Buderus Logano G334 X Bedienungsanleitung

6304 2381 – 09/2005 US/CA For heating engineers

Please read carefully before conversion

Propane Conversion Kit

Instructions

Logano G334 X gas-fired boiler

This conversion kit and the accompanying instructions are for conversion of

G334 X gas-fired boilers from natural gas to propane.

Required Input Rates

G334 X-73

301 MBtu/hr

G334 X-92

378 MBtu/hr

G334 X-116

476 MBtu/hr

G334 X-132

541 MBtu/hr

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.

CAUTION!

Before converting the heating system to a

different type of gas the gas line must first

be shut off and then the power to the

heating system must be disconnected.

Note: Please keep these instructions for future reference.

Contents

2Instructions for conversion kit for Logano G334 X gas-fired boiler • Issue 09/2005

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 to propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Start-up instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.1 Making boiler ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.2 Then carry out start-up procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety 1

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

Instructions for conversion kit for Logano G334 X gas-fired boiler • Issue 09/2005

1 Safety

Observe these instructions for your safety.

1.1 Correct use

The conversion set is supplied for conversion of the

G334X gas-fired heater from natural gas to propane.

1.2 Notes structure

Additional symbols for identification of dangers and user

instructions.

1.3 Please observe these notes

2 Scope of delivery

1. Honeywell gas solenoid valve conversion kit

# 393 691, comprising:

–black safety screw

–pressure adjustment screw

–red spring

–yellow label for gas valve

2. 2 BBR 12 ignition gas orifices

3. main gas orifices and seals

4. unit label (to be filled out and attached to the unit)

5. 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.

4Instructions for conversion kit for Logano G334 X gas-fired boiler • Issue 09/2005

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

Conversion to propane3

3 Conversion to propane

Read the instructions before conversion for your safety.

The following instructions must be followed for

conversion of the boiler to propane:

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.

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

position. Do not use force.

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.

Fig. 1 Removing front panel of boiler

1Screws

2Boiler front panel

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 9. If there is no sign of a gas odor,

continue with the next step.

Conversion to propane 3

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

Instructions for conversion kit for Logano G334 X gas-fired boiler • Issue 09/2005

Replace main gas orifices

5. Remove the safety screw for the orifice pressure

adjustment on the gas valve.

6. Remove manifold pressure adjustment screw.

7. Remove stainless steel spiral spring.

8. Install the red spring from the Honeywell LP

conversion kit in the gas valve.

9. Screw in the new gas adjustment screw from the

Honeywell LP conversion kit until it is flush with the

top of the gas valve.

Then turn the manifold pressure adjustment screw

six (6) full revolutions of 360° clockwise. This

corresponds to a pressure preset of approx. 10.0

W.C. This setting must be checked with a pressure

gauge on completion of the conversion.

10. Install new black safety screw from the Honeywell

LP conversion kit.

11. Clean the gas valve housing and attach to yellow

label from the Honeywell LP conversion kit to a

visible spot on the gas valve.

Fig. 3 Gas valve

1Safety screw

2Manifold pressure adjustment screw

3Stainless steel spiral spring

4Gas valve

5Yellow label

6Instructions for conversion kit for Logano G334 X gas-fired boiler • Issue 09/2005

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

Conversion to propane3

12. Disconnect pilot burner gas line from gas valve.

13. Disconnect ignition cable from automatic ignition.

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

disconnect from the roll-out switch.

15. Disconnect connection lines to the gas valve.

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

17. Unscrew retaining screws on gas supply line and on

burner. Place the gas connection pipe gasket in a

safe place.

18. Check gasket for damage and replace if damaged.

19. Unscrew retaining nuts on burner plate and pull gas

burner straight out.

20. When removing the burner make sure that the

spacers remain on the studs.

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

Check with ÎTab. 1 that the correct orifices for

operation of the boiler are installed.

Fig. 4 Removing gas burner

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 burner gas line

Fig. 5 Removing the gas burner

1Fixing nuts

2Threaded studs

WARNING!

RISK TO LIFE

due to incorrectly connected wiring.

zWhen conducting maintenance work

label all cables before disconnecting

them.

Orifice sizes for propane

Model G334 X-73 G334 X-92 G334 X-116 G334 X-132

Orifice

size

235 240 250 250

Number 567 8

Tab. 1 Orifce sizes

USER NOTE

These orifice sizes (Tab. 1) are

exclusively for installations between

0-8500 feet above sea level. Follow the

“Conversion instructions for high

altitudes” for installations between

8501 and 12000 feet above sea level.

Conversion to propane 3

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

Instructions for conversion kit for Logano G334 X gas-fired boiler • Issue 09/2005

22. Unscrew pilot burner unit from gas burner.

23. Disconnect ignition gas line frompilot burner.

24. Remove pilot burner orifice.

25. Place the new BBR 12 pilot burner orifice in the pilot

burner assembly.

26. Screw the ignition gas line to the pilot burner

assembly.

27. Install gas burners in boiler in reverse order of

removal. Tighten the fixing nuts well.

28. Tighten the screws (ÎFig. 4 page 6) on the gas

supply line and the burner again. Make sure that the

connection pipe gasket removed in step 17 is

replaced.

29. Check gasket for damage and replace if damaged.

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

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

supply line in step 16.

32. Connect pilot gas line (ÎFig. 4 page 6) to the gas

valve again.

33. Connect ignition cables (ÎFig. 4 page 6) to the

automatic igniters.

34. Enter the required information on the conversion

label and attach on the outside of the boiler jacket as

close as possible to the nameplate.

Fig. 6 Pilot burner assembly (cut-out view)

1Pilot burner assembly

2Pilot burner orifice

3Pilot gas line

4Ignition cable

8Instructions for conversion kit for Logano G334 X gas-fired boiler • Issue 09/2005

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

Conversion to propane3

Carrying out leak test

35. Open gas shut-off valve in the gas line.

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

leaks with soap solution. If no leaks are found,

continue with step 38. If any leaks are found, close

gas shut-off valve.

37. Seal leaks and repeat step 36.

38. Close main gas shut-off valve. Remove the screw

plug for the gas pressure measuring port on the gas

valve. Install pressure measuring nipple and attach

a manometer pressure gauge to measure the gas

pressure.

39. Remove the screw plug for the manifold pressure

measuring port on the gas valve. Install pressure

measuring nipple and attach a manometer pressure

gauge to measure the manifold pressure.

40. Open gas valve and measure the gas supply

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.

41. 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. 7 Gas valve

1ON/OFF button (at ON position)

2Screw plug for gas supply pressure measuring port

3Screw plug for manifold measuring port

Start-up instructions 4

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

Instructions for conversion kit for Logano G334 X gas-fired boiler • Issue 09/2005

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 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.

10 Instructions for conversion kit for Logano G334 X gas-fired boiler • Issue 09/2005

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

Start-up instructions4

4.1 Making boiler ready for operation

STOP! First read the safety instructions on Îpage 9 of

this manual.

1. Carry out leak test (Îpage 8). 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 9 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. 8 Switching on heating system (with aquastat)

1ON/OFF switch (main switch)

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