Buderus Logano GA124 Bedienungsanleitung

6304 0309 – 04/2005 US For heating engineers

Please read carefully prior to installation and maintenance.

Installation and maintenance

instructions

Sealed combustion gas boiler

Logano GA124

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 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.

Contents

2Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

We reserve the right to make any changes due to technical

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

5.2 Lifting and carrying the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6 Placing the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6.1 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6.2 Leveling the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7 Boiler installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7.1 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7.2 Heating circuit connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7.3 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7.4 Installation of Logamatic 2107 control (optional accessory) . . . . . . . . . . . . . . . . 18

7.5 Fuel supply connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.6 Installation of flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.7 Filling heating system and checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . 32

8 Openings for combustion air supply and venting . . . . . . . . . . . . . . . . . . 34

9 Placing the heating system in operation . . . . . . . . . . . . . . . . . . . . . . . . . 36

9.1 Start-up instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9.2 Making boiler ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9.3 Then carry out start-up procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9.4 Shutting off gas supply to boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9.5 Instruct owner/operator and hand over technical documentation . . . . . . . . . . . . . 45

9.6 Start-up protocol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

10 Taking the boiler out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

10.1 Normal boiler shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

10.2 Emergency shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

11 Boiler inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

11.1 Why is regular maintenance important? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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

Ventilation openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Contents

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

Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

11.3 Inspection of the boiler and burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

11.4 Preparing boiler for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

11.5 Cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

11.6 Cleaning the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

11.7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

11.8 Maintenance protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

12 Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

13 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

14 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Safety1

4Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

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 GA124 gas-fired boiler is designed to heat

water for a hot water heating system 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 B 149.1

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; see Chapter 11 "Boiler inspection

and maintenance", page 48.

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 GA124 special gas-fired boiler • Issue 04/2005

1.3.2 Installation notes

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.

zShut off main gas supply 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.

Safety1

6Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

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

1.3.3 Information on the boiler room 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.

Insufficient ventilation during operation

requiring room 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.

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 GA124 special gas-fired boiler • Issue 04/2005

2 Product description

The boiler is a low temperature gas-fired boiler.

The boiler consists of:

–Aquastat (control unit)

–Logamatic 2107 control (optional control)

–Boiler jacket and front panel

–Boiler block with insulation

–Burner

The control monitors and controls 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

energy loss.

Fig. 1 Logano GA124 boiler

1Burner

2Boiler jacket

3Boiler block with insulation

4Logamatic 2107 control (optional)

5Aquastat (control unit)

6Boiler front panel

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 GA124 special gas-fired boiler • Issue 04/2005

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

1Combustion air line connection

2Flue gas line

GAS

Connections (measurements see the following tables):

VK = Boiler supply - 1"

RK = Boiler return - 1"

EL = Drain - 1/2"

GAS = Gas connection - 1/2"

Boiler

size

Boiler

output

Combustion

air

connection

Flue gas

connecti

A B Min. overflow

valve cap.

Number of

orifices

Water

volume

Empty

weight

MBtu/hr Inches Inches Inches Inches lb/hr Qty US gal. lbs

17 59 3" 3" 7 1/5" 3 1/10" 62 2 2.4 229

23 79 3" 3" 8" 6 2/3" 86 32.9 240

30 104 3" 3" 9 1/5" 10 1/5" 110 4 3.4 337

Fig. 3 Pressure gradient

flowrate in GPM

Pressure drop

USER NOTE

For the size and dimensions of the main

gas orifice see ÎChapter 13, page 80.

Scope of delivery 4

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

Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

4 Scope of delivery

zCheck packaging on delivery for damage.

zCheck delivery for completeness.

1On pallet

Component Qty Packaging

Boiler, complete 1 1 pallet

B-kit components:

- supply manifold

11 foil package1

- 30 psi relief valve

- temperature/pressure gauge

- 90° elbow (1" NPT)

- 90° elbow (3/4" NPT)

- boiler drain (3/4")

- screw-in feet (4) (M10x51)

- wall penetration for

horizontal flue system

1 separate

packaging unit

- technical documents 11 foil package

Tab. 2 Scope of delivery

Optional Accessories1Unit

Logamatic 2107 control 1

Heat circulation pump 1

Cleaning brush 1

Vertical flue system 1

Tab. 3 Accessories

1Accessories available by separate order

10 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

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

Move the boiler with packaging and on pallet as much as

possible.

zPosition transport equipment (e.g. boiler cart) at the

back of the boiler.

zSecure boiler to cart.

zMove the boiler to the installation location.

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 boiler with trolley

CAUTION!

RISK OF INJURY

if the boiler is not properly secured to the

boiler cart.

zUse suitable transport equipment, such

as a boiler cart with a belt.

zSecure the boiler to prevent it from

falling.

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