Buderus Logano G334 X Bedienungsanleitung

6304 2270 – 09/2005 US/CA For heating engineers

Please read carefully prior to installation and maintenance.

CAUTION!

Observe the safety instructions of this

installation and maintenance manual

before placing the boiler in operation.

WARNING!

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 directions of this

installation and maintenance manual

must be followed precisely. Contact a

qualified service company, service

provider or the gas company if support

or additional information is required.

CAUTION!

The operating manual is a component

of the technical documentation and

must be handed over to the operator of

the heating system. Discuss the

instruction in this manual with the

owner or operator of the heating

system to ensure that they are familiar

with all information required for

operation of the heating system.

Note: Keep this installation and maintenance manual available for future

reference.

Installation and maintenance

instructions

Gas boiler

Logano G334 X

Contents

2Installation and maintenance instructions Logano G334 X gas-fired boiler • Issue 09/2005

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

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

1.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Observe the following symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 Please observe these notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.4 Tools, materials and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Dimensions and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Moving the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5.1 Moving the boiler with boiler cart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6 Placing the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.1 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.2 Leveling the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7 Boiler installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7.1 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7.2 Installing the draft hood and the main drain . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7.3 Installing the side panels and the front boiler jacket . . . . . . . . . . . . . . . . . . . . . 13

7.4 Connecting the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7.5 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7.6 Installation of Logamatic 2107 control (accessory). . . . . . . . . . . . . . . . . . . . . . 17

7.7 Gas supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.8 Filling heating system and checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.9 Install front boiler panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

8 Check openings for combustion air supply and venting . . . . . . . . . . . . . 24

9 Requirements for connection to chimneys or venting systems . . . . . . . 25

10 Flue pipe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

11 Placing the heating system in operation . . . . . . . . . . . . . . . . . . . . . . . . . 28

11.1 Start-up instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

11.2 Making boiler ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

11.3 Shutting off gas supply to boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

11.4 Instruct owner/operator and hand over technical documentation . . . . . . . . . . . . . 36

11.5 Start-up protocol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

12 Taking the boiler out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

12.1 Normal boiler shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

12.2 Emergency shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Contents

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

Installation and maintenance instructions Logano G334 X gas-fired boiler • Issue 09/2005

13 Boiler inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

13.1 Why is regular maintenance important? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

13.2 Testing the flue system, including combustion air, air inlets and

Ventilation openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

13.3 Inspection of the boiler and burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

13.4 Preparing boiler for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

13.5 Cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

13.6 Cleaning the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

13.7 Troubleshooting on the G334 X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

13.8 Maintenance protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

14 Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

15 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

16 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Safety1

4Installation and maintenance instructions Logano G334 X gas-fired boiler • Issue 09/2005

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

1 Safety

Observe these instructions for your safety.

The burner and control must be correctly installed and

adjusted to ensure safe and economical operation of the

gas-fired boiler.

Read this installation and maintenance manual carefully

and note the details on the boiler nameplate before

placing the boiler in operation.

1.1 Correct use

The Logano G334 X gas-fired boiler is designed to heat

water for a hot water heating system and for heating

single or multiple occupancy buildings.

1.2 Observe the following symbols

Two levels of danger are identified and signified by the

following terms:

Additional symbols for identification of dangers and user

instructions:

1.3 Please observe these notes

1.3.1 National regulations

The heating system must comply with the relevant

regulations issued by national authorities, or the

regulations issued by the National Fuel Gas Code,

ANSI Z 223.1. In Canada the regulations of CAN/CGA

B149.1 or 2, Installation Code for Gas Burning

Appliances and Equipment, must be observed.

If specified by the local regulatory authorities the heating

system must comply with the regulations of the

"Standard for Controls and Safety Devices for

Automatically Fired Boilers," ANSI/ASME CSD-1.

Carbon monoxide detectors must be installed as

specified by the local regulations. The boiler must be

serviced annually (ÎChapter 13, page 39).

Boiler operating conditions

The hot water pipe system must comply with the current

legislation and regulations. If an existing boiler is

replaced, the complete hot water pipe system must be

inspected to ensure that it is in perfect condition to

ensure safe operation.

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.

CAUTION!

RISK OF INJURY/

SYSTEM DAMAGE

Identifies potentially dangerous situations,

which might lead to medium or slight

injuries or to material losses.

WARNING!

RISK TO LIFE

from electric shock.

USER NOTE

Tip for the optimum utilization and setting

of the control(s) plus other useful

information.

Maximum boiler temperature 220 °F

Maximum operating pressure 58 psi

WARNING!

RISK TO LIFE

due to neglecting your own safety in case

of emergency, such as with a fire.

zNever put yourself at risk. Your own

safety must always take priority.

Safety 1

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

Installation and maintenance instructions Logano G334 X gas-fired boiler • Issue 09/2005

1.3.2 Installation notes

1.3.3 Information on the boiler room

WARNING!

RISK TO LIFE

from explosion of flammable gases.

If you smell gas there is a danger of

explosion.

zNever work on gas lines unless you are

licensed for this type of work.

zMake sure that a qualified company

installs the boiler, connects gas and

venting, places the boiler in operation,

connects the electrical power, and

maintains and repairs the boiler.

zNo open flame. No smoking. Do not

use lighters.

zPrevent spark formation.

Do not operate electrical switches,

including telephones, plugs or door

bells.

zClose main gas valve.

zOpen doors and windows.

zWarn other occupants of the building,

but do not use door bells.

zCall gas company from outside the

building.

zIf gas can be heard escaping, leave the

building immediately, prevent other

people from entering, notify police and

fire from outside the building.

CAUTION!

SYSTEM DAMAGE

due to incorrect installation.

zObserve all current standards and

guidelines applicable to the installation

and operation of the heating system as

applicable in your country.

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.

CAUTION!

SYSTEM DAMAGE

due to unsatisfactory cleaning and

maintenance.

zClean and service the system once a

year. Check that the complete heating

system operates correctly.

zImmediately correct all faults to prevent

system damage.

USER NOTE

Only use original Buderus spare parts.

Losses caused by the use of parts not

supplied by Buderus are excluded from the

Buderus warranty.

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.

zDo not carry out electrical work unless

you are qualified for this type of work.

zBefore opening a unit: disconnect

electrical power completely and lock to

prevent accidental reconnection.

zObserve the installation regulations.

WARNING!

RISK TO LIFE

by poisoning.

Insufficient ventilation may cause

dangerous flue gas leaks.

zMake sure that inlets and outlets are not

reduced in size or closed.

zIf faults are not corrected immediately,

the boiler must not be operated.

zInform the system operator of the fault

and the danger in writing.

Safety1

6Installation and maintenance instructions Logano G334 X gas-fired boiler • Issue 09/2005

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

1.4 Tools, materials and accessories

You need standard tools for the installation and

maintenance of the boiler as used in heating system

installation and oil, gas and water installations.

The following additional items will also be useful.

–Boiler cart with rope or Buderus boiler cart

–Cleaning brushes and/or chemical cleaning agents

for wet cleaning

1.5 Disposal

zDispose of the packaging material in an

environmentally compatible fashion.

zDispose of any components of the heating system

that require replacement in an environmentally

compatible fashion.

WARNING!

RISK TO LIFE

by poisoning.

When working on the flue gas monitoring

equipment leaking flue gas may endanger

the lives of people.

zDo not attempt to repair the flue gas

temperature sensor.

zUse only original parts when replacing

parts.

zWhen replacing the flue gas

temperature sensor install the new one

in the specified position.

WARNING!

RISK TO LIFE

by poisoning by leaking flue gas.

If the flue gas monitor trips frequently,

there may be a problem with the chimney

or the flue gas venting.

zIf the flue gas monitor trips frequently

the fault must be corrected and a

function test must be conducted.

WARNING!

RISK TO LIFE

by poisoning by leaking flue gas.

zMake sure that the boiler is not fitted

with a thermally controlled flue gas

baffle after the back flow check.

WARNING!

FIRE DANGER

due to flammable materials or liquids.

zMake sure that there are no flammable

materials or liquids in the immediate

vicinity of the boiler.

Product description 2

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

Installation and maintenance instructions Logano G334 X gas-fired boiler • Issue 09/2005

2 Product description

The boiler is a low temperature gas-fired boiler.

The boiler consists of:

–Automatic ignition unit and aquastat

–Logamatic 2107 control (accessory for separate

order)

–Boiler jacket and front panel

–Boiler block with insulation

–Burner

The automatic igniter, the aquastat and, if applicable,

the Logamatic 2107 monitor and control all electrical

components of the boiler.

The boiler jacket prevents energy loss and acts as

soundproofing.

The boiler block transfers the heat generated by the

burner to the heater water. The insulation prevents

stand-by losses.

Fig. 1 Logano G334 X boiler

1Boiler front panel

2Logamatic 2107 control (accessory)

3Boiler jacket

4Aquastat (control unit)

5Automatic igniter

6Boiler block with insulation

7Burner

USER NOTE

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.

8Installation and maintenance instructions Logano G334 X gas-fired boiler • Issue 09/2005

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

Dimensions and connections3

3 Dimensions and connections

Tab. 1 Dimensions

Fig. 2 Back, side and front view, measurements in inches

Boiler

size

Input Heating

capacity

A VENT Min. overflow

valve capacity

Number of

burner tubes

Water

volume

Empty

weight

MBtu/hr MBtu/hr Inches Inches lb/hr No. US gal. lbs

73 301 249 34.6 8249 59.2 758

92 378 314 41.7 9314 611.4 930

116 476 396 48.8 10 396 713.5 1093

132 541 450 55.9 10 450 815.6 1265

Fig. 3 Pressure chart

USER NOTE

For the size and dimensions of the main

gas orifice see ÎChapter 15, page 66.

Scope of delivery 4

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

Installation and maintenance instructions Logano G334 X gas-fired boiler • Issue 09/2005

4 Scope of delivery

zCheck packaging on delivery for damage.

zCheck delivery for completeness.

The boiler is supplied in one package with the gas

burner and gas valve, boiler jacket and technical

documentation.

The following accessories are supplied in separate

packages:

Tab. 2 Scope of delivery

Component Qty Packaging

Boiler block 11 pallet

Draft hood 11 box

Boiler jacket 11 box

Technical documents 11 foil

package

90° elbow (¾" NPT) 1

1 box

Safety valve 1

Drain valve ½" 1

Accessories1Qty

Logamatic 2107 control 1

Heat circulation pump 1

Cleaning brush 1

Exhaust flap 1

Tab. 3 Accessories

1Accessories available by separate order

10 Installation and maintenance instructions Logano G334 X gas-fired boiler • Issue 09/2005

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

Moving the boiler5

5 Moving the boiler

This chapter describes how to move the boiler safely,

5.1 Moving the boiler with boiler cart

zThe boiler must be fully packed for transport to the

installation location.

zRemove the straps and the cardboard packaging.

zRemove the bolts from the pallet.

zLift the boiler at the sides and slide to the edge of the

pallet. Place a pipe under the boiler (Fig. 4) and roll it

on additional pipes to the installation location.

zPlace the boiler in its final position.

CAUTION!

SYSTEM DAMAGE

due to bumps.

zCheck the transport diagrams on the

packaging to protect the sensitive

components from damage by bumping.

USER NOTE

zProtect the boiler connections from dirt

if the boiler is not installed immediately.

USER NOTE

Dispose of the packaging material in an

environmentally compatible fashion.

Fig. 4 Moving the boiler

USER NOTE

Make sure that all sheet metal parts, pipe

connections, burners and the controller

are protected during transport.

zNever lift the boiler by these parts.

CAUTION!

RISK OF INJURY

if the boiler is not properly secured to the

trolley.

zUse suitable transport equipment, such

as a trolley with a belt.

zSecure the boiler to prevent it from

falling.

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