6303 1818 – 07/2005 For heating engineers

Installation and maintenance

instructions

Oil and gas-fired boilers

Logano G215 US

Please read carefully prior to installation and maintenance

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 Table of Content

1 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 With respect to this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Application Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Guideline of Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Please observe these notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.1 If you notice a smell of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.2 Installation tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.3 Tips for the boiler room. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Tools, materials and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Technical information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Technical data for boiler without burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.1 General operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.2 Boiler room and environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.3 Combustion air supply conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.4 Fuel conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.5 Power supply conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.6 Hydraulic conditions and water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Packaging and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Moving the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 Placing the Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6.1 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 Boiler block assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7.1 Assembly when delivered in sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1.1 Preparing boiler sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1.2 Preparing push nipples and nipple ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1.3 Preparing the intermediate section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1.4 Inserting the section sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1.5 Knock intermediate section into place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1.6 Boiler section alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1.7 Join boiler sections by the nipples at the top and bottom boiler hub . . . . . . . . . . . . . . 19
7.1.8 Fitting the anchor rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.1.9 Fitting distribution tube and supply/return header . . . . . . . . . . . . . . . . . . . . . . . 22
7.1.10 Sealing the sensor well. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1.11 Positioning the flue outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.12 Sealing boiler hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.2 Check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2.1 Preparing for a leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2.2 Leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3 Installation when boiler is supplied assembled . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4 Installation steps for disassembled and assembled delivery . . . . . . . . . . . . . . . . . . . 26
7.4.1 Fitting adjustable feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4.2 Insert the flue gas baffle plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.4.3 Installing the burner door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.4.4 Fitting the boiler jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.5 Positioning and leveling the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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

2 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Table of Content

8 Boiler installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1 Flue connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.1 Chimney venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 Installation of water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2.1 Installing B-Kit: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2.2 Installation of boiler drain (included in B-Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2.3 Installation of system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.3 Filling heating system and checking for water leaks . . . . . . . . . . . . . . . . . . . . . . . . 36
8.4 Burner installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.5 Providing a fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.6 Aquastat installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.7.1 Fitting the Logamatic control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.7.2 Installation of the temperature sensor set and burner cable . . . . . . . . . . . . . . . . . . 40
8.7.3 Electrical connections and connection of additional components . . . . . . . . . . . . . . . . 41
8.7.4 Strain relief installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.8 Jacket panel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

9 Placing the boiler in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

9.1 Setting the operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.2 Check pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.3 Making the heating system operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.4 Starting up the control and the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.5 Guidelines for starting up the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.6 Raising flue gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.6.1 Removing flue gas baffle plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.6.2 Removing the blocking plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.7 Checking the high Limit cut-out (STB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.8 Installing jacket panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.9 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 maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.1 Why is regular maintenance important? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.2 Preparing the boiler for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.3 Boiler cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.3.1 Cleaning the boiler with cleaning brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.3.2 Wet cleaning (chemical cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.4 Checking the heating system operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . 51
11.5 Testing relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11.6 Inspection and maintenance protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

13 Examples of installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

14 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

15 Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

16 Table of Key Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 3
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 1 Safety Considerations

1 Safety Considerations

1.1 With respect to this manual – Electrical code requirements for connection to the
power supply.
This installation and maintenance manual contains
important information for the safe and correct – The technical rules of the gas supply company
installation, initial start-up and maintenance of this regarding the connection of a gas burner to the gas
boiler. system.

The oil and gas fired boiler Logano G215 is generally – Regulations and standards regarding safety
referred to below as a boiler. equipment of the heating system.

The installation and maintenance manual is provided for NOTICE

technicians who have been trained and have experience
in working with heating systems and oil and gas fired Use only original Buderus components.
installations. Losses caused by the use of parts not
supplied by Buderus are excluded from
the Buderus warranty.
1.2 Application Purpose
The boiler can only be used for hot water space heating 1.4.1 If you notice a smell of gas
and water heating for single and multi family homes.
DANGER TO LIFE
Please note the details on the rating plate and the
through the explosion of volatile gases.
specifications (Î Chapter 3, page 7) to ensure the
If you can smell gas there is a risk of
correct use of this equipment. WARNING!
explosion.
z Extinguish all open flames. Do not
1.3 Guideline of Notice smoke. Do not use lighters.
The following symbols are used in this manual: z Prevent sparks.
Do not operate electrical switches,
DANGER TO LIFE including telephones, plugs or door-
Identifies possible risks that may lead to bells.
serious injury or death if appropriate care is z Close the main gas shut-off valve.
WARNING!
not taken.
z Open windows and doors.
z Warn all occupants, but do not use
DANGER OF INJURY/
doorbells.
SYSTEM DAMAGE
z Call gas company from outside the
Identifies a possible dangerous situation building.
CAUTION!
that can lead to mild to moderate personal
injury or physical damage. z If you hear gas escaping, immediately
leave the building, prevent others from
entering and notify the police and fire
NOTICE brigade from outside the building.
Tip for optimum use of equipment and
adjustment as well as useful information. 1.4.2 Installation tips

DANGER TO LIFE
Î Cross references
through the explosion of volatile gases.
Cross references to a specific section or another
WARNING! z Work on gas components must be
document are identified with an arrow Î .
carried out by qualified and authorized
personnel only.
1.4 Please observe these notes
Observe all local codes and standards during installation
and operation:
– Local building code regulations regarding
installation, combustion air supply and flue gas
systems as well as connection to a chimney.

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

4 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Safety Considerations 1

DANGER TO LIFE 1.5 Tools, materials and equipment

from electric shock. Installation and maintenance of the boiler requires the
standard tools used in heating, oil, gas and water
WARNING! z Only qualified electricians are
installations.
permitted to carry out electrical work.
The following may also prove useful:
z Before you open a device: Shut off
electrical supply and secure against – Sack trolley with strap or Buderus boiler trolley
accidental activation. – Wood supports
z Please observe all installation – Cleaning brushes and/or chemical cleaning agent for
instructions. wet cleaning
If the boiler is delivered in sections, you will also require
1.4.3 Tips for the boiler room the following:
DANGER TO LIFE – Compression tool 1.2 if the boiler is supplied in
through poisoning. sections (Î compression tool documentation)
Insufficient ventilation can result in – Flat board
WARNING!
hazardous discharge of flue gas when – Cleaning agent
operation requires air from the room.
– Installation kit (accessory)
z Never block off or obstruct air ducts and
vents or reduce their size. – Steel hammer and wooden or rubber mallet

z The boiler must not be operated until the – Half-round bastard file
obstruction has been removed. – Screwdriver (Philips and slotted head)
z Inform the system user in writing of the – Flat chisel
fault and associated danger. – Wrench SW 19, 36, 13, 19, 18, 24, 27 and Allen key
SW19
RISK OF FIRE – Support wedge, flat iron
through flammable materials or liquids. – Cleaning rags and cloth
WARNING! z Never store flammable materials or – Fine emery cloth
liquids in the immediate vicinity of the – Wire brush
boiler.
– 3-in-1 oil
– Cleaning agent, ruler, chalk, straight edge
DANGER TO LIFE
– Blanking flange with vent facility (for pressure test)
through toxic flue gases.
WARNING! z Make sure that mechanical ventilation
equipment, such as kitchen extraction 1.6 Disposal
hoods, clothes dryers or fans, does not z Dispose of packaging in an environmentally
extract combustion air from the boiler responsible manner.
room.
z Dispose of all heating system components that have
to be replaced at an authorized disposal site.
DANGER TO LIFE
through toxic flue gases.
WARNING! z Make sure that the boiler is only
operated with chimneys or exhaust
systems that allow the required
pressure during operation.

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 5
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 2 Product Description

2 Product Description
This boiler is a low temperature boiler for oil or gas 1
combustion with modulating boiler water temperature
control.
The boiler consists of:
– Logamatic control panel (optional)
2
– Boiler jacket
– Boiler block with insulation
The control device monitors and controls all electrical 3
boiler components.
The standard boiler is equipped with an aquastat
control.
The boiler casing prevents heat losses and acts as a
noise insulator.
The boiler block transfers the heat generated by the
4
burner to the heating water. The insulation prevents
energy losses. Fig. 1 Boiler without burner
1 Logamatic control panel
Suitable burner
2 Boiler jacket
Install a suitable oil or a gas burner on the boiler. Note 3 Boiler block with insulation
the boiler specifications when selecting the burner 4 Burner door casing
(Î Chapter 3.1, page 7).

SYSTEM DAMAGE
due to incorrect burner.
CAUTION! z Use only burners that meet the
technical boiler requirements.

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

6 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Technical information 3

3 Technical information

3.1 Technical data for boiler without burner

Select a suitable burner for this boiler using the
information in this chapter.

23½”

41”

30¾” 1½” 34¾”

1” 1”
29¼” 29¼”
4¼”

1½”
27”
21”
3¼”
6”

11¾”
EL ¾”
2¾”

Fig. 2 Connections and dimensions (measurements in inches)

Connections (measurements see following tables):

VK = Boiler supply VS = Hot water tank supply
RK = Boiler return
EL = Boiler drain (connection for drain valve)

Boiler model 215/3 215/4 215/5 215/6 215/7

Boiler sections Number 3 4 5 6 7
Heating capacity (gross output) Btu/hr 134,000 171,000 207,000 256,000 294,000
Thermal output (net IBR output) Btu/hr 117,000 149,000 180,000 223,000 256,000
Boiler water content Gal approx. 12.9 approx. 16.1 approx. 19.3 approx. 22.5 approx. 25.6
Gas content cu.ft. 1.35 1.73 2.10 2.48 2.86
Oil firing rate GPH 1.1 1.4 1.7 2.1 2.5
Hot gas resistance psi 0.0023 – 0.0078
Permissible max. supply temperature1 °F 248
Allowable operating pressure psi 58
Maximum time constant of thermostat s 40
and high limit safety cut-out (STB)

Tab. 1 Technical data for boilers without burners

1
Safety limit (high limit safety cut-out STB)
Maximum possible flow temperature = safety limit (STB) – 32 °F
Example: Safety limit (STB) = 212 °F, maximum possible flow temperature = 212 – 32 = 180 °F
The safety limit must comply with the national regulations.

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 7
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 3 Technical information

Boiler model 215/3 215/4 215/5 215/6 215/7

Total boiler length (L) Inch 26 ¼ 31 35 ¾ 40 ½ 45 ¼
Boiler block length (LK) Inch 22 26 ¾ 31 ½ 36 ¼ 41
1 7
Boiler section insert (width; height; depth) Inch – 18 /8; 32 ¼; 5 /8
Boiler block insert (width; height; depth) Inch 18 1/8; 32 ¼; Length LK
Combustion chamber length Inch 16 ¾ 21 ½ 26 ¼ 31 35 ¾
Combustion chamber diameter Inch 13 ¼
Burner door thickness Inch 3¾
3
Burner pipe diameter (DB) Inch 4 /8 5 1/8
7
Hole circle diameter (DL) Inch 5 /8 6¾
Distance between boiler feet (FL) Inch 13 ¼ 18 22 ¾ 27 ¼ 32
1
Dry weight lbs 400 500 600 700 800
Tab. 2 Dimensions, weight and other data for boilers without burners
1 Weight incl. packaging material approx. 6 – 8 % more.

3.2 Operating conditions

If the operating conditions listed on the following page
are maintained, long and trouble-free operation of the
boiler can be expected. Some details relate only to
operation with Logamatic control panels from Buderus.

SYSTEM DAMAGE
Deviating from the stated operating
conditions may lead to faults. Major
CAUTION!
deviations may lead to the destruction of
individual components or of the boiler.
z Observe the details on the boiler rating
label, which are decisive. Please
always observe these.

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

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 Technical information 3

3.2.1 General operating requirements

Operating conditions
Min. boiler water Operating interruption Heating circuit control with
Min. return temperature
temperature (complete boiler shutdown) central heating mixer 1
In combination with Logamatic control for variable low-temperature operating modes, such as Logamatic 2107
not obligatory automatically by the Logamatic not obligatory but advantageous Not obligatory, except for
control panel with low-temperature heating operation with a modulating
system design 130/113 °F burner for:
Operating temperatures are
safeguarded by the Required for: Oil combustion: 113 °F
Logamatic control panel 2 Underfloor heating systems Gas combustion: 130 °F
Systems with high water content:
>115 gal/MBH
(1 MBH = 100,000 Btu/hr)
In combination with Logamatic control for constant boiler water temperatures, such as Logamatic 2109
or in combination with remote control and aquastat
150 °F 3 possible if, after interruption of required required for:
the operation, there is at least 3 Systems with high water
hours heating operation content >115 gal/MBH: 130 °F
Operation with a modulating
burner: 130 °F
Tab. 3 General operating requirements
1 A heating circuit with a mixer improves controllability and is specifically recommended for systems with several heating circuits.
2
If the control system does not influence the heating circuits or the a heating circuit actuating component (e. g. Pumplogic), the burner ON mode
must reach an operating temperature of 122 °F within 10 min by restricting volume flow.
3 Boiler control thermostat setting: During burner ON mode the minimum boiler water temperature in the boiler must be reached within 10 minutes
by suitable measures, such as flow restriction, and maintained as the minimum temperature.

3.2.2 Boiler room and environmental conditions

Operating conditions Notes – Requirement in greater detail

Temperature in the boiler room +40 to +104 °F
relative humidity max. 90 % No condensation or precipitation inside the boiler room
Dust/airborne seeds – Excessive dust inside the boiler room must be avoided when the boiler is
operating, e.g.:
– dust from building work
Combustion air supplied from outside must not be excessively loaded with
dust or airborne seed; if necessary, air filters should be fitted to prevent
this:
– Air supply contaminated with dust from dirt roads and paths.
– Air supply contaminated with dust from production and processing facilities,
e.g. quarries, mines, etc.
– Airborne seed from thistles and similar
Halogen-hydrocarbon – The combustion air must be free from halogen-hydrocarbon compounds.
compounds – Identify the source of halogen-hydrocarbon compounds and prevent them
from entering. Where this is impossible, route combustion air from areas that
are not contaminated by halogen-hydrocarbon compounds.
Fans, which extract air from the – During burner operation, no mechanical air handling equipment may be operated
boiler room. that could extract combustion air from the boiler room, e.g.:
– Extraction hood
– Clothes dryer
– Ventilation equipment

Tab. 4 Boiler room and ambient conditions

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

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 3 Technical information

Operating conditions Notes – Requirement in greater detail

Small animals – Protect the boiler room and particularly the combustion air inlet against the entry
of small animals, for example by means of a screen.
Fire protection – Maintain clearances between the boiler and flammable materials in accordance
with local regulations. A minimum clearance of 16" is required. Never store
flammable materials or liquids in the vicinity of the boiler.
Flooding – In case of an acute risk of flooding, disconnect the boiler in good time from its fuel
and power supply before water enters the room. Any general and burner
components or control equipment, which come into contact with water, must be
replaced before re-commissioning.
Tab. 4 Boiler room and ambient conditions

3.2.3 Combustion air supply conditions

Boiler output (in case of several Ventilation air cross-section in square inches
Operating conditions
boilers = total output) (unrestricted aperture)
Ventilation cross-section for < 170,000 Btu/hr min. 23,25 square inches
combustion air from outside
> 170,000 Btu/hr min. 23,25 square inches and also 0.91 square inches
(split over a maximum of
per 10,000 Btu/hr,
2 apertures)
that is above 170,000 Btu/hr
Tab. 5 Combustion air supply – observe local requirement for operation with room air.

3.2.4 Fuel conditions

Operating conditions Notes – Requirement in greater detail

Permissible fuels for boilers – This boiler can be operated with the following fuels. Select a burner that is suitable
without integral burners for one of these fuel types:
– Fuel oil in accordance with the burner specification
If a poorer quality oil (kinematic viscosity > 0.0093 sq in/sec (> 45.5 s
Sayboldt) at 68 °F) is used, the maintenance and cleaning periods must be
reduced. In that case, carry out maintenance and cleaning procedures at least
twice a year.
– Natural gas in accordance with the burner specification
– LPG in accordance with the burner specification
Contamination – Technically free of contaminants (for example dust, mist, humidity), i.e. a
constant operation will not lead to accumulation, which causes reductions in the
cross-section of valves, strainers and filters.

Tab. 6 Fuels

3.2.5 Power supply conditions

Operating conditions Notes – Requirement in greater detail

Power supply voltage 110 – 120 V Note the voltage range of the burner and control devices used. The housing/boiler
must be grounded for reasons of function and personnel protection.
Fuse (Logamatic) 10 A
Frequency 60 Hz Sinusoidal voltage curve
Protection – IP40 (protected against contact by entry of foreign bodies > 0.04 inches Ø
(> 1 mm Ø), no water proofing)
Tab. 7 Power supply

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

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 Technical information 3

3.2.6 Hydraulic conditions and water quality

Operating conditions Notes – Requirement in greater detail

Operating pressure 15 – 58 psi Maximum 30 psi with the supplied safety valve.
(overpressure)
Permissible site test pressure 45 – 75 psi
Protection against over- 122 – 194 °F
temperatures with TR
thermostat
Temperature safety limit by 212 – 248 °F On some controls adjustable on site from 212 to 248 °F.
STB safety temperature cut-out
Water quality – Use only drinking water to fill and top-up the boiler. We recommend a pH value
of 8.2 – 9.5.
Tab. 8 Hydraulic system and water quality

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

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 4 Packaging and Components

4 Packaging and Components

z After delivery, check all packaging for concealed Boiler in parts
damage.
Component Qty Packaging
z Check the delivery for completeness.
Front, center and back sections 1 1 pallet
Boiler as assembled block Control panel, 1 1 box
or aquastat
Component Qty Packaging
Jacket Package: 1 1 box on a
Boiler block 1 1 pallet1
pallet
Control panel, 1 1 box – Fittings 1 1 box1
or aquastat
– Boiler jacket 1 1 box1
Jacket Package: 1 1 box on a
– Insulation 1 1 plastic
pallet
– Burner door, burner door 1 package1
– Boiler jacket 1 1 box1
cover and assembly 1 box1
– Insulation 1 1 box1 equipment2
– Burner door, burner door 1 1 box1 1 plastic
cover and assembly – Technical documents package
equipment2
1 plastic B-Kit components: 1 1 package
– Technical documents package
– Supply manifold (11/4")

1 1 package – 30 psi relief valve

B-Kit components:
– Boiler drain (¾")
– Supply manifold (11/4")
– Pressure/temperature
– 30 psi relief valve
gauge
– Boiler drain (¾")
– 90°-elbow (¾")
– Pressure/temperature
– Burner mounting studs and
gauge
washers
– 90°-elbow (¾")
– Aquastat well (¾")
– Burner mounting studs and
– Bushing 1" x ¾"
washers
– Plug 1"
– Aquastat well (¾")
– Bushing 1" x ¾" Tab. 10 Packaging
1
– Plug 1" 1 pallet
2 The screw-in feet are in the burner door and burner door cover
Tab. 9 Packaging package.
1 1 pallet
2 The screw-in feet are in the burner door and burner door cover
package.

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

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 Moving the boiler 5

5 Moving the boiler

This chapter details how to move the boiler safely.

SYSTEM DAMAGE
due to bumps.
CAUTION! z Please observe the handling directions
on the packaging to protect
components from bumps and rough
treatment.

NOTICE
Protect boiler connections from damage
and dirt if the boiler is not installed
immediately.

NOTICE
Dispose of packaging in an
environmentally responsible manner.

RISK OF INJURY
by not securing the boiler adequately
during transport.
CAUTION!
z Use only suitable means for
transportation, e.g. a trolley with strap,
a stair or step trolley.
z Secure the load against falling.

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

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 6 Placing the Boiler

6 Placing the Boiler

This chapter details how to install and place the boiler in
the boiler room.

SYSTEM DAMAGE
due to freezing temperatures.
CAUTION! z Install the boiler in a frost-free room.

6.1 Clearances
Position the boiler at the recommended clearances
(Î Fig. 3). Reducing the minimum clearances makes
the boiler more difficult to access.
The boiler base or foundation must be perfectly flat and
level.
The burner door can be fitted with the hinge on the l.h.
or the r.h. side.
Mea-
Distance
sure

A Recommended 51 1/8"

minimum 39 3/8"

B Recommended 27 1/2"

minimum 15 3/4"

C Recommended 15 3/4"

minimum 3 7/8" Fig. 3 Boiler room clearances (see Tab. 11)

LK see "Technical Data" chapter

Tab. 11 Recommended and minimum clearances

(in inches)

NOTICE
Reduced clearances must comply with
local and state codes. The boilers are
designed for a side clearance of 6". Make
sure that there is a sufficient clearance
between combustible materials and the
chimney connection as specified by
NFPA 31 (distance of 18").

NOTICE
Where applicable, allow extra wall
clearances for additional components,
for example hot water tank, pipe
connections, flue gas muffler or other
components on the flue gas side.

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

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 Boiler block assembly 7

7 Boiler block assembly

The on-site installation is carried out using individual
sections if, because of physical limitations, a boiler block 6 7
cannot be assembled as a complete unit. 5
For installation of boiler supplied fully assembled
(Î Chapter 7.3, page 26).
4 8
RISK OF INJURY
9
by not securing the boiler adequately 3
during transport.
CAUTION!
z Use only suitable means for
transportation, e.g. a trolley with strap, a 2
7
stair or step trolley.
z Secure the load against falling.
1

Fig. 4 Boiler block in the assembled state

1 Foundation/installation location
2 Drain
3 Back section
4 Flue outlet
5 Connecting block
6 Central sections
7 Anchor rods
8 Front section
9 Burner door

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

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 7 Boiler block assembly

7.1 Assembly when delivered in sections

z Assemble all boiler sections in accordance with the
following instructions and diagrams.

7.1.1 Preparing boiler sections

z Position the rear section onto two wood blocks.
z Clean the boiler hubs with sandpaper and a rag.
1
z Remove any burrs with a file.
z Clean the packing spring or packing groove with a
wire brush and rag.

RISK TO HEALTH and

DANGER OF BURNS
2
due to released vapors and easily
CAUTION!
flammable cleaning agents.
z When using red lead putty, adhesives
and solvents ensure adequate
ventilation inside the installation room.
z When using solvents, avoid open 4 3
flames, incandescence and sparks. 1
z Please observe the manufacturer's
handling and safety instructions.
Fig. 5 Remove burrs
1 Boiler hubs
2 Back section
3 Wood blocks
4 Sealing spring

z Clean the hub sealing faces with a rag soaked in

cleaning agent.
z Evenly coat the boiler hub sealing faces with red lead 1
putty.
z Coat the packing spring or packing groove with
adhesive (adhesive base).

Fig. 6 Coat boiler hubs with red lead putty

1 Boiler hub sealing face
2 Sealing spring

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

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 Boiler block assembly 7

7.1.2 Preparing push nipples and nipple ports

z Clean the nipples with a cloth soaked in cleaning
agent.

1 1/8
z Evenly coat the nipples with red lead putty. 1

30
z Place nipple straight in the top and bottom boiler hub
of the back section and hammer in a crosswise
pattern.

NOTICE
After driving in the nipple leave it projecting
approx. 1 1/8" from the boiler hub.

z Remove any burrs with a file.

Fig. 7 Driving nipples home

1 Nipple in the upper boiler hub
2 Nipple in bottom boiler hub

7.1.3 Preparing the intermediate section

Prepare the central section in the same way as the back
section (Î Chapter 7.1.1, page 16).

Fig. 8 Preparing the central section

1 Boiler hub sealing face
2 Packing grooves

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

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 7 Boiler block assembly

7.1.4 Inserting the section sealing

z Unroll the required length of section sealing from the
roll supplied.

SYSTEM DAMAGE
due to leaking boiler sections.
CAUTION! z To ensure that the faces between the
boiler sections are sealed correctly
never stretch the sealing rope during
application.
z Carefully insert the sealing rope into the
boiler section packing grooves.

z Peel the backing paper from the sealing rope as you

insert the cord into the packing groove.
z Insert the flexible sealing rope into the packing
groove starting in the upper boiler hub area, and
lightly press in. Fig. 9 Inserting the section sealing rope
z Overlap sealing rope 3/4" at the joins and press in
well.

7.1.5 Knock intermediate section into place

z Turn the intermediate section around and locate with
the upper and lower boiler hubs on the nipples of the 1
rear section.
z Drive the intermediate section onto the rear section
using a wood or a rubber mallet.

Fig. 10 Knock intermediate section into place

1 Wood or rubber mallet
2 Rear section

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

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 Boiler block assembly 7

7.1.6 Boiler section alignment

RISK OF INJURY
due to inadequately secured boiler
sections.
CAUTION!
z Secure the boiler block section against
tipping.

z Position the partly assembled block of two boiler

sections.
z Position a flat board underneath the center section
so that the boiler block is slightly tilted for the
continuing assembly.

Fig. 11 Installing boiler block section

1 Flat board
2 Center section

7.1.7 Join boiler sections by the nipples at the top and bottom boiler hub

BOILER DAMAGE
due to unsuitable compression tool.
CAUTION! z Use only the compression tool size 1.2
(Î documents for compression tool)
suitable for the boiler.

COMPRESSION TOOL DAMAGE 1

The compression tool may be damaged or
destroyed, if you compress pull rods with
CAUTION!
loose threaded connections.
z Check the threaded connection of the
pull rods after every compression, and
tighten, if required.
The pull rod is correctly positioned if it is
fully inserted and no thread is showing.
z Keep the thread of the compression tool
2
clean. Dirty threads can damage the
compression tool during compression.
Fig. 12 Making the pull rod threaded connection
1 Pull rod threaded connection (incorrectly joined)
2 Pull rod threaded connection (correctly joined)

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

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 7 Boiler block assembly

z Push one pull rod each through the lower and the
upper boiler hub of the partly assembled block. 3 4 5
BOILER DAMAGE 2
due to incorrectly positioned auxiliary 1
flange.
CAUTION!
Leaks may occur if the auxiliary flange sits
on the packing spring/groove of the boiler
section during the compression process.
z Ensure that the auxiliary flange lies
level on the boiler hubs.

z Push the auxiliary flange onto the pull rods of the Fig. 13 Compression tool assembled at the upper boiler hub
lower and upper boiler hubs. 1 Compression unit
z Push the mating flange onto the pull rod of the lower 2 Auxiliary flange (Ø 5 3/8" × 1" top boiler hub)
and upper boiler hubs, and secure with the 3 Mating flange (Ø 5 3/8" × 1" top boiler hub)
respective wedges. 4 Wedge
z Thread the compression units onto the pull rod 5 Pull rod in the upper boiler hub
threads.

NOTICE
Push the compression units far enough
onto the pull rod threads that two thread
2
windings protrude from the compression
units.
3
z Hold the pull rods at the center of the boiler hubs and 1 4
5
slightly draw together the compression tools using
the compression unit.

Fig. 14 Compression tool assembled at the lower boiler hub

1 Compression unit
2 Auxiliary flange (Ø 3 1/8" × 1")
3 Mating flange (Ø 3 1/8" × 1" bottom boiler hub)
4 Wedge
5 Pull rod in the bottom boiler hub
z Set both ratchet wrenches on the clamping nuts of
the compression units and press the boiler sections
together by evenly tightening the nuts.

2
1

Fig. 15 Positioning ratchet

1 Ratchet
2 Clamping nut

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

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 Boiler block assembly 7

BOILER DAMAGE
due to leaking boiler sections.
CAUTION! z For each compression procedure
ensure that no more than one nipple
joint (one nipple joint comprises two
sections) is compressed.
z Never jam nipples into the boiler hubs of
the boiler section.
z Stop pressing the sections together
when the boiler hubs meet.

z Release and remove the compression tool.

z Hammer the nipples into the partly assembled boiler
block (Î Chapter 7.1.2, page 17).
z Prepare all other intermediate sections as described
above and join them at the nipples.

Fitting the front section

Due to the threaded studs, do not use the auxiliary
flange at the front of the upper boiler hub when
assembling the front section.
z Push the pull rod together with the compression unit
through the upper boiler hub.
z Carry out all other steps as described
(Î Chapter 7.1.7, page 19)

Fig. 16 Fit the compression tool to the front section

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

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 7 Boiler block assembly

7.1.8 Fitting the anchor rods

NOTICE
1
Insert the anchor rods before removing the
compression tool. 2 3
Never remove the compression tool first.

SYSTEM DAMAGE 4
due to incorrect spring washer assembly.
CAUTION! z Ensure that the spring
washers are arranged opposite each A
other on the anchor rods.

z Insert the anchor rods with spring washers into the

case cams on the l.h. and r.h. side as well as
adjacent to the lower boiler hubs. 1
z Tighten the nuts on the anchor rod threads by hand. 5
z Tighten the nuts 1 to 1½ turns on the anchor rods.
z Release and remove the compression tool. Fig. 17 Fitting the anchor rods – layout of spring washers
1 Anchor rods
2 Nut
3 Spring washers
4 Cast lugs
5 Compression tool
6 Spring washer arrangement

7.1.9 Fitting distribution tube and supply/return header

The distribution tube, the supply/return header and the
sensor well are already assembled if the boiler block is
supplied as a ready assembled unit.
NOTICE 4
Before installation of the supply/return
header, first push the distribution tube from
the boiler front into the boiler (don't forget
the boiler hub flat gasket) if insufficient
space is available behind the boiler.
3 2 1
z Secure the distribution tube to the supply/return
header with M 8 × 16 screws and flat gasket. Fig. 18 Fitting feed pipe on supply/return header
1 supply/return header
2 Flat gasket
3 Distribution tube
4 M 8 × 16 bolts (brass)

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

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 Boiler block assembly 7

z Remove the nuts from the threaded studs.

z Push the flat gasket over the distribution tube.
z Push the feed pipe with the supply/return header and
flat gasket into the upper boiler hub at the boiler back.

Fig. 19 Fitting feed pipe and supply/return header

1 Flat gasket
z Position the supply/return header on the threaded
studs and tighten four nuts by hand.
z Evenly tighten the supply/return header nuts
diagonally using a torque wrench (torque: maximum
44 lbs-ft). 1

Fig. 20 Fitting supply/return header

1 Torque wrench
Seal connections which are not required with the plugs
supplied. When the boiler is supplied as a ready
assembled block, these plugs have already been fitted.
z Insert plugs with flat gaskets into the connections
that are not required. 2

1
Fig. 21 Seal connections that are not required.
1 Plug
2 Flat gaskets

7.1.10 Sealing the sensor well

z Seal sensor well R ¾ from above in the Rp ¾" well
threaded hole of the test port of the connection block.
1

Fig. 22 Sealing the sensor well

1 Sensor well

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

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 7 Boiler block assembly

7.1.11 Positioning the flue outlet

The flue outlet comes with sealing rope already fitted.
z Remove the washers and nuts from the threaded
studs.
z Position the flue outlet on both threaded studs on the
back section and secure with nuts.

Fig. 23 Fitting the flue outlet

7.1.12 Sealing boiler hubs

The reducer included with the B-Kit is required for fitting
the boiler fill and drain valve (boiler fill & drain valve).
The boiler fill & drain valve is also a component of the
B-Kit.
z Seal with teflon tape or paste the reducer into the
bottom boiler hub at the back of the boiler.
z Install the boiler fill & drain valve on the reducer.

Fig. 24 Sealing the reducer

1 Reducer
z Close the top boiler hub on the front section with the
blank flange.
z Screw in the plug with the flat gasket into the lower 1
boiler hub.

Fig. 25 Seal boiler hubs at the front section

1 Blank flange
2 Plug

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

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 Boiler block assembly 7

7.2 Check for leaks

Conduct a leak test of the boiler block only when the
boiler was delivered disassembled.

7.2.1 Preparing for a leak test

z Close all boiler hubs (Î Chapter 7.1.12, page 24).
z Close front and back connections (fit vent to the
Rp ¾ connection block (Î Fig. 22).

7.2.2 Leak test

Carry out the leak test with a test pressure of 84 psi (in
accordance with the requirements of the European
Pressure Vessel Directive).
NOTICE
Please note the rating plate details.
Use a pressure gauge class 1.0 for the
pressure test.

SYSTEM DAMAGE
due to overpressure.
CAUTION! z Ensure that no pressure, control or
safety equipment is fitted.

z Slowly fill the boiler block via the boiler fill & drain
valve. Vent at the highest point of the system, until
water flows out of the air vent valve.

Hub joints leaking?

z If a hub joint is leaking, first drain the water through
the fill & drain valve.
z Remove the water pipes.
z Remove the distribution tube.
z Release and remove the anchor rods.
z Separate the leaking boiler by driving flat wedges or
chisels into the leaking part.

NOTICE
Clean the hubs before reassembly.
Use new nipples and new sealing rope for
the reassembly.
Compress the boiler block again.
Fit the anchor rods and feed pipe.
Install the water pipework.
Repeat the leak test.

For subsequent installation of the boiler see

(Î Chapter 7.3, page 26).

Fig. 26 Separate the boiler block

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

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 7 Boiler block assembly

7.3 Installation when boiler is supplied assembled

A leak test of the boiler block is carried out at the factory
when the boiler is supplied assembled.
z Cut through the straps.
z Remove the pallet prior to positioning the boiler
block.

DANGER TO LIFE
from falling material.
WARNING! z Ensure that a suitable means of
supporting the load is available.
z Observe all locally applicable 1
Occupational Health & Safety
regulations regarding lifting equipment.

Fig. 27 Boiler block on pallet (as delivered)

1 Securing straps

7.4 Installation steps for disassembled and assembled delivery

Carry out the steps detailed in this chapter for deliveries
in sections or as block. Where there are different
procedures for installation between disassembled and
assembled delivery, this is noted in the manual.

7.4.1 Fitting adjustable feet

Use the adjustable feet (packaging Î components
page 12) to adjust the boiler to a horizontal position to
prevent air from collecting in the boiler.
z Tip the boiler or support it on a wood block.
z Screw in adjustable feet 0.20 - 0.40 inches.
z Gently set the boiler down.

Fig. 28 Fitting adjustable feet

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

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 Boiler block assembly 7

7.4.2 Insert the flue gas baffle plates

z Remove the corrugated cardboard packaging when
the block is supplied ready assembled.
z When the boiler is supplied in sections, remove the
flue gas baffle plates from the carton containing the
small iron fittings.
z Install flue gas baffle plates in accordance with the
following table into the central second flue gas pass.
The cast lugs should point towards the center of the
boiler.

Fig. 29 flue gas baffle plates into the second flue gas pass
(here: centrally)
z Install flue gas baffle plates in accordance with the
following table into the third flue gas pass. The cast
lugs should point outwards.

Boiler section 3 4 5 6 7
2. flue gas pass top – – – – –
center 2 – 2 – –
bottom 2 – 2 – –
3. flue gas pass 2 2 – – –

Tab. 12 Arrangement of the flue gas baffle plates

The flue gas temperature can be increased by removing Fig. 30 flue gas baffle platesinto the third flue gas pass
the flue gas baffle platess (Î Chapter 9.6.1, page 44).

7.4.3 Installing the burner door

The burner door can be mounted either on the r.h. side
and on the l.h. side. Installation on the r.h. side is 1
described below.
z Screw the two hinge pins to the front section with one
M12 × 35 hexagon bolt each.

Fig. 31 Fit hinge pins (here: on the r.h. side)

1 M12 × 35 hexagon bolt

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

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 7 Boiler block assembly

z Secure both slotted hinge lobes with one M12 × 25

hexagon bolt each to the burner door.
z Hook the burner door with the hinge lobes onto the
hinge pins.
z Close the boiler door.

SYSTEM DAMAGE
due to leaking burner door.
CAUTION! z Tighten the hexagon bolts of the burner
door evenly.

Fig. 32 Hooking on the burner door (here: on the r.h. side)

1 M12 × 25 hexagon bolt

7.4.4 Fitting the boiler jacket

Installation of the boiler back panel

z Screw spacer pins to the rear section.

Fig. 33 Spacer pin installation

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

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 Boiler block assembly 7

z Secure the boiler back panel with nuts to the

threaded and spacer pins.
Installation of the top tie-bar

Fig. 34 Installation of the boiler back panel

z Secure the top tie-bar with the nuts supplied to the
1
anchor rod threads.

Fitting the bottom tie-bar

Fig. 35 Fitting the top tie-bar

1 Anchor rods
z Screw the bottom cross bar with hexagon bolts to the
front section.

Fig. 36 Fitting the bottom cross bar

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

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 7 Boiler block assembly

Installing thermal insulation

z Position the thermal insulation over the boiler block.
z Push the thermal insulation below the boiler block in
the direction of the arrow. 1

z Position the thermal insulation tabs in front of the top

tie-bar and draw them together with a spring clip.

Fitting the side panels

Fig. 37 Installing thermal insulation

1 Spring clip
2 Thermal insulation tabs
The side panels are fitted identically on each side (r.h.
side panel shown here)
z Push the snap nut onto the angled sheet steel of the
side panel until it locks into the hole provided.

Fig. 38 Positioning snap nut (here: r.h. side panel)

z Push the side panel into the angled part of the bottom
cross bar.

Fig. 39 Push in the bottom front corner of the side panel

1 Angled part of the bottom cross bar

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

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 Boiler block assembly 7

z Slightly lift the side panel.

z Hook the side panel upper cutout into the upper tie-
bar.
z Hook the rear part of the side panel to the extended
hook. 2

Fig. 40 Slot side panel into place

1 Top tie-bar
2 Extended hook
z Push against the lower end of the side panel and
secure with the rear panel using the snap nut.

Installing the top front boiler cover

Fig. 41 Fasten the side panel to the rear panel with screws
1 Snap nut
z Hook the front boiler cover with its cutout into the
upper tie-bar and push back.
z Secure the front boiler cover with two self-tapping
screws to the side panels.

NOTICE
Installation of the back boiler cover
(Î Chapter 8.8, page 41).

Fig. 42 Installing the front boiler cover

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

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 7 Boiler block assembly

Fitting the cable entry

z Screw the cable entry to the hole in the boiler back
panel.

Fig. 43 Fitting the cable entry

7.5 Positioning and leveling the boiler

z Position the boiler in its final location.
z Level the boiler horizontally by turning the adjustable
feet and using a spirit level.

Fig. 44 Leveling the boiler horizontally

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

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 Boiler installation 8

8 Boiler installation
This chapter details how to install your boiler correctly.
These details include:
– Flue connection
– Water connections
– Electrical connection
– Burner installation (field installation)
– Fuel connection

8.1 Flue connection

8.1.1 Chimney venting

Connect boiler to vertical chimney with a 6" vent pipe.
Use only venting systems that comply with local codes
and regulations. If local codes are not available, refer the
the following regulations:
– NFPA 31, Installation of Oil-Burning Equipment,
– NFPA 211, Standard for Chimneys, Fire Places and
Solid Fuel Burning Appliances,
– In Canada refer to CSA B139, Installation Code for
Oil-Burning Equipment,
– NFPA 211 requires chimney to be lined before
connecting boiler.

Inspecting and cleaning existing flue

Inspect and clean the old flue before installation of the
new boiler.
z Remove blockages and dirt from the chimney.
z Clean chimney
z Repair or replace faulty flues.
z If necessary, repair chimney with mortar and joints.

Down drafts
NOTICE
To prevent down drafts extend chimney at
least 3 feet above the roof opening at least
2 feet above any part of the roof within a
radius of 10 feet.

Minimum clearances to combustible objects

Minimum
Flue pipe Type
clearance
Double-wall L 6"
Single-wall L 18"
Tab. 13 Minimum clearances to combustible objects for flue
systems

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

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 8 Boiler installation

Minimum size of chimney

The minimum recommended chimney size is 8" x 8"
(6 3/4" x 6 3/4" inside liner) or 6" diameter with a
minimum height of 20 feet. Use a 6" flue pipe for
connection to an existing chimney.

Installing the flue pipe

z Slide 6" Insert flue pipe onto the flue outlet and
secure with 2 screws.

NOTICE
Avoid long horizontal flue pipe runs and
keep the number of bends to a minimum.

z Install flue connections between boiler and chimney

to slope up at least 1/4" per foot to the chimney. 2
z Connect the flue pipe to the chimney above the
bottom of the chimney to prevent blockages. 1
z Install cleaning and service hatches for cleaning the
flue system. Fig. 45 Installing the flue pipe
1 Flue pipe
After starting the burner, set breeching draft
2 Boiler flue outlet
to -.01 to -02 inches WC with a draft gauge. (The
overfire pressure can be positive). If necessary, install
draft controllers in the flue system to maintain the
negative pressure in the system or to meet code
requirements. Always install the draft controller in
vertical position. Use a draft gauge when making
adjustments.

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

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 Boiler installation 8

8.2 Installation of water connections

8.2.1 Installing B-Kit:

The relief valve and the pressure/temperature gauge are
mounted on the conversion nipple (included in B-Kit) on
the VK boiler supply connection as follows:
z Measure length of thread on R1¼" × 1¼" NPT
double nipple.
2
z Seal supply manifold to connection VK with the long
side to the boiler.

1
VK
RK

Fig. 46 Installing B-Kit

1 Supply manifold
2 Pressure/temperature gauge
z Seal conversion nipple on boiler inlet VK.
z Seal pressure/temperature gauge to conversion
nipple.

NOTICE
3
Do not install the pressure relief valve until
2
after the leak test (Î Chapter 8.3,
page 36). 1
The pressure relief valve must be installed
in a vertical position.

Fig. 47 Installing B-Kit

1 90°-elbow 1¼" NPT
2 Pressure relief valve
3 Conversion nipple 1" x ¾"

8.2.2 Installation of boiler drain (included in B-Kit)

z Install the boiler fill and drain valve with seal to
connector EL.
z Seal boiler drain to connection EL.
EL

Fig. 48 Installation of boiler drain

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

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 8 Boiler installation

8.2.3 Installation of system components

See the installation diagram for recommended
installation of the heating system components.
3 3 5 3 Supply
4 6

9 VK
10
1 2 8

3
3 Fill valve
7

Return

RK

Boiler drain

Fig. 49 Installation diagram

1 Pressure relief valve
2 Pressure/temperature gauge
3 Ball or stop valve
4 Air eliminator
5 System pump
6 Back flow preventer
7 Expansion tank
8 Automatic feed valve
9 Check valve
10 Purge station

8.3 Filling heating system and checking for water leaks

When the boiler is delivered assembled it is checked for
leaks at the factory. Before placing the heating system
into operation, check it for leaks to prevent leaks
occurring during operation. When supplied
disassembled (Î Chapter 7.2, page 25).
SYSTEM DAMAGE
due to overpressure during leak testing.
Pressure, control and safety equipment
CAUTION!
may be damaged by excessive pressure.
z When you carry out a leak test, make
sure that no pressure, control or safety
equipment is fitted which cannot be
isolated from the boiler water chamber. Fig. 50 Pressure/temperature gauge

Carry out the leak test at 1.5 times the standard

operating pressure and in accordance with the codes.

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

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 Boiler installation 8

Maximum Maximum site test

operating pressure pressure
30 psi (with the supplied 45 psi
pressure relief valve)
58 psi (with a different 75 psi
pressure relief valve)

z Seal pressure relief valve connection (Î Fig. 47

page 35) and all other open connection with blind
plugs.
z Close the expansion tank from the system by closing
the cap valve.
z Open the mixing and shut-off valves on the heating
water (primary) side.
z Connect the hose to the water tap. Attach a hose
filled with water onto the hose connection of the
boiler fill & drain valve, fasten with a hose clip and
open the valve.
z Slowly fill the boiler with water from the tap.
z Open the cap of the automatic air vent by one full turn
to allow air to escape.
z Slowly fill the heating system. Observe the pressure
gauge while filling.
z Close the water tap and the boiler fill & drain valve
once the required operating pressure has been
reached.
z Check the connections and pipework for soundness.
z Bleed the system via the radiator bleed valves.
z Top off with water if the pressure drops as a result of
bleeding the system.
z Installing pressure relief valve (Î Fig. 47 page 35).
z Remove the hose from the boiler fill and drain valve.

8.4 Burner installation

Only one burner that complies with the technical data of
the boiler can be mounted on boilers without integrated
burners (Î Chapter 3, page 7).
SYSTEM DAMAGE
due to incorrect burner.
CAUTION! z Only use burners which meet the
technical boiler requirements.

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

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 8 Boiler installation

z Screw studs included with the B-Kit to the burner

door.
z Fit the burner to the hole circle of the burner door.

NOTICE
Approved burners with accessories (such
as aquastat and circulator) are also
available as a package from Buderus
Hydronic Systems.

z Install burner with the correct nozzle and settings

(air, pump pressure, turbulator settings, flange
position).
4 3/8"
z Place the seal on the studs and secure the burner
with the included nuts. 5 7/8"

z Follow the manufacturer's direction for installation,

Fig. 51 Burner door mounting holes
fine adjustment and regular maintenance
procedures.

NOTICE
For the correct burner settings see the
Î documentation for the flue system and
the Î burner.

z Wire up the burner (see Î documentation for

burner).

8.5 Providing a fuel supply

Make the fuel connection in accordance with all locally
applicable regulations. We recommend the installation
of a fuel filter.
z Visually inspect the fuel pipe and clean or replace, if
necessary.
z Install a shut-off valve into the fuel supply pipe.
z Connect the fuel pipe free of stress to the boiler.
z Check the fuel line for leaks.

8.6 Aquastat installation

An aquastat controls the boiler supply temperature.
z Install aquastats in the sensor well as specified by
the installation manual.
For operating the boiler with aquastat Î Chapter 9,
1
page 42.

Fig. 52 Aquastat installation

1 Sensor well

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

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 Boiler installation 8

8.7 Electrical connections

This section only applies to boilers using Buderus
controls.
DANGER TO LIFE
from electric shock.
WARNING! z Only qualified electricians are permitted
to carry out electrical work.
z Before you open the control: shut off
electrical supply and secure against
accidental activation.
z Please observe all installation
instructions.

8.7.1 Fitting the Logamatic control panel

z Locate the push-in hooks of the Logamatic control
1
panel in the slots.
z Push the control panel towards the burner door.
z Let the flexible hooks of the control panel click into
the openings by pushing the control panel down. 2

4
Fig. 53 Fitting the control panel
1 Flexible hooks
2 Locking tabs
3 Slots
4 Openings
z Remove the Logamatic control panel cover. First
1
remove the cover screws.
z Secure the control panel with self-tapping screws.

Fig. 54 Removing the cover

1 Cover screws
2 Self-tapping screws

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

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 8 Boiler installation

8.7.2 Installation of the temperature sensor set and burner cable

SYSTEM DAMAGE
Capillary tubes may become unsound due
to severe kinking or sharp burrs.
CAUTION!
z Carefully route capillary tubes using
large radius.
1
z Route capillary tubes and sensor wiring through the 2
cable opening of the front boiler jacket and connect 3
to test port.
z Roll up surplus capillary tubes and sensor lead and 4
lay them on the thermal insulation.
5
z Route the burner cable through the cable entry in the
front boiler cover to the control panel.
z Connect the burner cable to the control in
accordance with the terminal markings.

Fig. 55 Routing and connecting cables

1 Cable entry in the front boiler cover
2 Capillary tubes and sensor cable
3 Burner cable
4 Cable entry
5 Sensor well (test port)

NOTICE
The sensor well for the aquastats is
supplied by the factory.
If you use a Buderus control, replace the 3
sensor well with the sensor well supplied
with the control. 2

z Slide temperature sensor bundle set with

compensating spring into the sensor well to the stop. 4
The plastic spiral is then pushed back automatically. 1
z Push the sensor holder (included with the control
device) over the side of the sensor well head.
Fig. 56 installing the temperature sensor set
NOTICE 1 Sensor well
Ensure good contact between the sensor 2 Plastic spiral
surfaces and the sensor well to ensure 3 Compensating spring
good temperature transfer. Use the 4 Sensor holder
compensating spring.

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

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 Boiler installation 8

8.7.3 Electrical connections and connection of additional components

Install a permanent electrical power connection in
accordance with local codes.
RISK OF FIRE
Hot components may damage electrical
wiring.
WARNING!
z Ensure that all wiring is routed in the
ducts provided or on the boiler
insulation.

z Route all cables through the cable entries to the

Logamatic control panel and connect in accordance
with the wiring diagram.

8.7.4 Strain relief installation

Secure all cable runs with cable ties (included with the
control):
z Insert the cable ties together with the cable from the
top into the slots of the clamp frame (step 1).
z Push the cable tie down (step 2).
z Push against the tie (step 3).
z Flick the toggle up (step 4).

Fig. 57 Securing cables with cable ties

8.8 Jacket panel installation

z Locate and secure the Logamatic control panel top
device cover. 1 2
z Fit the rear boiler cover.

Fig. 58 Install the back boiler cover

1 Control panel cover
2 Back boiler cover

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

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 9 Placing the boiler in operation

9 Placing the boiler in operation

This chapter describes the initial start-up procedure
regardless of the installed control device.
z Complete the start-up protocol during this process
(Î Chapter 9.9, page 46).
Further information on boiler room layout and
clearances, combustion air requirements and venting
systems and boiler operational requirements can be
found in Î Chapter 3.2, page 8.
BOILER DAMAGE
due to excessive dust and air
contamination.
CAUTION!
z Do not operate the boiler under very
dusty conditions, e. g. caused by
building work inside the installation
room.
z Install an air filter if the air supply is very
dusty (for example from unmade roads
and tracks in dusty working
environments, such as quarries, mines
etc.) or airborne seed from blossoms.

9.1 Setting the operating pressure

Set the operating pressure required before initial start-
up.
SYSTEM DAMAGE
due to material stress as a result of
temperature differentials.
CAUTION!
z Fill the system with cold water (the flow
temperature should be no more
than 100 °F).

z Adjust the red pointer of the pressure gauge to the

required operating pressure, i.e. at least 15 psi
(applicable to sealed systems).
Fig. 59 Pressure/temperature gauge for showing operating
z Top up the heating water or drain via the boiler fill and pressure and feed temperature
drain valve until the required operating pressure has
been reached.
z Vent the heating system during filling.

9.2 Check pressure relief valve

z Make sure that no persons are in the discharge area
of the pressure relief valve.
z Raise the lever on the pressure relief valve.
The pressure relief valve must open and release
pressure. If the pressure relief valve does not discharge,
it must be replaced, because system components may
be damaged by excessive pressure.

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

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 Placing the boiler in operation 9

9.3 Making the heating system operational

z Open fuel feed on the main shut-off valve.
z Switch on the heating system emergency stop switch
(if installed) and/or switch the corresponding house
circuit-breaker.

9.4 Starting up the control and the burner

For further start-up steps, follow the burner start-up
sequence. Refer to the Î burner documentation.
Switch on the heating system with the control switch.
The burner starts if a heat demand is present or if you
switch the control panel to manual.
(Î Logamatic service manual).
z Select "Manual" operation
z Set the required temperature at the boiler water
thermostat.
I 0
z Switch control on (position "I"). 2

Fig. 60 Switching on the control (for example

Logamatic 2000)
1 Boiler water thermostat
2 Main control switch

9.5 Guidelines for starting up the burner

Allow burner to operate for 15 to 20 minutes before a
combustion test. Earlier combustion tests can lead to
incorrect readings as a result of burning off the sealing
rope. We recommend checking the burner after a few
weeks of operation.
NOTICE
Incorrect burner adjustment can cause
contamination of the boiler (e.g. soot)
Faults may occur more often than normal.
Always check combustion with the
following instruments.
Never adjust burner visually.

Required instruments:
– CO2 measuring equipment
– Draft measuring equipment
– Oil pressure gauge
– Stack thermometer
– Smoke tester

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

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 9 Placing the boiler in operation

z Check the firebox pressure at the test port.

z Check the breeching draft at a test port drilled in the
vent connector (chimney vent models only). 1

9.6 Raising flue gas temperature

For the set flue gas temperature for the boiler see the
technical data (Î Chapter 3, page 7)
You may raise the flue gas temperature if you discover
during tests that the flue gas temperature is too low for
the type of chimney used (risk of condensation) by one
or several of the following measures:
– Remove flue gas baffle plates Fig. 61 Pressure test port on burner door
– Remove the flue gas check plate 1 Pressure test port

z Shut down the heating system (Î Chapter 10.1,

page 47).

RISK OF EXPLOSION
due to escaping gas.
WARNING! z Shut off the main shut-off valve if the
gas line to the gas burner must be
disconnected to open the burner door.
Route the remaining escaping gas
outdoors.

DANGER OF BURNS
by touching hot boiler parts.
CAUTION! z Wear appropriate protective gloves or
use pliers.

9.6.1 Removing flue gas baffle plates

You can remove the baffle plates in pairs to raise the flue
gas temperature.
z Open burner door by removing the two hexagon bolts
on the sides.
z Remove the baffle plates towards the front.
z Close burner door with the two hexagon bolts
(approx. 90 lbs/inch) Tighten the hexagon bolts
evenly to properly seal the burner door.
z Re-check the flue gas temperature.

Fig. 62 Removing hot gas baffle plates (example: 2. hot gas

flue)

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

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 Placing the boiler in operation 9

9.6.2 Removing the blocking plate

You can remove the blocking plate to further raise the
flue gas temperature if, after the removal of the hot gas
baffle plates, the flue gas temperature is still too low.
z Open burner door by removing the two hexagon bolts
on the sides.
z Remove blocking plate by loosening bolt.
z Re-check the flue gas temperature.

9.7 Checking the high Limit cut-out (STB)

The high limit cut-out interrupts the power supply if the
maximum permissible flow temperature is exceeded. To
enable a boiler reset and re-starting, the fault must be Fig. 63 Removing the blocking plate
removed and the system must have fallen back below
the limit.
z Check the high limit cut-out function (Î control
device service instructions).

9.8 Installing jacket panels

z Attach burner door jacket in the slots of the front
boiler cover.
z Slightly lift the burner door jacket until it hooks into
the bottom cross bar.

Fig. 64 Installing the burner door jacket

z Hook in the decorative panel in the direction of the
arrow.

Fig. 65 Fitting the decorative panel

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

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 9 Placing the boiler in operation

9.9 Start-up protocol

z Sign all start-up work as completed and enter the
relevant date.

Start-up steps Page Value measured Comments

1. Filling system and checking for leaks 36

__________ psi

2. Set operating pressure 42

vent heating system __________ psi
check operation of pressure relief valve
adjust the expansion tank pressure (Î see the expansion tank
manufacturer's documentation)

3. Check combustion air and venting system

5. Turn on control (Î refer to control service manual) 43

6. Turn on burner (Î see burner manual) 43

7. Measure flue gas temperature (adjust if required) 44

__________ °F

8. Check high limit cut-off (STB) 45

9. Adjust the control settings to customer's requirements (Î control service

manual)

10. Inform end user and hand over instructions

Confirm start-up procedure

Company stamp/signature/date

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

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 Taking the boiler out of operation 10

10 Taking the boiler out of operation

10.1 Normal boiler shut-down

z With Buderus Logamatic control: Switch the ON/OFF
switch on the control panel OFF (position "0"). This
switches the boiler and all its components OFF (for
example the burner).

I 0
1

Fig. 66 Shutting down the heating system (Logamatic 2000)

1 ON/OFF switch
z When using the aquastat: Shut off main heating
system switch (position "OFF"). This switches off the
boiler with all its components.
z Further shut-down procedure Î refer to aquastat
documentation.
z Shut off fuel supply by closing main valve.

SYSTEM DAMAGE
due to freezing temperatures.
CAUTION! The heating system can freeze up in cold
weather if it has been switched off.
z Leave the heating system switched on
Fig. 67 Heating system shut-down (with aquastat)
as long as possible.
z Protect your heating system against
freezing by draining the heating
system and hot water pipes at the
lowest possible point.

10.2 Emergency shut-down

Explain to your customer the measures required in
emergencies, for example in case of fire:
Proceed as follows in an emergency, such as a fire:
z Shut off fuel supply by closing main valve.
z Isolate the heating system from the electrical power
supply via the heating system emergency stop switch
or the building circuit-breaker.

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

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 11 Boiler maintenance

11 Boiler maintenance

11.1 Why is regular maintenance important?

Heating systems should be regularly maintained for the
following reasons:
– to achieve a high level of efficiency and to operate
the system economically (low fuel consumption),
– to achieve a high level of operational reliability,
– to maintain the cleanest possible combustion.
Offer an annual inspection and maintenance contract
(depending on requirements) to your customer. You can
check in the inspection and maintenance reports
(Î Chapter 11.6, page 52) what should be included in
such contracts.
NOTICE
You may order spare parts from your local
distributor.

11.2 Preparing the boiler for cleaning

z Shut down the heating system (Î Chapter 10.1,
page 47).

DANGER TO LIFE
from electric shock.
WARNING! z Before you open the control: shut off
electrical supply and secure against
accidental activation.

z Remove the burner door panel or the burner hood

from the boiler.
z Disconnect electrical supply to burner.

DANGER TO LIFE
through the explosion of volatile gases.
WARNING! z Work on gas components must be
carried out by qualified and authorized
personnel only.

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

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 Boiler maintenance 11

11.3 Boiler cleaning

The boiler can be cleaned with brushes and/or by a wet
method. Cleaning equipment is available as accessory.
DANGER OF BURNS
by touching hot boiler parts.
CAUTION! z Wear appropriate protective gloves or
use pliers.

z Open burner door by removing the two hexagon bolts

on the sides.

11.3.1 Cleaning the boiler with cleaning brushes

z Note the position of the flue gas baffle plates to
enable their correct re-installation later.
3
z Remove the flue gas baffle plates from the flue gas
flues.
2
z Clean the flue gas baffle plates with one of the two
cleaning brushes.
1

Fig. 68 Open the burner door

1 Combustion chamber
2 1. flue gas pass
3 2. flue gas pass
z Clean the flue passages by turning the round
cleaning brush.

Fig. 69 Brushing out the flue gas passages

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

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 11 Boiler maintenance

z Clean the combustion chamber with a flat brush.

Remove the debris from the combustion chamber,
the flue passages and the flue connection.
z Install the flue baffle plates in their original position.
z Check sealing rope on burner door. Replace
damaged or hardened sealing rope.

NOTICE
You can obtain suitable sealing rope from
your local Buderus distributor.

z Close burner door with the two hexagon bolts

Fig. 70 Brushing out the combustion chamber
(approx. 90 lbs/inch) Tighten the hexagon bolts
evenly to properly seal the burner door.

11.3.2 Wet cleaning (chemical cleaning)

When using a wet cleaning method use a suitable
cleaning agent (soot or accumulation of debris).
Proceed with the wet cleaning in the same order as
described for cleaning with brushes (Î Chapter 11.3.1,
page 49).
NOTICE
Observe the instructions for use of the
cleaning agent. You may need to proceed
differently from the method described here
in some circumstances.

z Cover the control panel with plastic to prevent spray

from entering the control panel.
z Spray cleaning agent evenly into the flue gas passes.
z Close burner door and start up the heating system.
z Heat the boiler to a temperature of at least 160 °F.
z Shut down the heating system.
z Brush out the hot gas flues.

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

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 Boiler maintenance 11

11.4 Checking the heating system

operating pressure
The system pressure for closed systems must be
12 – 30 psi (1 – 2.1 bar).
z Check system pressure
z If the pressure gauge shows less than 12 psi, the
pressure is too low. Top up with water.

SYSTEM DAMAGE
due to frequent topping up.
CAUTION! If you need to add water frequently, the
heating system may be damaged by
corrosion and lime accumulation.
z Ensure that your heating system is bled
properly. Fig. 71 Pressure/temperature gauge for showing operating
pressure and feed temperature
z Check the heating system for leaks and
proper operation of the expansion tank.

SYSTEM DAMAGE
due to material stress as a result of
temperature differentials.
CAUTION!
z Only fill the system when cold (the flow
temperature should be no more
than 100 °F).

z Add water through the feed valve.

z Vent heating system
z Check the pressure again.

11.5 Testing relief valve

The functioning of the pressure relief valve must be
checked at regular intervals (1-3 years as specified by
local codes).
z Make sure that no persons are in the discharge area
of the pressure relief valve.
z Raise the lever on the pressure relief valve.
The pressure relief valve must open and release
pressure. If the pressure relief valve does not discharge,
it must be replaced, because system components may
be damaged by excessive pressure.

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

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 11 Boiler maintenance

11.6 Inspection and maintenance protocols

z Sign all service work as completed and enter the The service and maintenance protocols can also be
relevant date. used as templates.
Service work Page Date: ______ Date: ______ Date: ______
1. Check the general condition of the heating system

2. Visual and function check of the heating system

3. Check all fuel and water components of the system for:

– leaks during operation
– leak test
– visible signs of corrosion
– signs of ageing
4. Check the combustion chamber and the heating surface for 48
contamination; shut down the system for this step

5. Check the burner (Î burner manual)

6. Check the combustion air supply and flue gas routing for function
and safety

7. Check the operating pressure, relief valve and expansion tank inlet 51
pressure

8. Check the DHW tank and corrosion anode for function (Î DHW
tank documentation)

9. Check the control settings (Î control manual)

10. Record the final checks of the inspection work, incl. measurements
and test results
Confirm service work

Company Company Company

stamp/signature stamp/signature stamp/signature

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

52 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Boiler maintenance 11

Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______
1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Company Company Company Company Company Company Company

stamp/signature stamp/signature stamp/signature stamp/signature stamp/signature stamp/signature stamp/signature

NOTICE
During the inspection if you identify any
required maintenance steps, do it as soon
as possible.

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 53
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 11 Boiler maintenance

On-demand maintenance procedures Page Date: ______ Date: ______ Date: ______

1. Shut down the heating system 47

2. Remove and clean the flue baffles 49

3. Clean the (heating surfaces) and combustion chamber, then re- 49

install the flue baffle plates in their original position.

4. Check and, if required, replace gaskets/sealing rope on the burner 50

door and burner

5. Start up the heating system 43

6. Carry out final check of the maintenance work

7. Check the function and safety in operation

Confirm professional maintenance

Company Company Company

stamp/signature stamp/signature stamp/signature

Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______

1.

2.

3.

4.

5.

6.

7.

Company Company Company Company Company Company Company

stamp/signature stamp/signature stamp/signature stamp/signature stamp/signature stamp/signature stamp/signature

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

54 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Troubleshooting 12

12 Troubleshooting
Two different types of faults are defined
– Burner faults and
– control and heating system faults.
If there is a burner fault the alarm light on the burner
comes on (Î burner manual). Such faults can generally
be reset by pressing the reset button on the burner only
once.
Control and heating system faults are indicated on the
control display if it is fitted with a display. For further
information see Î control manual.

Correcting burner faults

z Remove the burner hood if the boiler is equipped with 1
an integral burner.
z Press reset button on burner only once.

SYSTEM DAMAGE Fig. 72 Resetting the burner

due to freezing temperatures. 1 Burner

CAUTION! The heating system can freeze up in cold

weather if it has been switched off by a fault
shutdown.
z Immediately remedy the fault and
restart the heating system.
z If this is not possible, protect your
heating system against freezing by
draining the heating system and hot
water pipes at the lowest possible point.

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 55
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 13 Examples of installations

13 Examples of installations
Explanation of abbreviations

KR Check valve SH Mixing valve

MAG Expansion tank SR Adjustment for raising return temperature
PH System pump SV Air scoop
PW Domestic hot water pump THV Zone valve
WH Pressure bypass loop

THV
SV
PH

MAG

Fig. 73 Multiple circuits with circuit valves

KR
PH

SV

MAG

Fig. 74 Multiple circuits with circuit valves

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

56 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Examples of installations 13

THV

SV
PH

WH
MAG

Fig. 75 Multiple circuits of water diversion for systems with a high water volume

KR

PH
KR

PH
PW

SV
SH

MAG

Fig. 76 Multiple circuits with pumps and motor-actuated 3-way mixing valve

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 57
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 14 Spare parts

14 Spare parts
The following parts are available from your Buderus Legend for tables 14 and 15:
distributor. If there are several Buderus part numbers for x = no spare part
one item number, the numbers for the various models (x) = component of a set, only available with set
are listed in the relevant columns. Otherwise the table 0 = no picture available
shows the number of components for each model.

Boiler block and burner door (Fig. 77)

Part number
Item Description G215/40 G215/47 G215/58 G215/70 G215/85
3 section 4 section 5 section 6 section 7 section
10 Boiler block assembled 05178460 05178462 05178464 05178466 05178468

10 Boiler block unassembled 05178470 05178472 05178474 05178476 05178478

Available single components of the replacement boiler block:

20 Front section complete
Note: When ordering 63011536
also order seal no. 63006140

Available front section components:

30 Threaded stud DIN939 M12x35 5.6 03719184
40 Blank Flange lack Mod11306470, Vierk 130 05428094
50 Washer DIN125-A13-A3K (x)
60 Hexagon nut ISO4032-M12-8-A3K (x)
70 Flue Blocking plate 05626814
80 Countersunk bolt DIN7991-M8x16-Ms (x)

90 Gasket D94x120x1,5 L150 10C

Order for sealing the above flange when ordering 63006140
a front section

100 Plug G 1 1/2" 05317544

110 Gasket D48x63x1.5 mm C 4400 Klinger Sil green 02528162

115 Conversion nipple Tg no.241 black.a.i 1 1/2"X3/4" 80677076

120 Center section G215 63011537

130 Boiler nipple 119/50 Gr.2 must be sealed with red

05317071
lead putty (2045004)
140 Boiler nipple 48/50 Gr 0a must be sealed with red
05317046
lead putty (2045004)
0 Red lead putty, 0.25 kg container for sealing the
02045004
boiler nipple
0 Glue 181 "Buderus" 370 ml container for securing
05909922
sealing rope KMV(T20)

Required sealing rope: 2680 mm / center section; 2340 mm / back section

the section must be fitted with a new sealing rope at the join.

150 Sealing rope D15x4300 KMV Pack A = 2 rolls for

05830260
sealing between boiler sections
150 Sealing rope D15x4300 KMV Pack B = 3 rolls for
05830262
sealing between boiler sections

160 Back section complete G215 63011538

Available back section components

Tab. 14 Boiler block and burner door

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

58 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Spare parts 14

Part number
Item Description G215/40 G215/47 G215/58 G215/70 G215/85
3 section 4 section 5 section 6 section 7 section
170 Threaded stud DIN 939 M16x45 5.6 03719328
180 Washer DIN 125-A17-A3K (x)
190 Hexagon nut ISO 4032-M16-8-A3K (x)
200 Threaded stud DIN 939 M10x40 5.6 03719128
210 Washer DIN 125-A1.5-A3K (x)
220 Hexagon nut ISO 4032-M10-8-A3K (x)

230 Tie-bar M10x315 compl. for 3 sections 05127962 - – – –

230 Tie-bar M10x445 compl. for 4 sections – 05127966 – – –
230 Tie-bar M10x555 compl. for 5 sections – – 05127970 – –
230 Tie-bar M10x685 compl. for 6 sections – – – 05127974 –
230 Tie-bar M10x825 compl. for 7 sections – – – – 05127976

240 Gasket D125x170x2 L200 10C 63006141

250 Connection block G215 lack "US" 63012796

260 Sensor well 63032236

270 Plug G 3/4 05317714
290 Plug G 1 05317712
300 Gasket D33x44x2mm 63005462

310 Gasket for feed pipe G215 05452330

Feed pipe G215
320 Distribution tube 05436340 05436342 05436344 05436366 05436368

330 Hexagon bolt ISO4017-M8x16-Ms (x) (x) (x) (x) (x)

Boiler block components

Spare parts that are supplied with the spare boiler block
Flue connection complete G215
350 05521234
Available spare part:

340 Sealing rope GP 8x545 mm 05830718

Flue baffle Zug 2 G215 4 units in the center and

360 63019332 – 63019332 – –
bottom horizontal hot gas flues
Baffle plate Zug 3 left G215 in the center vertical
370 05347524 05347524 – – –
hot gas flue
Draft baffle plate 3 right G215 in the center vertical
380 05347526 05347526 – – –
hot gas flue

390 Hinge eyelet G215 05327454

400 Hexagon bolt ISO4017-M10x35-8.8 (x) (x) (x) (x) (x)
410 Washer DIN125-A10.5-A3K (x) (x) (x) (x) (x)
420 Hinge G215 05327451
430 Hexagon bolt DIN6921-M10x25-8.8-SW16-SV (x) (x) (x) (x) (x)
Hexagon bolt DIN6921-M10x65-8.8
440 (x) (x) (x) (x) (x)
for sealing the burner door

450 Boiler feet M10x51mm compl. 05236440

460 Gasket for flue collar DN150 compl. 05354012
Flue silencer DN150 compl. BL 690mm
470 without condensate drain; higher sound 05074544
absorption
Tab. 14 Boiler block and burner door

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 59
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 14 Spare parts

Part number
Item Description G215/40 G215/47 G215/58 G215/70 G215/85
3 section 4 section 5 section 6 section 7 section
Flue silencer DN150 compl. BL 315mm with
475 05074504
condensate drain; lower sound absorption

Flue silencer components

460 Gasket for flue collar DN150 compl. 05354012
Gasket for flue collar DN150 compl. 05354142
480
(step cuff)
Sealing rope 10x2000 GP
Sealing rope 1200mm for burner door for boiler
490 63020963
G215 with third-party burner and G215U with
Buderus burner
Burner door compl up to 72kW, burner hole
500 63015211
D 112mm G215
Burner door compl from 72kW, burner hole
500 63015212
D 130mm G215
510 Sealing rope 14x1855, GP 05830362
Gasket compound brown (cartridge 310ml) for
63014361
gluing sealing rope without residue

520 Burner door insulation compl. G215 63002402

Available spare parts:
530 Burner door panel insulation G215 63004464
540 Insulation plate for burner door G215 63004465
550 Washer DIN9021-A6.4-A3k (x) (x) (x) (x) (x)
Oval-headed screw ISO7045-M6x40-4.8-A3T
560 (x) (x) (x) (x) (x)
for fastening with packaged insulation

570 Gasket D42x52x1.5mm 05752520

580 Sight glass D49.5x5mm 05438172
590 Sight glass cover plate 05438166
600 Countersunk screw ISO7046-M5x16-Ms (x) (x) (x) (x) (x)
610 Pressure measuring port G1/8" (thread DIN288-1) 05481194

B-Kit G215 US
Components:
Supply manifold G215US
Elbow 90° 3/4 I/A
Boiler drain valve 3/4
Relief valve 3/4Mx3/4F 30PSI
Pressure/temperature gauge 1/4 NPT
Conversion nipple 1"x3/4" NPT
Plug 1" NPT 63032224
Sensor sleeve PMW-3SEE(162mm)

Bolt set B-Kit G215 US

Components:
Hexagon nut EN 1661 M8 8.8 A3k
Hexagon nut EN 1661 M10 8.8 A3k
Threaded stud DIN939 M8x30 5.6
Washer DIN125-A8.4-A3K

Tab. 14 Boiler block and burner door

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

60 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Spare parts 14

270
260 470
10
480
290
300 490
250

310 190
180
240 460
475
320
170
330

350

230 340 220

210
150
30
40 130 200
50
90 150
60 130
370
115
110

160

380

140
360
70
120 450

80 140
20
520
530
510
540
110
100
440
390
450

410
400
420 610

430
570
580
570
590 500

600 550
560
520
1023348-00-Kesselblock, Brennertür und Anbauteile G215 "US"

Fig. 77 Boiler block and burner door

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 61
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 14 Spare parts

Boiler jacket (Fig. 78)

Part number
Item Description G215/40 G215/47 G215/58 G215/70 G215/85
3 section 4 section 5 section 6 section 7 section
The components of a complete jacket
include:
Bottom bar, top bar, 2 side panels, front cover,
back cover, back panel, insulation cover for
connection block, heat shield and mounting
material.
The following must be ordered separately:
Front panel and burner cover, shield, insulation
and burner line.

10 Jacket compl. G215/-U 05261300 05261302 05261304 05261306 05261308

Available spare parts:

20 Bottom bar G215/-U 05261336
30 Hexagon bolt DIN6921-M8x12-8.8 (x) (x) (x) (x) (x)
40 Top bar G215/-U 05261334
50 Side panel compl. 506 mm long G215/-U 05261326 - - - -
50 Side panel compl. 626 mm long G215/-U - 05261328 - - -
50 Side panel compl. 746 mm long G215/-U - - 05261330 - -
50 Side panel compl. 866 mm long G215/-U - - - 05261332 -
50 Side panel compl. 986 mm long G215/-U - - - - 05261333

60 Snap nut 4.2-A3K-SNO6930-angular. (x) (x) (x) (x) (x)

70 Cover front compl. G215/-U V2 63020109
75 Cover panel 300x160 cover front 63021497
80 Flathead bolt St3.9x9.5-A3T (x) (x) (x) (x) (x)
90 Cover back compl. 227 mm long G215/-U 05261318 - - - -
90 Cover back compl. 347 mm long G215/-U - 05261320 - - -
90 Cover back compl. 467 mm long G215/-U - - 05261322 - -
90 Cover back compl. 587 mm long G215/-U - - - 05261324 -
90 Cover back compl. 707 mm long G215/-U - - - - 05261325

100 Back panel compl. G215/-U 05261314

Hexagon nut DIN6923-M10-8.8-A3K
110 (x) (x) (x) (x) (x)
with locking teeth
120 Spacer bolt M8x63.5 00475485
Hexagon nut DIN6923-M8-A3K
130 (x) (x) (x) (x) (x)
with locking teeth
150 Cable clamp 07060754

Mounting material for jacket G215/-U 05621700

Contents:
Tab. 15 Boiler jacket

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

62 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Spare parts 14

Part number
Item Description G215/40 G215/47 G215/58 G215/70 G215/85
3 section 4 section 5 section 6 section 7 section
5 flathead bolts ea. 3.9x9.5-A3T
2 hexagon bolts DIN6921-M8x12-8.8
1 cable clamp
2 snap nuts 4.2-A3K-SNO6930-angular
2 spacer bolts M8x63.5
4 hexagon nuts DIN6923-M10-8.8-A3K
with locking teeth
2 hexagon nuts DIN6923-M8-A3K-
with locking teeth

Articles that are not supplied with the jacket:

Front panel compl. G215
190 63029201
for boiler with third-party burner
Front panel plate compl. 462 mm long
200 63011712
with pressed-on unit plate G215

Boiler block insulation in plastic bag

220 Boiler block insulation G215/-U 05261060 05261065 05261070 05261075 05261076

Available spare part:

230 Retaining spring 00476378
Tab. 15 Boiler jacket

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 63
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 14 Spare parts

10

80

75 80

80

160
150
90
50 220 230
110
70
60
100

130
80

40
120

190

200

20
30 60

50

1023349-00-Kesselverkleidung G215 "US"

Fig. 78 Boiler block and burner door

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

64 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Fig. 79
SP30D Providing Domestic Priority w/ Buderus Boilers and Tanks
L1
Domestic
Heating Pump
L2 Tank Pump FOR MULTIPLE ZONES:
Circuit diagrams

Circuit diagram 1
JUMPER ON H 2

DELETE C1 2
L1 L2 T T
HEATING PUMP

Downloaded from www.Manualslib.com manuals search engine

C2
Aquastat
15 Circuit diagrams

L8148A Oil
or
ADD RELAY-BOARD AND WIRE IT WITH 2 AND L2
L8148E Gas L1 L2 L1 NO 1 NC NO 2 NC
115V 240V
C1 C2 B1 B2 AC AC

1
CONNECTED TO
POWER SUPPLY
2 L2
R W
L1 L2 L1 L2 L1 L2
3 COOL Heat

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

Tank Pump 1 Pump 2 Pump 3
Sensor
4 0
Set to 130 Pump-Relay-Board
5 Setpoint L1 L2
50 to 200 0 F
6

Burner
Oil or Gas

1 L1 L2 L1 NO 1 NC NO 2 NC
115 240
VAC VAC
On Gas Boilers G124/G234, B 1 and B2 will 120V AC
1 be connected to the Boiler Control, 24V 1

24V #18 Wire

2
R W
3 COOL Heat
Tank
Sensor
4 0
Set to 130

5 Setpoint
50 to 200 0 F
6

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
This wiring diagram is generic in scope and does not purport to address all design, installation, or safety considerations. This diagram is for reference use by code officials, designers and
licensed installers. It is expected that installers have an adequate knowledge of accepted industry practices for the equipment, procedures and applications involved.

BUDERUS HYDRONIC SYSTEMS FILE NAME : SP30D Type: SP30D AQUASTAT GENERIC WIRING SCHEMATIC

DATE : 3/12/2004 DRAWN BY: Holger Hinse APPROVED BY: Dr. Lou Vorsteveld FOR: GAS / OIL BOILER W/ L8148A OR L8148E HW AQUASTAT
15

65
 15 Circuit diagrams

Fig. 80 Circuit diagram 2

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

66 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Circuit diagrams 15

Fig. 81 Circuit diagram 3

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 67
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 15 Circuit diagrams

Fig. 82 Circuit diagram 4

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

68 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
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 Table of Key Words 16

16 Table of Key Words

A Installing thermal insulation . . . . . . . . . . . . 30
Anchor rods . . . . . . . . . . . . . . . . . . . . 22 Insulation . . . . . . . . . . . . . . . . . . . . . . 30
Aquastat . . . . . . . . . . . . . . . . . . . . . . 38 L
Assembly of boiler sections . . . . . . . . . . . . 16 L.h. closing . . . . . . . . . . . . . . . . . . . . . 27
B Leaking boiler block . . . . . . . . . . . . . . . . 25
B-Kit components: . . . . . . . . . . . . . . . . . 12 M
Blank flange . . . . . . . . . . . . . . . . . . . . 24 Main shut-off valve . . . . . . . . . . . . . . . . . 43
Boiler back panel . . . . . . . . . . . . . . . . . 28 Main switch . . . . . . . . . . . . . . . . . . . . . 47
Boiler block . . . . . . . . . . . . . . . . . . . . 58 Maintenance procedure . . . . . . . . . . . . . . 54
Boiler block leak test . . . . . . . . . . . . . . . . 25 Maintenance, subject to demand . . . . . . . . . 48
Boiler fill & drain valve . . . . . . . . . . . . . . . 24 O
Boiler room . . . . . . . . . . . . . . . . . . . . . .5 ON/OFF switch . . . . . . . . . . . . . . . . . . . 47
Burner door . . . . . . . . . . . . . . . . . . . . 58 On-site test pressure . . . . . . . . . . . . . . . . 37
Burner door installation . . . . . . . . . . . . . . 27 Original components . . . . . . . . . . . . . . . . .4
Burner installation . . . . . . . . . . . . . . . . . 37 P
Burner, guidelines for starting up . . . . . . . . . 43 Pressure relief valve . . . . . . . . . . . .35, 37, 42
C Pressure test port . . . . . . . . . . . . . . . . . 44
Cable entry . . . . . . . . . . . . . . . . . . . . . 32 Pressure/temperature gauge . . . . . . . . . . 42, 51
Capillary tubes . . . . . . . . . . . . . . . . . . . 40 Protocol, start-up . . . . . . . . . . . . . . . . . . 46
Check the temperature safety cut-out (STB) . . . 45 Protocols, inspection and maintenance . . . . . . 52
Checking for leaks (heating water side) . . . . . . 36 Providing a fuel supply . . . . . . . . . . . . . . . 38
Circuit diagrams . . . . . . . . . . . . . . . . . . 65 R
Clearances . . . . . . . . . . . . . . . . . . . . . 14 Raising flue gas temperature . . . . . . . . . . . 44
Combustion chamber . . . . . . . . . . . . . . . 49 Routing the burner cable . . . . . . . . . . . . . . 40
Compression tool . . . . . . . . . . . . . . . . . 19
S
Connect electrical power supply . . . . . . . . . . 41
Sealing rope, replacing . . . . . . . . . . . . . . . 50
Correcting burner faults . . . . . . . . . . . . . . 55
Sealing the boiler hub . . . . . . . . . . . . . . . 24
D Sensor well . . . . . . . . . . . . . . . . . . . . . 23
Disposal . . . . . . . . . . . . . . . . . . . . . . . 5 Sensor wire . . . . . . . . . . . . . . . . . . . . 40
Distribution tube . . . . . . . . . . . . . . . . . . 22 Shutting down . . . . . . . . . . . . . . . . . . . 47
E Side panels . . . . . . . . . . . . . . . . . . . . . 30
Emergency stop switch – heating system . . . . . 47 Strain relief installation . . . . . . . . . . . . . . . 41
F Supply/return header . . . . . . . . . . . . . . . . 22
Fitting adjustable feet . . . . . . . . . . . . . . . 26 T
Fitting the control panel . . . . . . . . . . . . . . 39 Technical information . . . . . . . . . . . . . . . .7
Fitting the side panels . . . . . . . . . . . . . . . 30 Test port . . . . . . . . . . . . . . . . . . . . 23, 40
Fitting the tie-bars . . . . . . . . . . . . . . . . . 29 Tools . . . . . . . . . . . . . . . . . . . . . . . . .5
Flue outlet . . . . . . . . . . . . . . . . . . . . . 24 Troubleshooting . . . . . . . . . . . . . . . . . . 55
H W
Heating circuits, multiple . . . . . . . . . . . . . . 56 Wet cleaning . . . . . . . . . . . . . . . . . . . . 50
Hinge lobes . . . . . . . . . . . . . . . . . . . . 28
Hinge pins . . . . . . . . . . . . . . . . . . . . . 27
Hot gas baffle plates, removing . . . . . . . . . . 49
Hot gas flues, cleaning . . . . . . . . . . . . . . . 49
I
If you notice a smell of gas . . . . . . . . . . . . .4
Initial start-up . . . . . . . . . . . . . . . . . . . 42
Inserting the hot gas baffle plates . . . . . . . . . 27
Installation diagram . . . . . . . . . . . . . . . . 36
Installation of boiler drain . . . . . . . . . . . . . 35
Installation of the boiler jacket . . . . . . . . . . . 28
Installing B-Kit . . . . . . . . . . . . . . . . . . . 35
Installing boiler fill and drain valve . . . . . . . . . 35
Installing the boiler cover . . . . . . . . . . . . . 31
Installing the burner door jacket . . . . . . . . . . 45
Installing the temperature sensor set . . . . . . . 40

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 69
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 Notes

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

70 Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004
Downloaded from www.Manualslib.com manuals search engine
 Notes

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

Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 11/2004 71
Downloaded from www.Manualslib.com manuals search engine
 Heating Contractor:

PRODUCTS MANUFACTURED BY

BBT Thermotechnik GmbH

35573 Wetzlar
www.buderus.de

BBT North America Corporation

50 Wentworth Avenue
Londonderry, NH 03053
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