom once.Fig. 41 Resetting the burner

1 Burner

1

WARNING

SYSTEM DAMAGE

durch Frost.

When the entire system is shut off, it cancause a freeze-up condition.

z Have any lock-out condition correctedimmediately and restart the heatingsystem.

z If this is not possible, protect the sys-

tem for freeze-up by draining the hea-ting system and domestic hot watersystem at their respective lowestpoints.


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Piping Diagrams 12

43




12 Piping Diagrams

Explanation of the abbreviations

KR Flow check SH 3-way motorized valve

MAG Expansion tank WH Boiler bypass

PH Heating pump SV Relief valve / Air elimination

PW DHW charging pump THV Zone valve

Fig. 42 Zoning with zone valve

Baseboard

Baseboard

Baseboard

G115

PHSV

MAG

THV


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Piping Diagrams12

Fig. 43 Zoning with pumps

G115

Baseboard

Baseboard

Baseboard

MAG

SV

PH

KR

Fig. 44 Zoning with zone valves and built-in bypass for larger water volume systems

Baseboard

Baseboard

Baseboard

G115 " Boiler Bypas

PHSV

MAG

THV

WH


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Piping Diagrams 12

45




Fig. 45 Multiple zones with DHW, high temperature and low temperature circuits with a motorized 3-way valve

G115

R2107

M

Baseboard

1800

100 0120 0

160 0180 0

100 0

PS

SV

MAG

KR

SH

PH

PH

KR


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Spare Parts13

13 Spare Parts

The following parts are available through BuderusHydronic Systems. Model specific part numbers arelisted under the various models. In other cases the tableshows the number of components for each model.

Boiler block and burner door(Fig. 46)

Legend for tables 12 and 13:

x = no spare part

(x) = component of a set, only furnished with the set

0 = no picture available

Item Description Part number

G115/21

3 section

G115/28

4 section

G115/34

5 section

10 Boiler block G115 05952285 05952290 05952295

Front section components:

21 Plug G1 1/4" right 86055310

22 Gasket for plug D41,7x55x1,5mm AFM 34,white 86159710

23 Blocking plate with screw M8x16 63015342

24 Screw DIN7991 M8x16 Ms (x)

rear section components:51 Plug DIN2950 291 1" 05317680

52 Threaded stud M10x65 5.6 05555070

53 Distance sleeve R3/8"x39 (x)

54 Hex. head nut ISO4032-M10-8-A3K (x)

55 Washer DIN125-A10,5-A3K (x)

60 Immersion well Pmw-3See (4 1/2")"US" 00472887

70 Tie bar - Set M8x310mm 05127574

70 Tie bar - Set M8x440mm 05127578

70 Tie bar - Set M8x555mm 05127580

80 Flue collector 05354074

Flue collector components81 Sealing rope 8x1050 GP 63020961

0 Glue for securing rope (a 310ml) 63014361

90 Return diffuser 1 1/4-NPT1 compl. G115"US" 63028062 63028062 63028061

91 Gasket 55x41,7x1,5mm 05752540

Spare parts which are not furnished with the spare boiler b lock:

120 Flue baffle 05347085 05347087 05347089

130 Boiler rail 420mm long 05198102



131 Washer DIN126-9 (x)

132 Hex. head screw ISO4017-M8x25-8.8 (x)

133 Hex. head nut DIN6923-M8-8.8-A3K (x)

140 Door hinge G105/G115 05327033

141 Scheibe DIN125-A10,5-A3K (x)

142 Sechskantschraube ISO4017-M10x25-8.8 (x)

150 Sechskantschraube ISO4014-M10x65-8.8 (x)

160 Washer DIN125-A10,5-A3K (x)

180 Boiler feet M10x51mm complete 05236440

Tab. 12 Boiler block and burner door


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Spare Parts 13

47




190 Gasket for flue collar DN130 complete 05354010

200Flue silencer DN130 complete, without condensate drain; higher sound

absorption05074020

or:

210Flue silencer D130 with adapter 100mm long, with condensate drain,

lower sound absorption05074022

Flue silencer components:

190 Flue collar DN130 complete 05354010

220 Flue collar DN130 complete (step cuff) 05354030

230 Sealing rope10x2000 GP 63020963

250 Burner door complete 63023858

Burner door components:

260 Door hinge 05327020

270 Washer DIN125 A10,5 A3K (x)

280 Hex. head screw ISO4017 M10x25 8.8 (x)

290 Observation port cover complete G115/G125/G135 63023634

Observation port cover components:

300 Gesket 30x30x3 63014382

310 Sight glass Tempax 30x30x3,3mm 05447620

320 Sight glass cover plate x330 Hex. head screw ISO4017 M6x12 8.8 A3K (x)

340 Pressure measuring port M6 SW10 V2 63026521

350 Burner door insulation G115 W607 63002401

Burner door insulation components:

360 Insulating plate for burner door 24mm 63004169

370 Insulating ring for burner door 10mm 63004170

380 Washer DIN9021 A6,4 A3K (x)

390 Sheet metal screw DIN7981 C ST6,3x25 A3T (x)

400 Sealing rope14x1650 GP 63020965

0 Glue for securing sealing rope to burner door (a 310ml) 63014361

(x)

Mounting material for boiler block G115 "US"

63031288

Components:

1 Hex. head screw M8x16 Ms

2 Distance sleeve R3/8"x39

2 Hex. head nut ISO4032 M10 8 A3K

8 Washer DIN125 A10,5 A3K

4 Washer DIN126 9

4 Hex. head screw ISO4017 M8x25 8.8

4 Hex. head nut DIN6923 M8 8.8 A3K

4 Hex. head screw ISO4017 M10x25 8.8

2 Hex. head screw DIN6921 M10x65 8.8

1 Hex. head screw ISO4017 M6x12 8.8A3K

2 Washer DIN9021 A6,4 A3K

2 Sheet metal screw DIN7981 C ST6,3x25 A3T

0

B-KIT G115"US"

63029762

Components:

1 Supply manifold G115"US"

1 90 degree 1 1/4 NPT elbow

1 90 degree 3/4 NPT elbow

1 Conversion nipple R11/4-11/4NPTx75

1 Boiler drain valve 3/4

1Relief valve 3/4Mx3/4F 30PSI

1 Pressure / Temperature gauge 1/4NPT

1 Screw-Set B-Kit G115"US"1 Boiler feet set M10x51

Tab. 12 Boiler block and burner door


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Spare Parts13

Fig. 46 Boiler block and burner door

1023033-00-Kesselblock G115 US

21

23

24

133

133

180

180

5253

22

21

370

380

390

280

270

260

250

350

300290

310

330

340

320

350

400

360

22

52

5554

80

142

141

140

130

131

132

120

70

70

9190

10

8151

60

150160

70

230220

200

210

190


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Spare Parts 13

49




Boiler Jacket Components (Fig. 47)

Item Description Part number

G115/21

3 section

G115/28

4 section

G115/34

5 section

The complete boiler jacket for a G115 boiler contains the following components: front panel, name plate, front insulation, top gross bracket, 2 side

panels, boiler block insulation, holding clips, top front cover, top rear cover, rear panel and mounting material set.

Boiler jacket components:10 Front panel G115/S105 63029203

18 Name plate Logano G115 67902824

20 Front insulation G115 63025265

40 Hex. head screw ISO4017-M8x12-8.8 (x)

50 Top groos bracket G115/G115U 63029209

60 Hex. head nut DIN555 M8 5 (x)

70 Washer DIN126 9 (x)

80 Side panel 445mm long 63029945



85 Sheet metal screw C ST3,9x13 A3T (x)

90 Screw 3,9x9,5 A3T (x)

95 Clip (x)

100 Boiler block insulation G115 05670040



110 Holding clips for boiler block insulation 00476378

120 Top front cover G115/G115U/S105/S105U 63029222

125 Cover plate 300x160 63021497

130 Top rear cover complete G115 "US" 05198112 05198114 05198176

140 Rear panel complete G115 05198084

150 Cable rail way 07060754

160 Washer DIN432 10,5 St A3E (x)

170 Hex. head nut DIN555 M10 5 (x)

(x)

Mounting material for boiler jacket G115, GC115, G125, G134

05180842

Components:

17 Screw St3,9x9,5-A3T

3 Sheet metal screw C-St3,9x13-A3T

1 Screw DIN7985-M6x16-4.8-A3T

2 Clip

4 Hex. head screw ISO4017-M8x12-8.8

1 Hex. head nut DIN555 M8 5

4 Washer DIN126 9

4 Washer DIN432 10,5 St A3E

4 Hex. head nut DIN555 M10 5

Tab. 13 Boiler jacket components


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Spare Parts13

Fig. 47 Boiler jacket components

1023034-00-Kesselverkleidung G115 US

4070

85

80

18

4070

80

4070

6050

85

20

100

10

170160

90

130

120

90

90

12590

140 150

170160

90

95

110


51/56


52/5652




SP30D and Burner Wiring14

Fig. 49 Wiring diagram 2


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SP30D and Burner Wiring 14

53




Fig. 50 Wiring diagram 3


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54




SP3

201001221723430.63030586_g115installationmanual0304.pdf

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