Installation and Maintenance Instructions Gas-fired boiler WARNING! Before commissioning the boiler, heed the safety instructions for mounting and maintenance. DANGER! If installation, adjustment, modification, operation or maintenance of the heating system is carried out by an unqualified person, this may result in danger to life and limb or property damage. The installation and servicing instructions must be followed precisely.
Contents 1 Explanation of symbols and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.1 Explanation of symbols . . . . . . . . . . . . . . . . . 3 1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . 3 2 Product description . . . . . . . . . . . . . . . . . . . . . . 5 2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 Standards, regulations and directives . . . . 5 2.2.1 National regulations . . . . . . . . . . . . . . . . . . . 5 2.2.
Explanation of symbols and safety information 1 Explanation of symbols and safety information 1.1 Explanation of symbols Warnings Warnings in the text are indicated by a warning triangle with a gray background in a framed box. In case of danger due to current, the exclamation point on the warning triangle is replaced with a lightning symbol. Signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing damage are not taken.
1 Explanation of symbols and safety information Danger from escaping flue gases B Make sure that the vent pipes and gaskets are not damaged. B Use silicone as sealing compound. B The boiler must not be fitted with a barometric damper or a thermally controlled flue flap downstream of the flue socket. B Connect only one boiler to each venting system or chimney flue. B Connection of another boiler may cause serious injury or death. B The venting system piping must not feed into another air extraction duct.
Product description 2 2 Product description This installation and maintenance manual contains important information for the safe and correct installation, initial commissioning, and maintenance of this boiler. The special gas-fired boiler Logano G234X is generally referred to below as a boiler. Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1). Carbon monoxide detectors must be installed as specified by the local regulations.
2 2.4 Product description Tools, materials and equipment For the installation and maintenance of the boiler, you will need the standard tools used for central heating and gas and water systems plus set of a metric wrenches and Allen wrenches The following may also prove useful: • Pipes for transport • Wood battens • Cleaning brushes and/or chemical cleaning agent for wet cleaning 2.5 Disposal B Dispose of boiler packaging in an environmentallyresponsible manner.
2 Product description 2.8 Dimensions and specifications 2.8.1 Logano G234X dimensions Fig. 2 Connections and dimensions for Logano G234X, dimensions in mm (dimensions in inches) VK/VS GAS RK RSL/EL Boiler supply/Storage tank supply Gas connection + main isolating valve Boiler return Return safety line/draining Boiler capacity Unit 38 45 55 64 MBtu/hr 160 187 228 266 kW 46.9 54.8 66.8 78.0 MBtu/hr 130 154 188 219 kW 38 45 55 64 Inches 25.6 25.6 29.1 32.
2 Product description 2.8.2 Specifications Fig. 3 Pressure drops (1 psi = 69 mbar, 1 GPM = 0.23 m³/h) x y Flow Rate in GPM ( m³/h) Pressure drops in psi 1 2 3 160 500/187 700 BTU/hr (boiler rating 38/45) 228 400 BTU/hr (boiler rating 64) 266 400 BTU/hr (boiler rating 55) 2.8.3 Main gas orifice identification and rated orifice pressure Boiler capacity Number of injectors Main gas orifice identification Rated orifice pressure for natural gas 0 - 2000 ft (0 - 610 m) [In. W.C.
Moving the boiler 3 3 Moving the boiler This section details how to move the boiler safely. NOTICE: Risk of system damage from impact shocks! Fragile components could be damaged. B Observe the transport instructions on the packaging. B Remove the straps and the cardboard packaging. B Loosen the retaining screws. B Lift the boiler at the sides and slide to the edge of the pallet. B Place a pipe under the boiler and roll it on additional pipes to the installation location.
4 4 Placing the boiler Placing the boiler This section explains how to erect and position the boiler correctly in the boiler room. 4.1 Boiler room requirements NOTICE: Risk of system damage due to freezing! B Install the heating system in a frost-free room. 4.2 Recommended wall clearances Wherever possible, position the boiler with the recommended wall clearances. Reducing the minimum clearances makes the boiler more difficult to access.
Placing the boiler 4.3 4 Leveling the boiler The boiler must be leveled horizontally and vertically to prevent air pockets forming inside. B Level the boiler vertically and horizontally, inserting metal shims underneath as required. NOTICE: Risk of system damage due to contamination! B Protect boiler connections from damage and dirt if the boiler is not to be installed immediately. Fig. 7 Leveling the boiler (example) Logano G234X - Technical specifications are subject to change without prior notice.
5 5 Installing the boiler Installing the boiler This section details how to install your boiler correctly. This involves the following steps: • Flue gas connection • Heating circuit connection • Making the electrical connections • Connecting the fuel supply 5.1 5.2 Connecting the heating system This section explains how the boiler is connected to the heating system. 5.2.
Installing the boiler NOTICE: Risk of system damage due to high temperature variations in the heating system! B If the boiler is operated in conjunction with an air conditioning system, it is essential to ensure that the pipes for the refrigerant fluid are connected in parallel with the boiler system using suitable valves to prevent the refrigerant from entering the boiler.
5 5.3 Installing the boiler Electrical connection 5.3.2 The electrical connections to the boiler must conform to the locally applicable regulations and the relevant requirements of the National Electrical Code, ANSI/ NFPA-70. In Canada the regulations of CSA C22.1 Canadian Electrical Code, Part 1, must be observed. Mount the Logamatic 2000 control unit (accessory) The boiler is fully functional with the factory-installed aquastat.
Installing the boiler B Position the tabs of the control unit in the slots. B Slide control toward the boiler front panel. B Push to snap plastic tabs of the control into the knockouts. 5 B Unscrew left and right screws in the side panels, lift front panel up, pull outward and remove to the front. Fig. 12 Put the control unit on the boiler B B B B Unscrew the cover screws of the cover unit. Remove the cover. Secure the controls with self-tapping screws.
5 Installing the boiler B Mount the Logamatic sensor well [2] on the boiler instead of the temperature/pressure gauge and seal. B Place the Logamatic sensor packet [1] under the front boiler cover towards the front for the sensor well. Fig. 16 Mounting the Logamatic sensor well on the boiler 1 2 3 Logamatic sensor packet Logamatic sensor well Logamatic 2000 control unit B Place entire Logamatic sensor packet fully into the immersion well [1] to the stop.
Installing the boiler Installing outer casing panels B Swivel display unit to the desired position. We recommend positioning the display unit straight on combinations with an L-tank. Fig. 19 Swivel display unit B Position the cover and secure on the control unit. 5 5.3.3 Installing the rear boiler cover B Slide tabs of rear boiler cover under the front boiler cover and press down at back. B Screw rear boiler cover to rear panel of boiler. Fig.
5 5.4 Installing the boiler Connecting the gas supply Heed the following points for connecting the fuel supply: B Work on gas components may only be carried out by qualified and authorized personnel. B Observe the local regulations or else the requirements the National Fuel Gas Code, ANSI Z 223.1 when connecting the gas supply. In Canada, the requirements of CAN/CSA-B.149.1 and 2, Installation Guidelines, must be observed.
Installing the boiler 5 Gas pipe delivery rate in cubic feet of gas per hour1) (1 ft3/h = 28.3 l/h) Length of the pipe in feet (1 foot = 0.3 m) 1" 1¼ " 1½ " 2" 2½ " 10 520 1060 1600 3050 4800 20 350 730 1100 2100 3300 30 285 590 890 1650 2700 40 245 500 760 1450 2300 50 215 440 670 1270 2000 75 175 360 545 1020 1650 100 160 305 480 870 1400 150 120 250 380 710 1130 Tab.
5 Installing the boiler Leak test DANGER: Risk of explosion! Leakage from the gas pipes and gas connections may cause an explosion. B Carry out a proper leakage test using soap solution. NOTICE: Risk of system damage due to short-circuits! B Cover the areas at risk before carrying out the leakage test. B Do not spray leak detector onto cable conduits, plugs or electrical connecting leads or allow it to drip onto them. Use only sealant that is resistant to corrosion by LPG for the pipe connections.
Installing the boiler 5.5 Filling the heating system and checking for water leaks The boiler is tested for leaks at the factory. Before putting the heating system into operation, it must be checked to ensure that no leaks will occur during operation. NOTICE: Risk of damage to system due to temperature stress! If you fill the heating system when it is hot, the resulting temperature stress can cause stress cracks. The boiler will then leak. B Only fill the heating system when it is in a cold state.
5 Installing the boiler B Install safety valve. 5.6 Install front wall of boiler B Hang front wall of boiler [2] from above, fold down and screw in securing screws [3] into the front cover below. Fig. 24 Supply connection 1 2 3 4 5 Boiler Supply connection Safety valve Supply manifold pipe (factory-installed) 90°-elbow (¾ " NPT) Fig.
Installing the boiler 5.7 Connecting the flue 5.7.1 Check openings for combustion air supply and venting To ensure an adequate combustion air supply and venting of the heating system, suitable measures must be taken in accordance with the National Fuel Gas Code, NFPA 54 (ANSI Z223.1), Section 5.3, Air for Combustion and Ventilation, and the local building codes. In Canada the regulations in accordance with CAN/CSA B 149.1 and 2 Installation Codes apply.
5 Installing the boiler 5.7.2 Requirements for connection to chimneys or venting systems The flue connection must comply with the regulations of the National Fuel Gas Code NFPA 54, Part 7, Venting of Equipment, and the local building codes. In Canada the regulations of CAN/CSA B 149.1 as well as local building codes apply. Flue connections of heating systems with natural venting must not be connected with any component of a mechanically operated venting system that operates with overpressure.
Installing the boiler G Any incorrect status of the common venting system must be corrected to ensure that the heating system complies with the regulations of the National Fuel Gas Code, ANSI Z 223.1. If the size of any component of the common venting system is changed, the complete venting system must be resized to comply with the relevant tables in Part 11 of the National Fuel Gas Code, ANSI Z 223.1. In Canada the regulations in accordance with CAN/CSA B 149.1 and 2 Installation Codes apply. 5.7.
5 5.7.6 Installing the boiler Installing electrical connection of vent damper DANGER: Risk of fatal injury from electric shock! B Only qualified electricians are permitted to carry out electrical work. B Before opening the appliance, disconnect it from the power supply by means of the emergency shutoff switch or the relevant circuit breaker in the main fuse board. B Take measures to ensure that the heating system cannot be switched on again unintentionally. B Please observe all installation instructions.
Commissioning the heating system 6 Commissioning the heating system B Complete the commissioning log during the commissioning procedure (Æ page 35). 6.1 6 Test safety valve The safety valve must open and release pressure. If the safety valve fails to release excess pressure, it must be replaced, because otherwise system components may be damaged by excessive operating pressure. 6.
6 Commissioning the heating system Carrying out leak test 5. Open the gas shut-off valve. NOTICE: Risk of system damage due to short-circuits! B Cover any hazardous locations prior to locating the leaks. B Do not spray leak detector onto conduits, plugs or electrical connection cables or allow it to drip onto them. 10. Open gas shut-off and measure the supply pressure of the boiler. The connection pressure for natural gas must be between 7 and 10.5 inches W.C. (17.4 to 26.
Commissioning the heating system 6.3 Start-up instructions A This unit is fitted with an ignition module that automatically starts the pilot burner. Do not attempt to ignite it manually. B Check for an odor of gas around the heating system. This test must also be conducted at floor level, because some types of gas are heavier than air and may accumulate at floor level. C Switch on the ON/OFF switch on the gas valve by hand only. Never use a tool as assistance.
6 6.4 Commissioning the heating system Making boiler ready for operation STOP! First read the safety instructions on page 29 of these instructions. 1. If the boiler is not commissioned directly after the installation: carry out another leak test (Æ page 28). Wait five (5) minutes until all gas residues have dissipated. Finally check whether there is any smell of gas, including at floor level. If you smell gas, STOP! Seal leaks and repeat the leak test. If you do not smell gas, go to the next step. 2.
6 Commissioning the heating system 6.5 Then carry out start-up procedures. The following commissioning work must be performed regardless of the control unit type. 7. Look at the pilot burner through the inspection hole [1] in the burner cover. Fig. 32 Inspection hold in the burner cover Fig. 33 Gas valve 1 1 2 3 4 5 Inspection hole 8. Turn gas valve ON/OFF switch [1] counterclockwise to ON position. 9. The burner control unit must generate ignition sparks towards the pilot burner.
6 Commissioning the heating system 13. Check nozzle pressure. To set the nozzle pressure according to Tab. 11 while the boiler is operating, the safety screw for setting the nozzle pressure [3] on the gas valve must be removed. Turn the adjustment screw clockwise to increase the nozzle pressure. Turn the adjustment screw counterclockwise to decrease the pressure. 14. Record the value set in the commissioning log (Æ page 35).
Commissioning the heating system Checking flame sensor 21. Test the safety switch by closing the gas shut-off. The main burner flame (Æ Fig. 36) and the ignition flame (Æ Fig. 35) are extinguished. After six (6) seconds at the most the main gas solenoid valve on the gas valve must close with an audible noise. 22. After 90 seconds the ignition module must switch to lock status and stop generating sparks. 23. Shut off the heating system from the power supply. Open the gas shut-off valve.
6 6.6 Commissioning the heating system Shutting off gas supply to boiler B Set thermostat to the lowest value. B Disconnect the heating system from the power supply before carrying out maintenance work. B Turn the gas valve ON/OFF button [1] clockwise to the OFF position. Do not use force. 6.7 Inform owner/operator, hand over technical documentation Familiarize the owner/operator with the entire heating system and the operating instructions for the boiler.
Commissioning the heating system 6.8 6 Commissioning log Please check off the commissioning work as it is completed and record the measured values in the table. Commissioning operations Comments or measured value Page 1. Type of gas supply Natural Gas Propane Gas 2. Check combustion air, inlet and outlet openings and flue page 23 3. Check the appliance orifices (correct nozzles Æ Tab. 12), if necessary adjust gas type. page 35 4.
7 7 Shut down the heating system Shut down the heating system NOTICE: Risk of system damage due to freezing! The heating system can freeze up in cold weather if it is switched off. B Shut off the fuel supply by closing the main valve. B Leave the heating system switched on as long as possible. B Protect your system from freezing by draining the boiler, the heating system and hot water pipes at the lowest point. 7.1 Normal shut-down With aquastat: B Switch off the on/off switch ("OFF" position).
Heating system inspection and maintenance 8 Heating system inspection and maintenance When carrying out maintenance work, observe: DANGER: Risk of fatal injury from electric shock! B When carrying out servicing work, label all connection cables before disconnecting them. B If cables are connected incorrectly, the system may not operate correctly with possibly dangerous consequences. B Always check that the heating system is working properly after carrying out any maintenance work. 8.1 8 8.
8 8.4 Heating system inspection and maintenance Preparing boiler for cleaning DANGER: Risk of fatal injury from electric current when appliance is opened up! B Before opening the boiler: Disconnect the heating system from the electrical power supply by means of the emergency shutoff switch or the heating system circuit breaker on the main fuse panel. B It is not sufficient just to switch off the control panel. B Take measures to ensure that the heating system cannot be switched on again unintentionally.
Heating system inspection and maintenance 8.5 Cleaning the boiler 8 B Disconnect connection lines to the gas fitting [7]. The boiler can be cleaned with brushes and/or by a wet method. Cleaning equipment is available as accessory. 8.5.1 Cleaning the boiler with cleaning brushes Remove burner: DANGER: Risk of fatal injury from electric shock! If cables are connected incorrectly, the system may not operate correctly with possibly dangerous consequences.
8 Heating system inspection and maintenance Cleaning the boiler: B Remove the boiler cover and heat insulation, check for damage. B Unscrew cleaning cover from the draft diverter. B Cover control unit with foil to prevent entry of metal dust into the control unit. B Use boiler brush to clean out flue gas passages. B Clean combustion chamber and bottom panel. B Screw cleaning cover into place and replace insulation. B Install boiler cover. 8.5.
Heating system inspection and maintenance 8.6 Cleaning the burner B Remove the burner (Æ page 39). B Check burner tubes for dirt. If necessary, clean burner as described below. B Unscrew ignition burner unit [1] from burner. B Disconnect pilot gas pipe [3] from pilot burner unit. B Remove pilot nozzle [2] and blow out. B Immerse burner rods in water with cleaning agent and brush off. 8 B Flush the burner rod with a water jet.
8 8.7 Heating system inspection and maintenance Troubleshooting Required tools: wiring diagrams (Æ page 61 and 62) and voltage testers 120 VAC and 24 VAC. 1. 2. 3. Steps for troubleshooting Beginning of troubleshooting Close the gas shut-off valve. Set thermostat (control unit) to heat requirement (vent damper opens). Switch on power. Observe ignition sparks in gap between electrode and sensor through inspection hole. 4. Open the gas shut-off valve. Ignition flame is burning. 5.
Heating system inspection and maintenance 8 Sequence of normal operation START Room thermostat (control unit) signals heat requirement vent damper opens. PHASE 1 ignition attempt Ignition spark generator is working pilot gas valve opens. PHASE 2 Main burner Pilot burner operation Ignition flame burns, burner control unit reports constant ignition flame. or ignition flame does not burn, burner control unit starts ignition attempt, switches off after 90 seconds.
8 8.8 Heating system inspection and maintenance Maintenance log book Maintenance Page 1. Check of the flue system, including combustion air, inlet, page 23 and outlet openings 2. Inspection of boiler page 37 3. Inspection of burner page 37 4. Cleaning boiler page 39 5. Cleaning burner page 41 6. Measure gas supply pressure [inches W.C.] or [mbar] page 31 7. Measure nozzle pressure [inches W.C.] or [mbar] page 31 8. Leak test in operating status page 28 9.
Heating system inspection and maintenance 8 Date: Date: Date: Date: Date: Date: Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Unit_____ Unit_____ Unit_____ Unit_____ Unit_____ Unit_____ Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Unit_____ Unit_____ Unit_____ Unit_____ Unit_____ Unit_____ 1.
9 9 Spare parts Spare parts The following spare parts are available from Buderus Hydronic Systems. If there are several Buderus article numbers for one item number, the numbers for the various models are listed in the relevant columns. Otherwise the table shows the number of components for each model. Boiler outer casing (Æ Fig. 50) Item No.
Spare parts 9 Fig. 50 Boiler casing Logano G234X - Technical specifications are subject to change without prior notice.
9 Spare parts Boiler heat exchanger (Æ Fig. 51) Item No. Designation Productnumber G234X/38 5 sections G234X/45 5 sections G234X/55 6 sections G234X/64 7 sections 10 Bottom cover, non-combustible 5024- 140 140 142 144 20 Suspension plate 5015 257 2 2 2 2 30 Shield rear 5015 273 2 2 2 2 40 Screw M8x25 Æ Mounting kit no. 2 4 4 4 4 50 Lock washer Æ Mounting kit no. 2 4 4 4 4 60 M8-8-A3K nut Æ Mounting kit no. 2 4 4 4 4 70 Block shoe Æ Mounting kit no.
Spare parts Item 9 Productnumber G234X/38 5 sections G234X/45 5 sections G234X/55 6 sections G234X/64 7 sections Screw M6x16-MS Æ Mounting kit no. 3 2 2 2 2 220 Washer A 6.4 Æ Mounting kit no. 3 2 2 2 2 230 Jacket clip M6-A3F-MCU5315 Æ Mounting kit no. 3 2 2 2 2 Glue PK-W11 2037 038 1 1 1 1 240 M8 nut Æ Mounting kit no. 3 4 4 4 4 250 Washer Æ Mounting kit no. 3 4 4 4 4 260 Screw M8-25 Æ Mounting kit no.
9 Spare parts Fig. 51 Boiler heat exchanger 50 Logano G234X - Technical specifications are subject to change without prior notice.
Spare parts 9 Control unit GAW025 US (Æ Fig. 52) Item No. Designation Productnumber G234X/38 5 sections G234X/45 5 sections G234X/55 6 sections G234X/64 7 sections 10 Control unit GAW025 US 5557 946 1 1 1 1 20 Cable protector Æ Installation material no. 4 1 1 1 1 30 Attachment bracket for flue gas safety switch Æ Installation material no. 4 1 1 1 1 40 Flue gas safety switch 7079 498 1 1 1 1 50 Screw F ST 3.5x6.5 A3K Æ Installation material no.
9 Spare parts Fig. 52 Control unit GAW025 US 52 Logano G234X - Technical specifications are subject to change without prior notice.
Spare parts 9 Gas distributor (Æ Fig. 53) Item No. Designation Product-number G234X/38 5 sections G234X/45 5 sections G234X/55 6 sections G234X/64 7 sections 10 Burner assembly 5181- 742 742 744 746 20 Gas pipe 7747 002 195 1 1 1 1 30 M8 nut Æ Installation material no. 5 2 2 2 2 40 Gasket 5489 280 3 3 3 3 50 Heat shield incl.
9 Spare parts Fig. 53 Gas distributor 54 Logano G234X - Technical specifications are subject to change without prior notice.
Spare parts 9 Burner models, gas conversion parts G234X US (Æ Fig. 54) The complete burner is supplied only in the model for natural gas G20 for 0 - 2000 feet (0 - 610 m). If you want another model burner, you must also order the appropriate gas conversion parts. The replaced parts must remain with the heating system for a possible future reconversion. Item No.
9 Spare parts Fig. 54 Burner models, gas type conversion parts AE234X US 56 Logano G234X - Technical specifications are subject to change without prior notice.
Spare parts 9 Gas valve VR8304H4206 G234X FAS US/CA (Æ Fig. 55) Item No. Designation Productnumber G234X/38 5 sections G234X/45 5 sections G234X/55 6 sections G234X/64 7 sections 10 Gas valve 5181 870 1 1 1 1 WARNING: Do not use the screw fitting included with the gas fitting for the pilot gas pipe! Tab. 18 Gas fitting VR8304H4206 ¾ 24V 60Hz Logano G234X - Technical specifications are subject to change without prior notice.
9 Spare parts Fig. 55 Gas fitting VR8304H4206 ¾ 24V 60Hz 58 Logano G234X - Technical specifications are subject to change without prior notice.
Spare parts 9 Pilot burner for G234X (Æ Fig. 56) Item Productnumber G234X/38 5 sections G234X/45 5 sections G234X/55 6 sections G234X/64 7 sections Allen screw 8x32x3/16 Æ Mounting kit no. 5 1 1 1 1 20 Pilot burner Q345 1E 5181 443 1 1 1 1 30 Ignition gas nozzle, natural gas, BCR20 5181 648 1 1 1 1 30 Ignition gas nozzle, LP gas, BBR12 5176 998 1 1 1 1 40 Screw fitting for pilot gas pipe 5181 672 1 1 1 1 50 Ignition burner holder Æ Installation material no.
9 Spare parts Fig. 56 Pilot burner for G234X 60 Logano G234X - Technical specifications are subject to change without prior notice.
Logano G234X - Technical specifications are subject to change without prior notice. 2 1 H 1 N L1 L2 C1 C2 Z on-off switch T W TV black brown orange yellow Flame roll out safety shutoff means Blocked vent switch blue black 4 3 2 1 Vent damper device (Effikal RVG..
US N Circulator pump C2 C1 L2 Transformer T-Start K1 TV T W Z TR High limit 4 yellow B1 blue 3 white Flame roll out safety shutoff means black 2 white black B2 24VGND black 4 black 24V black 1 orange Blocked Vent switch 3 1 Effical Vent damper B orange B K1 2 brown Wiring diagram gas-boiler G234X USA-CDN Intermittent pilot M K1 L1 On-off switch Edition : 63001271 MV MV Drwg. no.
10 Notes Logano G234X - Technical specifications are subject to change without prior notice.
United States and Canada Bosch Thermotechnology Corp. 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-584-1681 www.buderus.us U.S.A. Products manufactured by Bosch Thermotechnik GmbH Sophienstrasse 30-32 D-35576 Wetzlar www.buderus.com Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.
