Buderus Logano G334 X Bedienungsanleitung

Please read carefully before conversion

6304 2382 – 2012/11 US/CA For heating engineers

Instructions for High Altitude

Conversion

Logano G334 X gas-fired boiler

Required Sealevel Input Rates of 0-8500 feet

G334 X-73

301 MBtu/hr

G334 X-92

387 MBtu/hr

G334 X-116

476 MBtu/hr

G334 X-132

541 MBtu/hr

This conversion kit and the accompanying instructions are for conversion of

G334 X gas-fired boilers for operation at altitudes above 8500 feet.

Note: Please keep these instructions for future reference.

WARNING!

This conversion kit is intended for use by a

qualified service company only as

specified by the manufacturer’s

instructions and the current applicable

rules and regulations of the local

authorities and the regulations of NFPA54,

CAN/CGA B149.1 and 2, Installation

Code, must also be observed. If these

instructions are not followed exactly, a fire,

explosion or release of carbon monoxide

may occur with serious property damage

or loss of life and serious injury. The

heating contractor is liable for correct

conversion of the heating system with this

conversion kit.

WARNING!

Please use the enclosed instructions for

conversion from natural gas to propane.

Contents

2Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11

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

1Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Notes structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3 Please observe these notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Conversion of the boiler at altitudes over 8500 feet . . . . . . . . . . . . . . . . . 4

4 Start-up instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Making boiler ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.2 Then carry out start-up procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety 1

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

Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11

1 Safety

Observe these instructions for your safety.

1.1 Correct use

The conversion kit is for conversion of the G334 X gas-

fired boiler for operation at altitudes above 8500 feet.

1.2 Notes structure

Additional symbols for identification of dangers and user

instructions.

1.3 Please observe these notes

2 Scope of delivery

The conversion kit for high altitudes includes the

following components:

–main gas orifices and seals

–conversion date label (to be filled out and attached to

the unit)

–conversion instructions

–Technical documents

WARNING!

RISK TO LIFE

Identifies possible dangers emanating

from a product, which might lead to serious

injury or death if appropriate care is not

taken.

WARNING!

RISK TO LIFE

from electric shock.

USER NOTE

Tip for the optimum utilization and setting

of the control(s) plus other useful

information.

WARNING!

RISK TO LIFE

from explosion of flammable gases.

zNever work on gas lines unless you are

licensed for this type of work.

WARNING!

RISK TO LIFE

from electric shock.

zDisconnect the power supply to the

heating system before conducting any

work on it, e.g. switch off the heating

emergency switch outside the boiler

room.

zIt is not sufficient just to switch off the

control.

4Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11

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

Conversion of the boiler at altitudes over 8500 feet3

3 Conversion of the boiler at altitudes over 8500 feet

Read the instructions before conversion for your

safety.

When converting the boiler for operation at high

altitudes observe the following directions:

The boiler must be converted before installation.

1. If the boiler has been operating, close the gas valve.

Otherwise continue with step 3.

2. Disconnect heating system from the power supply

and set the thermostat to the lowest setting.

3. Remove safety screws from the left and right side

panels, then lift the front panel of the boiler and pull

it forward.

WARNING!

RISK TO LIFE

due to not observing the attached

conversion instructions.

zIf you wish to convert the boiler for

operation with propane, the conversion

from natural gas to propane must be

carried out first as specified by the

attached conversion instructions. The

conversion for high altitudes can only

be made after this.

Fig. 1 Removing front panel of boiler

1Screws

2Boiler front panel

Conversion of the boiler at altitudes over 8500 feet 3

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

Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11

4. Turn gas valve ON/OFF button clockwise to OFF

position. Do not use force.

Replacing main gas orifices

5. Disconnect pilot gas line from gas valve.

6. Disconnect ignition cable from automatic ignition.

7. Tie gas line with wire or cord (secure).

8. Unscrew retaining screws of gas feed line at burner.

Place the gas connection pipe gasket in a safe

place.

9. Check gasket for damage and replace if damaged.

10. Label connection lines of flame roll-out switch and

disconnect from the flame roll-out switch.

Fig. 2 Gas valve

WARNING!

RISK TO LIFE

from explosion of flammable gases.

zWait five (5) minutes until all gas

residues have dissipated. Check

whether there is any smell of gas,

including at floor level. If there is a gas

odor: STOP! Follow instructions in

section "B" of the safety instructions on

page 8. If there is no sign of a gas odor,

continue with the next step.

USER NOTE

When converting the boiler for high

altitudes it is only necessary to replace the

main gas orifices, not the pilot gas orifice.

Fig. 3 Front view

1Ignition cable

2Flame roll-out switch

3Connection lines to the gas valve

4Gas valve

5Connection lines to the flame roll-out switch

6Gas supply line

7Retaining screw on the gas feed line

8Pilot gas line

WARNING!

RISK TO LIFE

due to incorrectly connected wiring.

zWhen conducting maintenance work

label all cables before disconnecting

them.

6Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11

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

Conversion of the boiler at altitudes over 8500 feet3

11. Unscrew retaining nuts on burner plate and pull gas

burner straight out.

12. When removing the burner make sure that the

spacers remain on the studs.

13. Install the new main gas orifices and copper gasket.

Check with ÎTab. 1 and ÎTab. 2 to ensure that

the correct orifices for operation of the boiler are

installed.

14. Install gas burners in boiler in reverse order of

removal. Tighten the fixing nuts well.

15. Tighten the screws (ÎFig. 3, page 5) between the

gas valve and the burner again. Make sure that the

connection pipe gasket removed in step 8 is

replaced.

16. Check gasket for damage and replace if damaged.

17. Attach connection lines for the flame roll-out switch.

18. Remove wire or rope that was used to hold the gas

supply line in step 7.

19. Connect ignition gas line (ÎFig. 3, page 5) to the

gas valve again.

20. Connect ignition cables (ÎFig. 3, page 5) to the

automatic igniters.

21. Enter the required information on the conversion

label and attach on the outside of the boiler jacket as

close as possible to the name plate.

Fig. 4 Removing burner

1Fixing nuts

2Threaded studs

Orifice sizes for natural gas

Altitude in feet

Model 0–8500 8501–12000

G334 X-73 3.60 3.55

G334 X-92 3.70 3.65

G334 X-116 3.90 3.85

G334 X-132 3.90 3.85

Tab. 1 Orifice size for natural gas

Orifice sizes for propane

Altitude in feet

Model 0–8500 8501–12000

G334 X-73 2.35 2.30

G334 X-92 2.40 2.35

G334 X-116 2.50 2.45

G334 X-132 2.50 2.45

Tab. 2 Orifice size for propane

Conversion of the boiler at altitudes over 8500 feet 3

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

Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11

Carrying out leak test

22. Open gas valve in the gas line.

23. Check the gas connection line to the gas valve for

leaks with soap solution. If no leaks are found,

continue with step 25. If any leaks are found, close

gas valve.

24. Seal leaks and repeat step 23.

25. Close main gas valve. Remove the screw plug for

the gas connection port on the gas valve. Install

pressure measuring nipple and attach a pressure

gauge to measure the gas pressure.

26. Remove the screw plug for the manifold pressure

port on the gas valve. Install pressure measuring

nipple and attach a pressure gauge to measure the

manifold pressure.

27. Open gas valve and measure the gas pressure of

the boiler. The supply pressure for natural gas must

be between 7" and 10.5" W.C. and between 11" and

13" W.C. for propane gas. If the supply pressure for

natural gas is not between 7" and 10.5" W.C. and not

between 11" and 13" W.C. for propane gas, contact

the customer service technician or the gas

company.

28. Always follow the start-up instructions on the next

page.

USER NOTE

The boiler has two gas valves. Make all

measurements and adjustments on both

gas valves.

CAUTION!

SYSTEM DAMAGE

due to short-circuit.

zCover the hazardous locations before

checking for leaks.

zDo not spray the leak solution on wiring

openings, plugs or electrical

connections. Do not allow the solution

to drip on these locations.

Fig. 5 Gas valve

1ON/OFF button (at ON position)

2Screw plug for gas supply pressure measuring port

3Screw plug for manifold pressure measuring port

8Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11

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

Start-up instructions4

4 Start-up instructions

Read the instructions before start-up for your

safety.

AThis unit is equipped with an igniter that automatically

starts the pilot burner. Do not attempt to ignite it manually.

BCheck 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.

CSwitch on the ON/OFF switch on the gas valve by hand

only. Never use a tool as assistance. If you cannot actuate

the ON/OFF switch on the gas valve by hand, do not

attempt to repair it. Contact a qualified technician. Any

attempt to use force or to repair the switch may cause a fire

or explosion.

DDo not operate the unit if any part is under water. Contact

a qualified customer service technician immediately to

have the unit checked and to replace the parts of the

control and gas valves that were under water.

WARNING!

RISK TO LIFE

due to not observing the start-up

instructions and resulting incorrect

operation.

zIf these instructions are not followed

exactly, a fire or explosion may be

caused with serious property damage

or loss of life or serious injury.

zObserve the start-up instructions.

WARNING!

DANGER OF EXPLOSION

If you smell gas there is a danger of

explosion.

zNo open flame. No smoking.

zPrevent spark formation.

Do not operate electrical switches,

including telephones, plugs or door

bells.

zShut off main gas supply valve.

zOpen doors and windows.

zWarn other occupants of the building.

zEvacuate the building.

zCall gas company or fire department

from outside the building.

Start-up instructions 4

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

Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11

4.1 Making boiler ready for operation

STOP! First read the safety instructions on Îpage 8 of

this manual.

1. Carry out leak test (Îpage 7). Wait five (5) minutes

until all gas residues have dissipated. Finally check

whether there is any smell of gas, including at floor

level. If there is a gas odor: STOP! Follow

instructions in section "B" of the safety instructions

on Îpage 8 of this manual. If there is no sign of a

gas odor, continue with the next step.

2. Open main gas valve.

4.1.1 Placing heating system with aquastat control in operation

The boiler is fully functional with the factory-installed

aquastat.

3. Switch on ON/OFF switch (building side)

(ON position). This switches on the boiler with all its

components. Then continue with step 7.

4. Make sure that the room thermostat signals a heat

requirement (set thermostat at least 10 °F above

room temperature).

Fig. 6 Switching on heating system (with aquastat)

1ON/OFF switch (main switch)

10 Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11

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

Start-up instructions4

4.1.2 Placing heating system with Logamatic 2107 (accessory) in operation

The boiler is fully functional with the factory-installed

aquastat. The Logamatic 2107 control can also be

installed in addition to the factory-installed aquastat.

Switch on the heating system with the ON/OFF switch

on the control. The burner starts operating if heat is

required (Îobserve control service manual).

5. Make sure that heat is required at the control. Select

"Manual operation" (hand symbol) with the mode

selector switch.

6. Switch on ON/OFF switch ("I" position). Then

continue with step 7.

4.2 Then carry out start-up procedures.

The following start-up procedures must be carried out

regardless of the control type.

7. Look at the igniter through the sight glass in the

burner housing.

Fig. 7 Switching on heating system (with Logamatic 2107

control)

1Mode selection switch

2ON/OFF switch

USER NOTE

After carrying out the instructions for

starting described below, the control must

be set to "AUT" mode (automatic

operation) with the mode selector.

Fig. 8 Front view

1Sight glass

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