Oil and Gas Boiler Installation Manual for Logano G115 US Cast Iron Boiler

6303 0586 03/2004 US/CA
For installers
Boiler Installation and Maintenance Manual

Oil and Gas fired Cast Iron Boiler Logano G115 US
Please read these instructions carefully.
Inhaltsverzeichnis
Safety Considerations
1.1 1.2 1.3 1.4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 4 4 4 4 5 5 5
1.5 1.6
. . . . 1.4.1 . 1.4.2 . 1.4.3 . Tools, Materials and Accessories . Disposal . . . . . . . . . . . . . . .
Regarding this Manual . . . . . Suitable Applications . . . . . . Guideline of Notices. . . . . . . Observe the following Symbols
. . . . In Case of Smoke . . . . . Installation Guidelines . . . Boiler Room Guidelines . .
2 3
PRODUCT DESCRIPTION .
3.1 3.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TECHNICAL INFORMATION
Technical Data less Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 General Operating Requirements . . . . . . . . . Requirements for Boiler Room and Surroundings . Combustion Air Requirements . . . . . . . . . . . Fuel Conditions. . . . . . . . . . . . . . . . . . . Requirements for Power Supply . . . . . . . . . . Conditions Pertaining to Piping and Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . 9 10 10 11 11
4 5
Packaging and Components . Moving the Boiler .

5.1 5.2 5.3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reducing Boiler Weight for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lifting and Carrying the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Moving the Boiler with Boiler Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 16 17 17
Placing the Boiler .

6.1 6.2 6.3 6.4
Clearances . . . . . . . . . . . . . . . . . . . . . . Reversing the Burner Door Swing . . . . . . . . . Installation of Boiler Feet (Components of B-Kit) Placement of the Boiler . . . . . . . . . . . . . . .
Boiler Installation .
7.1
7.1.1 7.1.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 18 20 20 21 21 21 23 23 24 24 25 26 26 27 27
Installation of Venting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

For Oil-Fired, Direct Vent Applications . . . . . . . . . For Chimney Venting . . . . . . . . . . . . . . . . . . Installation of Water Connections . . . . . . . . . . . . . . 7.2.1 B-Kit Installation . . . . . . . . . . . . . . . . . . . . 7.2.2 Installation of Boiler Drain (B-Kit Component) . . . . . 7.2.3 Installation of System Components . . . . . . . . . . Filling and Checking for Water Leaks . . . . . . . . . . . . Burner Mounting . . . . . . . . . . . . . . . . . . . . . . . . Installation of Oil Line . . . . . . . . . . . . . . . . . . . . . Aquastat Installation . . . . . . . . . . . . . . . . . . . . . Electrical Connections . . . . . . . . . . . . . . . . . . . . 7.7.1 Control System Installation . . . . . . . . . . . . . . . 7.7.2 Installation of Temperature Sensor and Burner Cable . 7.7.3 Electrical Connections . . . . . . . . . . . . . . . . . 7.7.4 Strain Relief Installation . . . . . . . . . . . . . . . . Jacket Panel Installation . . . . . . . . . . . . . . . . . . .
7.2
7.3 7.4 7.5 7.6 7.7
7.8
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH http://www.heiztechnik.buderus.de
Boiler Installation and Maintenance Manual Logano G115 US Issue 03/2004
Inhaltsverzeichnis
Placing the Boiler in Operation .

8.1 8.2 8.3 8.4 8.5 8.6 8.7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . 28 . 29 . 29 . 29 . 30 . 30 . 31 . 31 . 32 . 32 . 32 . 33
. . . . . . . 8.7.1 . 8.7.2 . 8.7.3 . 8.8 Testing of the Manual Reset High Limit (STB) of Logamatic controls. 8.9 Install Front Jacket Parts . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 Detailed Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Initial System Pressure . . . . Checking Relief Valve . . . . . . . . . . . Check Position of Flue Baffle Plates . . . Get System Ready for Proper Operation Start-up of Control and Burner . . . . . . Guidelines Regarding Burner Start-up . . Adjusting Stack Temperatures . . . . . .
. . . . . . . Adjusting Flue Baffles . . . . . . . . . Removing Flue Baffles . . . . . . . . Removing Blocking Plates . . . . . . .
Taking the Boiler out of Operation

9.1 9.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Normal Boiler Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Emergency Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10
Boiler Maintenance
10.1 Why do Maintenance? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 10.2 Prepare Boiler for Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 10.3 Boiler Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.3.1 Cleaning the Boiler with Brushes 10.3.2 Wet Cleaning . . . . . . . . . . 10.4 Testing System Pressure . . . . . . . 10.5 Testing Relief Valve . . . . . . . . . . . . . . 10.6 Inspection and Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . 37 . 37 . 38 . 39
11 12 13 14 15
Restoring Sytem Lock-outs Piping Diagrams Spare Parts .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SP30D and Burner Wiring Table of Key Words .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1
1.1
Regarding this Manual 1.4 Observe the following Symbols
This document contains important information regarding safe and proper installation, operation and maintenance of the boiler. The G115 is designated as a hot water heating boiler. The Installation and Maintenance Instructions are directed to the installing contractor who has professional knowledge regarding boiler installation and maintenance.
The local and state codes and regulations must be observed during the installation of the boiler: The local building code requirements regarding placement, combustion air and venting and chimney system must be followed. Follow applicable electrical code requirements. Follow the regulations of the local gas utility if the boiler is to be operated with a gas burner. Follow the local code and standards regarding safe boiler operation. NOTICE Use only original Buderus spare parts for replacement purposes. Buderus can not be held liable for damage caused by non Buderus parts. 1.4.1 In Case of Smoke
1.2
Suitable Applications
The boiler can only be used for hot water space heating applications 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
WARNING!
DANGER due to explosion of flammable gases! z No open fire! Do not smoke! z Avoid formation of sparks! Do not touch any electric switch, phone, electric plug or bell! z Shut off main gas supply. z Open windows and doors!
Two levels of danger are identified by the following warning labels: DANGER Denotes a possible severely dangerous situation where, without proper caution, bodily injury or loss of life may result. DANGER OF INJURY/ SYSTEM DAMAGE
CAUTION!
WARNING!
z Notify all occupants! z Leave the building! z Immediately call your gas supplier, heating contractor or fire department from a phone outside the building! 1.4.2 Installation Guidelines DANGER due to explosion of flammable gases.
WARNING!
Denotes a possible dangerous situation that can lead to mild to moderate bodily injury or physical damage. APPLICATION NOTICE Application comment for optimum use of equipment and adjustment as well as useful information.
Cross notice Designated by means of a narrow , referral to a notice in another document .
z Work only on gas components when you have a license to do so.
DANGER due to electricity.
DANGER!
1 1.6 Disposal
z Please dispose of any trash in an environmental friendly fashion. z Please discard properly of any heating system related components.
z One is only allowed to work on electrical components, if one is certified for such work. z Prior to opening the control: shut down the power supply and pad lock against accidental reactivation. z Observe all applicable installation guidelines.
1.4.3 Boiler Room Guidelines DANGER due to poisoning. Insufficient combustion air can result in dangerous operation if all combustion air is taken from indoors. z Please observe that combustion air openings are not reduced in size or closed. z If this problem has not been corrected, one can not operate the boiler. z Make the end-user aware of these guidelines and their potential danger. FIRE DANGER due to flammable or liquid materials
WARNING!
WARNING!
z Make sure that flammable and liquid materials are not in the close vicinity of the boiler.
1.5
Tools, Materials and Accessories
For the installation and maintenance of the boiler you will need typical tools used in the trade. In addition, the following components are useful: Boiler cart with rope or Buderus boiler cart. Wood blocking. Cleaning brushes and/or chemical cleaning agents for a wet cleaning.
PRODUCT DESCRIPTION
PRODUCT DESCRIPTION
1
The G115 boiler is a low temperature boiler for oil or gas firing 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 control functions in a heating system. As an alternative, a Honeywell aquastat can be used for boiler control. The boiler jacket serves to reduce energy loss and as a noise reducing agent. The boiler block transfers the heat generated by the burner to the boiler water. The insulation reduces the stand-by losses.
Fig. 1 1 2 3 4 Boiler less burner
2 3
Control panel Boiler jacket Boiler block with insulation Burner door cover
Customized burner The boiler must be equipped with a customized burner for operation. Please observe the technical data of the boiler when selecting a burner ( Chapter 3.1, page 7). SYSTEM DAMAGE due to improper burner.
CAUTION!
z Use only burners recommended by Buderus as is discussed in our technical documents.
3
3.1
Technical Data less Burner
Select your suitable burner based on this information.
23 5/8"
39 5/8" 30 3/8"
L LK 1 3/4" 25 1/4" VK Rp11/4" 8 7/8"
5"
5 7/8" 4 3/8"
10 3/8"
20" 3 1/4" RK 1" NPT 8 7/8" EL Rp 3/4" 2 7/8"
12 1/4"
5/8" 1"
2 7/8"
FL
Fig. 2
Dimensions and connections (measurements in inches)
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 Number of sections Heating Capacity (Gross Output) Net IBR Boiler water content Fireside volume Oil firing rate Fireside pressure drop Permissible max. supply temperature 1 Btu/hr Btu/hr Gal cu.ft. GPH psi F psi s 115/21 3 74,000 64,000 8.7 1.20 .60 115/28 4 98,000 85,000 10.8 1.75 115/34 5 120,000 104,000 12.9 2.21
.80
0.00058 0.00145 230 58 40
1.0
Allowable operating pressure Maximum Reset High Limit for temperature sensor and overheat thermostat (STB)
Table. 1 Technical data less burner

1
High limit (overheat thermostat STB) Permissible maximum supply temperature = High limit (STB) 32 F e.g.: High limit (STB) = 212 F, maximum permissble supply temperature = 212 32 = 180 F Select the your high limit (STB setting) according your local codes and requirements.
Boiler model 115/21 Inch Inch Inch Inch Inch Inch Lbs 10 3/8 330 22 7/8 21 1/8 16 115/28 27 7/8 25 3/4 20 1/2 10 5/8 3 5/8 16 1/8 403 20 7/8 476 115/34 32 5/8 30 1/2 25 1/4
Total boiler length (L) Boiler block length (LK) Combustion chamber length Firebox diameter Burner door thickness Distance between boiler feet (FL) Dry weight 1
Table. 2 Dimensions, Weight and other Data

1
Weight incl. packaging material approx. 6 8 % more.
3.2
Operating Conditions
By maintaining the operating requirements listed on the following page, one can expect long and trouble free operation of the boiler. Proper and timely maintenance procedures must be followed. SYSTEM DAMAGE In case one does not follow these operating requirements it can lead to premature failures. Major deviations can cause permanent damage to the boiler. z Follow the instructions on the rating label and those in the manual.
CAUTION!
3.2.1 General Operating Requirements
Operating conditions Minimum boiler temperature Boiler Shut-down Mixed temperature Heating Circuit w/ mixing valve 1 Minimum 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 No requirement, except with with low temperature boiler with modulating burner 130/113 F system design Oil firing: 113 F Necessary with: Gas firing: 130 F radiant floor applications Systems with large water content > 115 gal/100,000 Btu/hr)
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. In case the control system has no influence 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. 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.
3.2.2 Requirements for Boiler Room and Surroundings

Operating Conditions Boiler room temperature Relative humidity Dust +40 to +104 F max. 90 % No condensate or dampness in boiler room. 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. Hydrohalogen contamination Combustion air from nearby production facilities such as chemical plants & shops. Airborn particulates. Comments - Detailed Information
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
Comments - Detailed Information The boiler room and specially the air inlet openings for combustion air must be kept free from animals entering by means of grills. 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. Separate the fuel supply and electrical power supply from the boiler during flood conditions. Replace the boiler components such as insulation, electrical and control components afterwards.
Operating Conditions Animals Fire protection
Flood zone conditions
Table. 4 Boiler room and surroundings
3.2.3 Combustion Air Requirements

Operating Conditions Two air inlet openings from outside: one top, one near bottom Boiler capacity (combine total boiler capacity for multiple units) < 170,000 Btu/hr > 170,000 Btu/hr Cross area required At least 43 square inch 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
3.2.4 Fuel Conditions

Operating Conditions Permissible fuels w/ customs burners Comments - Detailed Information 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 maintenance 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 Biogas methane waste gas
All fuels shall be free of contaminants (such as dust, particulates, liquids) that could cause damage to the nozzles or oil lines. 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
10
3.2.5 Requirements for Power Supply
Operating Conditions Main power supply High amp protection Frequency Protection 110 120 V 10 A 60 Hz AC voltage Ground all equipment per local code. Comments - Detailed Information
Observe the acceptable voltage range for the burner.Provide proper ground to boiler for equipment and personal protection.
Table. 7 Power supply
3.2.6 Conditions Pertaining to Piping and Water Quality

Operating Conditions Operating pressure (over pressure) Allowable test pressure Adjustable temperature limit TR Manual reset high limit Water quality 15 58 psi 45 75 psi 122 194 F 212 248 F Adjustable high limit range under normal operating conditions Suitable range for manual reset high limit of 212 to 248 F. Initial fill water and make-up water should be potable water type quality. A pH range of 8.2 to 9.5 is desired. Comments - Detailed Information Maximum pressure is 30 psi based on furnished relief valve.
Table. 8 Piping and water quality
11
Packaging and Components
Packaging and Components
z Check the packaging for consealed damage. z Check the packaging for completeness. Contact your wholesaler in case of missing parts.
Component Boiler block 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 Control panel, alternative aquastat2 Technical documents 1 1 Plastic packaging with boiler1 Qty 1 Packaging 1 Pallet
1 cardboard box (ordered separately) 1 Plastic packaging w/ boiler
Table. 9 Packaging and components

1 2 B-Kit packaging is supplied inside the combustion chamber. Honeywell aquastat is supplied with customized burner if so ordered.
12
Moving the Boiler
Moving the Boiler

SYSTEM DAMAGE due to bumps. z Protect the boiler from bumps and rough treatment. NOTICE z Protect the boiler connections from damage and dirt, when the boiler is not installed immediately. NOTICE Please dispose of the packaging in an environmental fashion.
This chapter describes how to move the boiler.
CAUTION!
5.1
Reducing Boiler Weight for Transport
One can reduce boiler weight by removing the front panel and burner door itself. z Remove the screws holding the front panel in place. z Lift up the front panel slightly and remove.
Fig. 3
Removing the front panel
z Open burner door by removing the two burner door bolts. z Lift burner door from hinges. NOTICE Protect the burner door and the burner tube from damage and dirt, when burner door is removed from the boiler.
Fig. 4
Removal of burner door
13
5 5.2
Moving the Boiler Lifting and Carrying the Boiler

NOTICE The boiler is secured to the pallet with two bolts. z Remove the bolts from pallet before lifting the boiler.
The boiler can be picked up at the hand grips located along the lower jacket panels. NOTICE BODILY DANGER due to carrying of heavy loads.
DANGER!
Fig. 5
Lifting and carrying the boiler
z Lift and carry the boiler with at least two people at the designated hand grip positions.
5.3
Moving the Boiler with Boiler Cart
You can order a Buderus kuli cart from your local wholesaler. BODILY DANGER if the product is not properly secured to the cart. z Use proper moving equipment such as the Buderus kuli cart or other dolly. z Secure the boiler to the cart and move the boiler to the job location. z Lift up the boiler from the rear side by using moving equipment (e. g. Buderus kuli cart or other dolly). z Secure the boiler to the cart. z Move the boiler to the job location. NOTICE By tipping the cart, you can install the boiler feet ( Chapter 6.3, page 17).
Fig. 6 Moving the boiler with a Buderus kuli cart
DANGER!
14
Placing the Boiler
Placing the Boiler
This chapter discusses how to place the boiler in the boiler room. SYSTEM DAMAGE due to freezing temperatures.
CAUTION!
z Place the boiler in a frost free room.
6.1
Clearances
Position the boiler while observing the clearances in ( Fig. 7). Access to the boiler is reduced when reducing these clearances. The boiler foundation must be level and sufficiently strong. The burner door is factory installed right swinging. You can reverse the door swing in the field.
Measure A Distance Recommended minimum B Recommended minimum C Recommended minimum LK 51 1/8" 39 3/8" 27 1/2" 15 3/4" 15 3/4" 3 7/8"
Fig. 7
Clearance dimensions for G115 boilers
see Chapter 3 for Technical Data
Table. 10 Recommended and minimum clearances (Measurement in Inches)
NOTICE Smaller clearances must abide with state and local code. The boiler is approved for 6" side clearances. A minimum distance to combustible materials must be maintained of 18" per NFPA 31 code requirements. NOTICE Observe required distances to other components such as water piping, venting and other components.
Boiler Installation and Service Manual Logano G115 US Issue 03/2004
15
6 6.2
Placing the Boiler Reversing the Burner Door Swing
The burner door hinges are factory installed on the right hand- the burner door swings to the right. You can adjust the hinges so that the burner door swings to the left 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 and remove hinges. z Install the hinges on the left side of the boiler with the hex head bolts. 1 2 2 1
Fig. 8
Reversing burner door (on boiler block)
1 Hex head bolts for hinges 2 Door hinges
z Remove the eyelets from the burner door by removing the hex head bolts. z Locate and secure with hex head bolts these eyelets to 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 are horizontally 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 evenly with about 7.5 ft-lbs torque. NOTICE When reversing the swing of the burner door, make sure to remove the burner cable and oil line from the burner first.
Fig. 9 1 2 3 4 5
3 2
5
Reversing burner door (on burner door)
Hex head bolts for door eyelets Door eylet Burner door Door hinges Flue baffles
16
Placing the Boiler 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). NOTICE When installing a G115 boiler on top of a horizontal Buderus DHW indirect tank, do not use the boiler feet on the boiler, but rather use the feet to level the tank. z Tip the boiler slightly using the boiler cart ( Chapter 5.3, page 14) or put a piece of wood under one side. z Screw in the boiler feet 1/4" to 3/8". z Level the boiler.
Fig. 10 1 2 Installation of boiler feet Boiler rail Boiler feet
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 level the boiler. NOTICE Protect the boiler connections from dust and debris, if the boiler will not be connected right away.
Fig. 11
Leveling the boiler
17
Boiler Installation
Boiler Installation
This chapter describes how the individual components must 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 and use vent material approved by local codes for oil-fired boilers. 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 for Oil-Burning Equipment. NFPA 211 requires chimney to be lined prior to connecting 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 chimney at least 3 feet above location of roof penetration and at least 2 feet above any roof portion within 10 feet.
We reserve the right to make any changes due to techincal modification!
18
Boiler Installation
Minimum clearances to combustibles for vent pipe
Vent Pipe Typ Minimum clearances
Double-wall Single-wall
L L
6" 18"
Table. 11 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 with 2 screws using pre-drilled holes in boiler breeching.
NOTICE Avoid long horizontal runs, excessive number of elbows and tees. z Slope vent pipe at least " per foot up towards chimney. z Connect breeching above the bottom of chimney to avoid blockage. Avoid extending breeching too far into chimney. z Install thimble or slip joint at connection point to allow removal for cleaning. After burner start-up, set breeching draft to -.01 to -.02 inches WC using draft guage. (Over fire pressure can be slightly positive). When necessary, install barometric control in breeching, to relieve excessive draft or to comply with applicable codes. Always position barometric control blade vertically. Set proper opening using draft gauge. 2
Fig. 12 1 2 Securing the flue connection
Flue connector Boiler vent collar
DANGER Do not use barometric control and seal all vent joints if: z excessive resistance to flow of combustion gases can be expected. z actual chimney diameter and/or height is less than recommended. Installation of a CO detector is recommended in this case. Positive over fire pressure operation of boiler will establish draft in venting system.
WARNING!
19
7 7.2
Boiler Installation Installation of Water Connections

SYSTEM DAMAGE due to leaking connections. z Install the piping connections to the boiler without having undue stress on the near boiler piping.
CAUTION!
7.2.1 B-Kit Installation Use the B-kit components located in the boiler fire box to finalize the boiler supply connection. z Use the 1-1/4" BSP x NPT conversion nipple at the supply connection. Identify the section with the longer thread length is threaded BSP (straight thread). The threads on this side also have no taper. (NPT side has taper). z Using high quality Teflon and/or pipe dope, insert the longer threaded end into the boiler supply connection (VK). VK
1"
R1" (Europe)
1"
1"
1" NPT (USA)
Fig. 13
Measuring thread length on 1-1/4" conversion nipple
z Install 90 degree elbow 1" NPT on conversion nipple. Orient in desired direction. z Install supply manifold into 90 degree elbow. You can orient this manifold in three different directions (Fig. 14). z Install pressure/temperature gauge. NOTICE The pressure relief valve can only be installed after the hydrostatic test ( Chapter 7.3, page 21). Use the supplied " street 90 to ensure that the relief valve discharge is installed horizontally. NOTICE We recommend, specially in older, large volume systems, to install a dirt filter in the return connection to the boiler to reduce waterside debris build-up. 1 2
4 5 3
Fig. 14 1 2 3 4 5
B-Kit Installation
90 degree 1" NPT elbow Supply manifold Pressure/temperature gauge Relief valve 90 degree " NPT street elbow
20
Boiler Installation
7.2.2 Installation of Boiler Drain (B-Kit Component) z Install the " boiler drain (B-kit component) into the EL tapping. NOTICE Install a fill connection in the supply piping to the boiler. RK EL
Fig. 15
Boiler drain installation
7.2.3 Installation of System Components Use the adjacent diagram as an aid during the installation of near boiler components. Legend for Fig. 16
1 2 3 4 5 6 7 8 9 10 Relief valve Pressure/temperature gauge Ball valve Air eliminator System pump Back flow preventer Expansion tank Automatic feet valve Flow check Purge station
10 3 2 1 3 7 4
Supply
3 VK
Fill valve
Return
RK
Boiler drain
Additional installation samples are found in Chapter 12, page 43.
Fig. 16
Installation diagram
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 the system in operation to prevent leaks during operation. SYSTEM DAMAGE Be careful not to expose the system to excessive test pressures during the hydrostatic test as it can damage pressure, control and safety components. z Make sure that all pressure, control and safety components are NOT installed during the hydrostatic test. Perform the hydrostatic at 1.5 times the expected operating pressure and in accordance with local code requirements:
CAUTION!
Fig. 17
Pressure and temperature gauge
21
Boiler Installation
Maximum operating pressure Maximum test pressure 45 psi 75 psi
30 psi 58 psi
(based on supplied relief valve) (based on 50 psi relief valve)
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 to escape. z Slowly fill the heating system. Monitor the pressure gauge. z Check all water connections for leaks. z Vent the heating system by opening and bleeding radiators. Open purge valve slowly and allow air to escape. z When water pressure drops during the fill, open up the fill valve more. z When no leaks are found, remove plug, drain water and install relief valve (Fig. 14, page 20).
22
Boiler Installation 7.4 Burner Mounting
Install only burners that have been tested and approved by Buderus Hydronic Systems, Inc. for use on a G115 boiler. ( Chapter 3, page 7). SYSTEM DAMAGE due to incorrect burner.
CAUTION!
z Use only burners approved for use with Buderus G115 boilers.
z Burner mounting studs and washers are included with the G115 B-kit. Install the studs into the burner door. NOTICE The burner KP kit, supplied by Buderus Hydronic Systems, Inc. contains a customized, pre-set oil burner, a Taco 007 or Grundfos circulator and pump flanges, a Honeywell L8148A aquastat and a flexible oil line. z Install the correct burner into the G115 boiler. Check pump pressure, air setting, turbulator setting and flange position. Refer to burner specifications included with KP burner package. z Put the washers on the studs and secure burner to boiler using furnished nuts. z Follow burner manufacturers recommendation regarding installation, fine tuning and maintenance procedures. NOTICE Observe for fine tuning of the burner both the draft conditions of the chimney and burner manufacturers documentation.
Fig. 18
4 3/8" 5 7/8"
Burner stud mounting locations on G115 burner door
7.5
Installation of Oil Line
Install the fuel line in accordance with local code. We recommend 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 when necessary. 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.
23
7 7.6
Boiler Installation Aquastat Installation
A Honeywell aquastat controls the boiler supply temperature when not using a Buderus Logamatic control. z Install the Honeywell aquastat into the brass boiler well. Make sure the capillary is fully inserted in the well. Do not kink capillary tubing. Refer to Chapter 8, page 28 regarding placing the boiler in operation. 1
Fig. 19
Installation of aquastat
1 Capillary
7.7
Electrical Connections
This section only applies to G115 boilers equipped with a Buderus Logamatic control. DANGER due to electrical currents.
WARNING!
z All electrical work must be performed by a qualified electrician. z Before opening the control: Shut off electrical supply and prevent from accidental reactivation. z Observe all installation instructions.
z Remove rear top cover. Remove first rear sheet metal screws. z Remove top cover plate. The electrical wiring will run through this race way.
Fig. 20
Removal of top rear cover and top cover plate
24
Boiler Installation
7.7.1 Control System Installation z Slide plastic front tabs of control panel in the oval shaped openings. z Slide the control panel forward. z Push forward on plastic snap tabs in rear of control to engage them into the top panels square knock-outs. 2 1
3 4
Fig. 21 1 2 3 4 Installation of control
Plastic snap tabs Plastic front tabs Oval knock-outs Square knock-outs
z Remove top cover of control panel. Remove cover screws. z Secure control to top cover using small sheet metal screws.
Fig. 22 1 2
Removal of top cover
Top cover screws Sheet metal screws
25
Boiler Installation
7.7.2 Installation of Temperature Sensor and Burner Cable SYSTEM DAMAGE Be careful not to kink or have the capillary tubes come in contact with sharp surfaces. z Route the capillary tubing carefully and avoid kinking. Route capillaries and sensor wiring to the immersion well. z Route the capillary tubing carefully and avoid kinking. Route capillaries and sensor wiring to the immersion well. z Strap excess tubing and wiring together and place on top of insulation. z Burner wiring can be routed down towards the front of the boiler. If burner is supplied with a wiring harness, route harnesss between jacket panels and boiler insulation. z Install burner wiring per wiring instructions included with Logamatic control or refer to diagrams located on pages 51 to 53. NOTICE Every G115 boiler has a factory installed immersion well for use with a Honeywell aquastat. z When installing a Logamatic control, you must replace the installed brass well with the chrome well supplied with the Logamatic control. z Bring the sensor bundle to the installed chrome well and slide bundle into the well. The plastic holding clip will slide back. z Insert all sensing elements fully into the well and secure tubing with furnished metal holding clip. NOTICE Make sure all sensing elements are all fully inserted into the well and make good contact with well inner surface. Make sure to use the tension clip in the middle of sensing elements. 7.7.3 Electrical Connections Install a power supply point near the boiler in accordance with local and state code. 4 1 2 3
CAUTION!
Fig. 23 1 2 3 4
Routing and connecting of capillary, sensor and electrical wiring
Cable raceway opening in top front cover Capillary tubing and sensor wiring. Well location. Burner cable/wiring
3 2 1 4 1
Fig. 24 1 2 3 4 Installation of sensor bundle Chrome immersion well Plastic holding clip Tension clip Metal holding clip
26
Boiler Installation
FIRE HAZARD Electrical wiring can be damaged by hot boiler parts. z Make sure that all tubing and wiring components are all placed on top of the boiler insulation.
WARNING!
z Route all electrical wiring through the top cover race way and install wiring per electrical schematics in Logamatic manuals. 7.7.4 Strain Relief Installation Secure all electrical wiring near the Logamatic using the furnished plastic cable ties. z Install cable ties with the tab facing up into the rear of the 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).
Fig. 25
Secure wiring with cable ties
7.8
Jacket Panel Installation
z Put control top cover back and secure. z Install rear top panel on boiler. 1
Fig. 26 1 2
Installation of rear top cover
Control top cover Rear top panel
27
Placing the Boiler in Operation
This chapter describes the initial start-up procedure for the G115 boiler irrespective of the employed control system. z Please fill out the start-up protocol during this process ( Chapter 8.10, page 33). Further information regarding boiler room lay-out and clearances, combustion air requirements and venting system as well as boiler operational requirements refer back to Chapter 3.2, page 8. Boiler DAMAGE due to excessive dust and air contamination. z Do not operate the boiler under high dust conditions, such as sheet rock dust and construction dust. Make sure to provide clean combustion air if the boiler needs to operate under such conditions, z Install an airfilter, or other means to ensure clean combustion air. Dust can originate from within during construction, but also from outside when the installation is in close vicinity of chemical plants, shop or dusty outside conditions.
CAUTION!
8.1
Setting the Initial System Pressure
Set the system for regular operation during the initial start-up procedure. SYSTEM DAMAGE due to material stresses as a result of temperature differences. z Use cold water for the initial fill. Limit the fill water temperature to 100 F maximum.
CAUTION!
z Add additional make-up water until the desired pressure is achieved; at least 12 - 15 psi, but no more than 30 psi. (Actual settings are dependent on the pressure rating of the relief valve). z Vent the system during the initial fill.
Fig. 27
Pressure and temperature gauge
8.2
Checking Relief Valve
z Make sure nobody is near the discharge of the relief valve. z Lift up on the relief valve. The relief valve has to open and relief water and pressure. Replace the relief valve immediately if it does not discharge. A defective relief valve can cause damage to the system.
28
Placing the Boiler in Operation 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 burner door bolts. z Pull the baffle plates slightly out of the boiler. z Bring the baffles in a fully horizontal position and push back into the boiler. z Close the burner door and torque door bolts evenly with 90 lbs-inch torque using hex-head bolts. 1
8.4
Get System Ready for Proper Operation
Fig. 28 1
Opening of the burner door
Flue baffles in secondary passages
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 burner manufacturer' recommendations. Follow the instructions furnished with the burner. Turn on the main switch of the Logamatic control to activate the heating system. The burner comes on when the control is switched to manual mode. Follow the instructions in the Service Manual of the control. z Select "manual" operation. 2 1
Fig. 29 1 2 Switching control panel (Logamatic 2000 series controls)
I 0
z Set the desired adjustable limit temperature on the control. z Turn control on (Position I).
Adjustable high limit dial Main control switch
29
8 8.6
Placing the Boiler in Operation 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 readings due to burning off of the sealing rope. We recommend to check the burner after a few weeks of operation.
NOTICE Improper burner adjustments can lead to improper combustion and sooting of the boiler. Burner lock-outs can also occur as a result. z Always check the combustion with the following instruments. z Never check and/or adjust burner operation by eye sight. Necessary instruments: CO2 measuring equipment Draft measuring equipment Oil pressure gauge Stack thermometer Smoke tester z Measure the over fire pressure at the measuring port on the burner door. z Measure the breeching draft in the vent connector two vent pipe diameters away from the vent connections. (Only on chimney vent models: refer to Direct Vent Manual for proper test location). 1
Fig. 30
Pressure test port on burner door
1 Pressure test port
8.7
Adjusting Stack Temperatures
Refer to ( Chapter 3, page 7) for approximate stack temperatures. When you determine that the stack temperature is too low, and condensate formation might take place in the chimney, the stack temperature can be increased by the following steps: Adjust the flue baffles Remove the flue baffles Remove flue blocking plates z Shut-off the boiler ( Chapter 9.1, page 34).
30

EXPOSION DANGER due to leaking gases.
WARNING!
z Shut-off main valve when, in order to open the burner door, the gas line must be disconnected from the burner. Allow the remaining gas to disperse into the air. Do not smoke or generate a spark. Combustion Hazard due to contact with hot boiler surfaces. z Wear thermal protection gloves or use a set of pliers.
CAUTION!
8.7.1 Adjusting Flue Baffles Adjust or remove the flue baffles always in pairs. z Open burner door by removing the two hex head bolts. z Pull the flue baffles slightly out of the flue passages. z Rotate flue baffles inward and slide back into the flue passages. z Close burner door and secure with burner door bolts (ca. 90 Lbs/inch). Tighten bolts evenly. z Measure the stack temperature again.
Fig. 31
Adjusting flue baffles
8.7.2 Removing Flue Baffles To further increase the stack temperature, remove both flue baffles. z Open burner door by removing the two hex head bolts. z Remove flue baffles from the front. z Close burner door and secure with burner door bolts (ca. 90 Lbs/inch). Tighten bolts evenly. z Measure the stack temperature again.
Fig. 32
Removing flue baffles
31
8.7.3 Removing Blocking Plates When the stack temperature after removal of flue baffles is still too low, you can also remove the front section blocking plates to increase the stack temperature. z Open burner door by removing the two hex head bolts. z Remove blocking plates by removing set screw from the front section. z Measure the stack temperature again.
Fig. 33
Removing blocking plates
8.8
Testing of the Manual Reset High Limit (STB) of Logamatic controls
The manual reset high limit will permanently interrupt burner operation once its limit (230 F) is exceeded. To restore operation, it is required to reset this control and lower the water temperature well below its fixed setting. z Refer to Logamatic Service Manual to check operation of manual reset high limit.
8.9
Install Front Jacket Parts
z Hang boiler front panel into slots of boiler side panels. z Secure front panel with the two screws into the side panels.
Fig. 34
Installation of boiler front panel
32
Placing the Boiler in Operation 8.10 Detailed Start-up Procedure

z Check off performed start-up steps, sign and date.
Start-up Procedure 1. Filling of system and check for leaks Page Value Measured 21 __________ psi 2. Set operating pressure vent heating system check operation of relief valve pre-set expansion tank pressure ( see expansion tank manufacturer' instructions) 3. Check combustion air and venting system 4. Check position of flue baffles 5. Turn on control ( Refer to control Service Manual) 6. Turn on burner ( Refer to burner manual) 7. Measure stack temperature (Adjust if needed) 29 29 29 30 __________ F 8. Check manual reset high limit (STB) 9. Adjust control settings based on requirements ( Refer to control Service Manual)) 10. Inform end user and hand over instructions Confirm start-up procedure 32 28 __________ psi Comments
Company stamp/signature/date
NOTICE z Always inform your customer regarding proper fuel source and record in Operating Manual.
33
9
9.1

Normal Boiler Shut-down
z With Buderus Logamatic controls: Turn the main switch to "0" position. This shuts off power to components wired directly to the control panel.
1
1 ON/OFF switch
I 0
Abb. 35 Shutting down heating system (Logamatic 2000)
z With Honeywell aquastat control: Shut off main heating system switch. (Position "OFF") This shuts off power to all components wired through this switch. z Further shut-down procedure: refer to aquastat documentation.
Fig. 36
Heating system shut-down (with aquastat)
z Shut off fuel supply by closing main valve. SYSTEM DAMAGE due to freezing.
CAUTION!
When the system is shut off, the system could potentially freeze up. z Keep the system operational as long as possible. z Protect the system against freeze-up by draining the entire system at its lowest point.
9.2
Emergency Shut-down
Please explain suitable system operation during emergency conditions, such as fire: z Shut off fuel supply by closing main valve. z Shut down the heating system electrically either using the main emergency switch or the suitable electrical breaker.
We reserve the right to make any changes due to techincal modifications!
34
Boiler Maintenance
10
10 Boiler Maintenance
10.1 Why do Maintenance?
Regular maintenance is required for the following reasons: To maintain high efficiency operation and minimize fuel usage. To sustain reliable operation. To maintain clean combustion and reduce pollutant emissions. Please offer your customer an annual service and maintenance plan. You can review the service and maintenance protocol regarding precise description of suitable services ( Chapter 10.6, page 39). NOTICE Spare parts can be ordered by contacting your Buderus wholesaler.
10.2 Prepare Boiler for Cleaning

z Shut down the heating system ( Chapter 9.1, page 34). DANGER due to electricity.
WARNING!
z Prior to opening control panel: Shut down electricity supply and padlock shut to protect against accidental operation.
z Remove boiler front panel and possibly burner cover ( Chapter 5.1, page 13). z Disconnect electrical supply to burner. DANGER due to explosion of flammable fumes.
WARNING!
z Perform service work on gas components only, when one has the necessary certification.
35
10
Boiler Maintenance
10.3 Boiler Cleaning

The boiler can be cleaned using boiler brushes and/or with a wet cleaning. Boiler brushes are available from your Buderus wholesaler. COMBUSTION DANGER Due to contact with hot boiler parts.
CAUTION!
z Wear thermal protection gloves or use a set of pliers.
z Open burner door by removing the two hex head bolts. 10.3.1 Cleaning the Boiler with Brushes z Record the position of the flue baffles so they can be placed back in their original position. z Remove blue baffles from passages. z Clean flue fire baffles using a hard bristled brush.
Fig. 37
Opening of burner door
1 Flue baffles in secondary flue passages
z Brush out flue passages by rotating the round brush.
Fig. 38
Brushing our of flue passages
z Clean the combustion chamber with a flat brush. Remove the loosened debris from combustion chamber, flue passages and breaching connection areas. z Insert the flue baffles into the boiler in their original position. z Check burner door sealing rope. Replace damaged or hardened sealing rope. NOTICE Burner door sealing rope is available through your local Buderus wholesaler. z Close burner door by tightening the burner door bolts (Torque to 90 Lbs-in ). Torque burner door evenly for proper door closure.
We reserve the right to make any changes due to technical modifications! Buderus Heiztechnik GmbH http://www.heiztechnik.buderus.de
Fig. 39
Brushing out the combustion chamber
36
Boiler Installation and Maintenance Manual Logano G115 US Issue03/2004
Boiler Maintenance
10.3.2 Wet Cleaning Use for the wet cleaning a suitable cleaning agent designed to dissolve the internal build-up or clean the soot. Following the wet cleaning, proceed with the brushing steps outlined in ( Chapter 10.3.1, page 36). NOTICE Observe and follow recommendations of the cleaning agent' manufacturer. Under certain conditions you may need to deviate from the guidelines below. 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
10.4 Testing System Pressure

The system pressure should be 15 to 30 psi for a closed system. z Check system pressure. z When the pressure gauge shows less than 12 - 15 psi, the pressure is too low. SYSTEM DAMAGE due to frequent make-up water.
CAREFUL!
When you add frequently make-up water to the system, this can lead to corrosion and lime build-up in the system. z Make sure that the heating system is equipped with automatic air elimination. z Verify that the system has no leaks and check the expansion tank for proper operation.
Fig. 40 Pressure/temperature gauge to display system pressure and supply temperature
37
10
Boiler Maintenance
SYSTEM DAMAGE due to material stresses as a result of temperature differences. z Add only additional make-up water when the system is cold (Temperature gauge reading should not exceed 100 F).
CAREFUL!
z Add make-up water through the automatic feed valve. z Vent system. z Check system working pressure.
10.5 Testing Relief Valve

Check the functioning of the relief valve every 1 to 3 years as required per local code. z Make sure nobody is near the discharge of the relief valve. z Lift up on the relief valve. The relief valve must open and discharge water. If the valve does not discharge, replace the valve and recheck. If the defective valve is not replaced, it can lead to damage to certain system components due to excessive high pressures.
38
Boiler Maintenance 10.6 Inspection and Maintenance Procedure

z Sign off and date performed service work.
Service work 1. Check general status of system
10
This service and maintenance protocol can also be copied for further use.
Page Date: ______ Date: ______ Date: ______
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 5. Check burner operation ( See burner manual) 35
6. Check combustion air inlets and vent system
7. Check system pressure, relief valve and expansion tank 8. Check DHW tank anode status ( See DHW tank manual) 9. Check control settings ( See manual)
37
10. Final check, record combustion test results
Confirm service work
Sign/date
Sign/date
Sign/date
39
10
Boiler Maintenance
Date: ______ 1.
Date: ______
Date: ______
Date: ______
Date: ______
Date: ______
Date: ______
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 the annual service/maintenance work that require attention, please perform the necessary remedial steps.
40
Boiler Maintenance
10
Maintenance Procedure
1. Take the boiler out off operation 2. Remove blue baffles from passages and clean flue fire baffles 3. Clean flue passages and the combustion chamber, Insert the flue baffles into the boiler in their original position 4. Check burner door sealing rope. Replace damaged or hardened sealing rope. Close burner door by tightening the burner door bolts. 5. Take the boiler in operation 6. Final check at the system after maintenance and service inspection 7. Check boiler in operation Confirm service and maintenance work
page Date: ______ 35 35 35
Date: ______
Date: ______
36
29
Sign/date
Sign/date
Sign/date
Date: ______ 1.
Date: ______
Date: ______
Date: ______
Date: ______
Date: ______
Date: ______
2.
3.
4.
5.
6.
7.
Sign/date
Sign/date
Sign/date
Sign/date
Sign/date
Sign/date
Sign/date
41
11
Restoring Sytem Lock-outs
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 ( see burner manual) during its lock-out. Press the burner reset button once to restart the burner. Call your service company immediately if the burner locks out again. Do NOT continue to reset the burner. Error conditions on the control or in the system are typically 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 equipped. Press the burner reset buttom once. SYSTEM DAMAGE durch Frost.
WARNING
Fig. 41
Resetting the burner
1 Burner
When the entire system is shut off, it can cause a freeze-up condition. z Have any lock-out condition corrected immediately and restart the heating system. z If this is not possible, protect the system for freeze-up by draining the heating system and domestic hot water system at their respective lowest points.
42
Installation and Maintenance Manual Logano G115 US Issue 03/2004
Piping Diagrams
12
12 Piping Diagrams
Explanation of the abbreviations
KR PH PW Flow check Heating pump DHW charging pump SH WH SV THV 3-way motorized valve Boiler bypass Relief valve / Air elimination Zone valve
MAG Expansion tank
Baseboard Baseboard Baseboard

THV SV PH
G115
MAG
Fig. 42 Zoning with zone valve
43
12
Piping Diagrams
Baseboard Baseboard
KR PH SV
Baseboard
G115
MAG
Fig. 43
Zoning with pumps
Baseboard Baseboard Baseboard

THV SV PH
G115
MAG
" Boiler Bypas
WH
Fig. 44
Zoning with zone valves and built-in bypass for larger water volume systems
44
Piping Diagrams
12
180 0
Baseboard
160 0
KR PH KR PS
120 0
100 0
PH
R2107
SV
SH
100 0
180 0
G115
MAG
Fig. 45 Multiple zones with DHW, high temperature and low temperature circuits with a motorized 3-way valve
45
13
Spare Parts
13 Spare Parts
The following parts are available through Buderus Hydronic Systems. Model specific part numbers are listed under the various models. In other cases the table shows the number of components for each model. Boiler block and burner door(Fig. 46)
Item Description G115/21 3 section
10 Boiler block G115 05952285
Legend for tables 12 and 13: x = no spare part (x) = component of a set, only furnished with the set 0 = no picture available
Part number G115/28 4 section

05952290
G115/34 5 section
05952295
Front section components: 21 22 23 24 Plug G1 1/4" right Gasket for plug D41,7x55x1,5mm AFM 34,white Blocking plate with screw M8x16 Screw DIN7991 M8x16 Ms 86055310 86159710 63015342 (x)
rear section components: 51 52 53 54 55 60 70 70 70 80 81 0 90 91 Plug DIN2950 291 1" Threaded stud M10x65 5.6 Distance sleeve R3/8"x39 Hex. head nut ISO4032-M10-8-A3K Washer DIN125-A10,5-A3K Immersion well Pmw-3See (4 1/2")"US" Tie bar - Set M8x310mm Tie bar - Set M8x440mm Tie bar - Set M8x555mm Flue collector Sealing rope 8x1050 GP Glue for securing rope (a 310ml) Return diffuser 1 1/4-NPT1 compl. G115"US" Gasket 55x41,7x1,5mm 63028062 00472887 05127574 05127578 05354074 63020961 63014361 63028062 05752540 63028061 05127580 05317680 05555070 (x) (x) (x)
Flue collector components
Spare parts which are not furnished with the spare boiler block: 120 130 130 130 131 132 133 140 141 142 150 160 180 Flue baffle Boiler rail 420mm long Boiler rail 540mm long Boiler rail 660mm long Washer DIN126-9 Hex. head screw ISO4017-M8x25-8.8 Hex. head nut DIN6923-M8-8.8-A3K Door hinge G105/G115 Scheibe DIN125-A10,5-A3K Sechskantschraube ISO4017-M10x25-8.8 Sechskantschraube ISO4014-M10x65-8.8 Washer DIN125-A10,5-A3K Boiler feet M10x51mm complete 05347085 05198102 05347087 05198104 (x) (x) (x) 05327033 (x) (x) (x) (x) 05236440 05347089 67900117
Tab. 12 Boiler block and burner door
46
Spare Parts
190 200 or: 210 Flue silencer D130 with adapter 100mm long, with condensate drain, lower sound absorption Flue collar DN130 complete Flue collar DN130 complete (step cuff) Sealing rope10x2000 GP Burner door complete Door hinge Washer DIN125 A10,5 A3K Hex. head screw ISO4017 M10x25 8.8 Observation port cover complete G115/G125/G135 Gesket 30x30x3 Sight glass Tempax 30x30x3,3mm Sight glass cover plate Hex. head screw ISO4017 M6x12 8.8 A3K Pressure measuring port M6 SW10 V2 Burner door insulation G115 W607 Insulating plate for burner door 24mm Insulating ring for burner door 10mm Washer DIN9021 A6,4 A3K Sheet metal screw DIN7981 C ST6,3x25 A3T Sealing rope14x1650 GP Glue for securing sealing rope to burner door (a 310ml) Mounting material for boiler block G115 "US" 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 (x) 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 B-KIT G115"US" Components: 1 Supply manifold G115"US" 1 90 degree 1 1/4 NPT elbow 1 90 degree 3/4 NPT elbow 0 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 63029762 63031288 05074022 Gasket for flue collar DN130 complete Flue silencer DN130 complete, without condensate drain; higher sound absorption 05354010 05074020
13
Flue silencer components: 190 220 230 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 0 05354010 05354030 63020963 63023858 05327020 (x) (x) 63023634 63014382 05447620 x (x) 63026521 63002401 63004169 63004170 (x) (x) 63020965 63014361
Burner door components:
Observation port cover components:
Burner door insulation components:
Tab. 12 Boiler block and burner door
47
13
Spare Parts
210
220 230 190 200
70
80 60 51 22 21 10 70 52 120 81 54
55
160 150 23 24 70 141 140 142 22 21 133 180 130 131 132 180
90 91 53 52 133
350 390
380
400 360
290 310 320 330
300 270 280
370
350
250 260
1023033-00-Kesselblock G115 US
340
Fig. 46
Boiler block and burner door
48
Spare Parts
Boiler Jacket Components (Fig. 47)
Item Description G115/21 3 section Part number G115/28 4 section
13
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 18 20 40 50 60 70 80 80 80 85 90 95 100 100 100 110 120 125 130 140 150 160 170 Front panel G115/S105 Name plate Logano G115 Front insulation G115 Hex. head screw ISO4017-M8x12-8.8 Top groos bracket G115/G115U Hex. head nut DIN555 M8 5 Washer DIN126 9 Side panel 445mm long Side panel 565mm long Side panel 685mm long Sheet metal screw C ST3,9x13 A3T Screw 3,9x9,5 A3T Clip Boiler block insulation G115 Boiler block insulation G115 Boiler block insulation G115 Holding clips for boiler block insulation Top front cover G115/G115U/S105/S105U Cover plate 300x160 Top rear cover complete G115 "US" Rear panel complete G115 Cable rail way Washer DIN432 10,5 St A3E Hex. head nut DIN555 M10 5 Mounting material for boiler jacket G115, GC115, G125, G134 Components: 17 Screw St3,9x9,5-A3T 3 Sheet metal screw C-St3,9x13-A3T 1 Screw DIN7985-M6x16-4.8-A3T (x) 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 05180842 05198112 05670040 63029945 63029203 67902824 63025265 (x) 63029209 (x) (x) 63029946 (x) (x) (x) 05670045 00476378 63029222 63021497 05198114 05198084 07060754 (x) (x) 05198176 05670046 63029947
Tab. 13 Boiler jacket components
49
13
Spare Parts
90 125
90
90 120 130 90 140 150 90
110 100
170 160
170 160 85
80 70 40 40 70 60 20 50
10
85 18 80 95 40 70
1023034-00-Kesselverkleidung G115 US
Fig. 47
Boiler jacket components
50
SP30D Providing Domestic Priority w/ Buderus Boilers and Tanks

Domestic Tank Pump Heating Pump
L1
Fig. 48 Wiring diagram 1

FOR MULTIPLE ZONES:
JUMPER ON 2 HEATING PUMP H 2 DELETE C2 C1 L1
115V AC 240V AC
L2
SP30D and Burner Wiring
L1
L2
Aquastat L8148A Oil or L8148E Gas L2 L1 NO 1 NC NO 2 NC ADD RELAY-BOARD AND WIRE IT WITH 2
AND
L2
C1 1 2 R COOL Heat W 3 4 Set to 130

0
C2 CONNECTED TO POWER SUPPLY L2
B1
B2
14 SP30D and Burner Wiring
L1
L2 Pump 1
L1
L2 Pump 2
L1
L2 Pump 3
Tank Sensor
Pump-Relay-Board Setpoint 50 to 200 0 F

L1 L2

5 6 L1
115 VAC
Burner Oil or Gas L2

240 VAC

L1 NO 1 NC NO 2 NC 120V AC 24V #18 Wire 1 2 3 Tank Sensor 4 5 6 COOL Heat Set to 130
0
On Gas Boilers G124/G234, B 1 and B2 will be connected to the Boiler Control, 24V
Setpoint 50 to 200 0 F
This wiring diagram is generic in scope and does not purport to address all design, installation, or safety considerations. This diagram is for reference use by code officials, designers and licensed installers. It is expected that installers have an adequate knowledge of accepted industry practices for the equipment, procedures and applications involved.
BUDERUS HYDRONIC SYSTEMS
FILE NAME : DRAWN BY:
SP30D Holger Hinse APPROVED BY: Dr. Lou Vorsteveld
Type: FOR:
SP30D AQUASTAT GENERIC WIRING SCHEMATIC GAS / OIL BOILER W/ L8148A OR L8148E HW AQUASTAT
DATE :
3/12/2004
14
51
14
Fig. 49
Wiring diagram 2
52
14
Fig. 50 Wiring diagram 3
53
14
R7184B
Fig. 51
Wiring diagram 4
54
Table of Key Words
15
15 Table of Key Words

A
Aquastat . . . . . . . . . . . . . . . . . . . . . . 24
R
Restoring lock-out conditions . . . . . . . . . . . . 41 Reversing burner door swing . . . . . . . . . . . . 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . 23 . 23 . 13 . 13 . 32 . 41 . 17 7, 8 5, 9 . . . . . 15 36 10 .7 25
B
Burner assembly . . . . . . . . . Burner cable installation . . . . . Burner cover removal. . . . . . . Burner door reversal . . . . . . . Burner door jacket panel removal Burner door jacket installation . . Burner lock-out resolution . . . . Boiler feet installation . . . . . . . Boiler model . . . . . . . . . . . Boiler room . . . . . . . . . . . .
S
Sealing rope replacement. . . Stack temperature adjustment Strain relief adjustments . . . Supply manifold . . . . . . . . System operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . 30 . . . 27 . . . 7 . 11, 22
T
Technical data . . . . . . . . . . . . . . . . . . . 7 Temperature sensor installation . . . . . . . . 26 Tools . . . . . . . . . . . . . . . . . . . . . . . . 5 Transport w/ kuli cart/dolly . . . . . . . . . . . . . 14
C
Clearance. . . . . . . . . . . Cleaning of flue passages . . Combustion air requirements . Connections . . . . . . . . . Control panel installation . . . . . . . . . . . . .
V
Vent connection installation . . . . . . . . . . . . . 18
W
Water quality considerations . . . . . . . . . . . . 11 Wet cleaning . . . . . . . . . . . . . . . . . . . . 37
D
Dirt trap system . . . . . . . . . . . . . . . . . . . 21 Disposal . . . . . . . . . . . . . . . . . . . . . . . 5 Drain valve installation . . . . . . . . . . . . . . . 21
E
Electrical connections . Electricity restoration . . Emergency switch . . . Environmental concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 24 34 .9 31 29 .4 10 23
F
Flue baffle removal . . . . . . . Flue baffle position confirmation Fuel fumes . . . . . . . . . . . Fuel requirements . . . . . . . Fuel supply restoration . . . . .
H
Heating system emergency switch . . . . . . . . . 34 Hydrostatic pressure test . . . . . . . . . . . . . . 22
I
Input ratings . . . . . . . . . . . . . . . . . . . . . 7
J
Jacket component installation . . . . . . . . . . . 32
M
Main electrical shut-off switch Main fuel shut-off valve . . . . Maintenance requirements . . Make-up water . . . . . . . . Manual reset high limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 29 35 37 32
O
Operating pressure (allowable) . . . . . . . . . . . . 7 Operating requirements . . . . . . . . . . . . . . . 8 Original parts . . . . . . . . . . . . . . . . . . . . 12
P
Placing the boiler in operation . . . Placing the boiler out of operation . Protocol, service and maintenance . Protocol, start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 34 39 33
55
Heating Contractor:
PRODUCTS MANUFACTURED BY
BBT Thermotechnik GmbH 35573 Wetzlar www.buderus.de
BBT North America Corporation 50 Wentworth Avenue Londonderry, NH 03053 Tel: 603-552-1100 Fax: 603-584-1681 www.buderus.net
BBT North America Corporation reserves the right to make changes without notice due to continuing engineering and technological advances.

Oil and Gas Boiler Installation Manual for Logano G115 US Cast Iron Boiler

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Oil and Gas Boiler Installation Manual for Logano G115 US Cast Iron Boiler

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6303 0586 03/2004 US/CA

Boiler Installation and Maintenance Manual

Please read these instructions carefully.

. . . . 1.4.1 . 1.4.2 . 1.4.3 . Tools, Materials and Accessories . Disposal . . . . . . . . . . . . . . .

. . . . In Case of Smoke . . . . . Installation Guidelines . . . Boiler Room Guidelines . .

Technical Data less Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Packaging and Components . Moving the Boiler .

Placing the Boiler .

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

7.3 7.4 7.5 7.6 7.7

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

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

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

Placing the Boiler in Operation .

. . . . . . . Adjusting Flue Baffles . . . . . . . . . Removing Flue Baffles . . . . . . . . Removing Blocking Plates . . . . . . .

Taking the Boiler out of Operation

Normal Boiler Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Emergency Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Restoring Sytem Lock-outs Piping Diagrams Spare Parts .

SP30D and Burner Wiring Table of Key Words .

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

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

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

Cross notice Designated by means of a narrow , referral to a notice in another document .

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

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

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

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

Tools, Materials and Accessories

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

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

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

z Use only burners recommended by Buderus as is discussed in our technical documents.

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

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

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

Select your suitable burner based on this information.

L LK 1 3/4" 25 1/4" VK Rp11/4" 8 7/8"

20" 3 1/4" RK 1" NPT 8 7/8" EL Rp 3/4" 2 7/8"

Dimensions and connections (measurements in inches)

Table. 1 Technical data less burner

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

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

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

Table. 2 Dimensions, Weight and other Data

Weight incl. packaging material approx. 6 8 % more.

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

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

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

Table. 3 General Operating Requirements

3.2.2 Requirements for Boiler Room and Surroundings

Combustion air must be free of hydro halogen components.

Eliminate any chemical compound such as paints, lacquers, thinners,

bath room exhaust fans dryer airconditioning equipment

Table. 4 Boiler room and surroundings

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

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

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

Operating Conditions Animals Fire protection

Flood zone conditions

Table. 4 Boiler room and surroundings

3.2.3 Combustion Air Requirements

3.2.4 Fuel Conditions

Please select the proper burner based on desired fuel.