Buderus GC 124 II User Manual

Installation and Service

Instructions

Logano GC 124 II

720 804 440 (2012/07) EN-US

Gas boiler

WARNING!

Installation, adjustment, modification, operation or maintenance of the heating system carried out by unqualified personnel may result in property damage, personal injury, and loss of life.

The directions of this installation and maintenance manual must be followed precisely.

Contact a qualified service company, service provider or the gas company if support or additional information is required.

CAUTION!

Before placing this boiler in operation observe the safety instructions of this installation and maintenance manual.

CAUTION!

The operating manual is a component of the technical documentation handed over to the operator of the heating system. Discuss the instructions in this manual with the owner or operator of the heating system and ensure that they are familiar with all information required for operation of the heating system.

In the Commonwealth of Massachusetts this boiler must be installed by a licensed plumber or gas fitter.

Keep this installation and maintenance manual available for future reference.

In the Commonwealth of Massachusetts this boiler must be installed by a licensed plumber or gas fitter.

C

6

Contents

Contents

1	Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3
	1.1	Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
	1.2	Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
2	Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4
	2.1	Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4
	2.2	National regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4
	2.3	Boiler Operating Conditions . . . . . . . . . . . . . . . . . . . . . .	4
	2.4	Tools, materials and accessories . . . . . . . . . . . . . . . . . . .	4
	2.5	Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4
3	Dimensions and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .		5
4	Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		6
5	Moving the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		6
	5.1	Moving the boiler with boiler cart . . . . . . . . . . . . . . . . . .	6
	5.2	Lifting and carrying the boiler . . . . . . . . . . . . . . . . . . . . .	7
6	Placing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		7
	6.1	Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	6.2	Leveling the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7

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

7.1 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . 7 7.2 Connecting the heating system . . . . . . . . . . . . . . . . . . . . 8 7.3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.4 Fuel gas supply connection . . . . . . . . . . . . . . . . . . . . . . 10 7.4.1 Gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7.4.2 Installation at high altitudes . . . . . . . . . . . . . . . . . . . . . . 11 7.5 Filling heating system and checking for leaks . . . . . . . . 11

8 Check openings for combustion air supply and venting . . . . 12

9 Requirements for connection to chimneys or venting

systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

10 Flue pipe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

11 Placing the heating system in operation . . . . . . . . . . . . . . . . . 14

11.1 Starting up the GC124 II . . . . . . . . . . . . . . . . . . . . . . . . 15 11.1.1 Prepare pressure measurement . . . . . . . . . . . . . . . . . . 15 11.1.2 Turning on heating system . . . . . . . . . . . . . . . . . . . . . . . 16

13 Start-up protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

14 Taking the heating system out of operation . . . . . . . . . . . . . . 20

14.1 Normal system shut-down . . . . . . . . . . . . . . . . . . . . . . . 20 14.2 Emergency shut-down procedures . . . . . . . . . . . . . . . . 20

15 Boiler inspection and maintenance . . . . . . . . . . . . . . . . . . . . . 20

15.1 Why is regular maintenance important? . . . . . . . . . . . . 20

15.2Testing the flue system, including combustion air, air inlets

	and Ventilation openings . . . . . . . . . . . . . . . . . . . . . . .	20
15.3	Inspection of the boiler and burner . . . . . . . . . . . . . . . .	20
15.4	Preparing boiler for cleaning . . . . . . . . . . . . . . . . . . . . .	20
15.5	Cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
15.5.1	Cleaning the boiler with brushes . . . . . . . . . . . . . . . . . .	21
15.5.2	Wet cleaning (chemical cleaning) . . . . . . . . . . . . . . . . .	22
15.6	Cleaning the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
15.7	Maintenance protocol . . . . . . . . . . . . . . . . . . . . . . . . . .	25
15.8	Troubleshooting the GC124 II . . . . . . . . . . . . . . . . . . . .	27

16 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

17 Electrical circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

12 Final start-up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2	GC 124 II – 6 720 804 440 (2012/07)

						Safety considerations		1
				Risk to life from electrical shock.
	1	Safety considerations
				B Disconnect the power supply to the boiler heating system before
	1.1	Key to symbols			conducting any work on it, e.g. turn off the heating system emergency
					switch outside the boiler room.
	Warnings			B It is not sufficient just to turn off the control.
				B	Do not carry out electrical work unless you are qualified for this type
			Warnings in this document are identified by a warning		of work.
			triangle printed against a grey background.	B Before disconnect electrical power completely and pad lock to
			Keywords at the start of a warning indicate the type and		prevent accidental reconnection.
			seriousness of the ensuing risk if measures to prevent	B Observe the local installation regulations.
			the risk are not taken.	Risk of fatal injury from flue gas poisoning
	The following keywords are defined and can be used in this document:			Insufficient ventilation or combustion air availability may cause
				dangerous flue gas leaks or formation.
	• NOTE indicates a situation that could result in damage to property or
				B	Make sure that inlets and outlets are not reduced in size or closed.
	equipment.
				B	If faults are not corrected immediately, the boiler must not be
	• CAUTION indicates a situation that could result in minor to medium
					operated until all faults have been corrected.
	personal injury.
				B	Inform the system operator and/or owner of the fault and the danger
	• WARNING indicates a situation that could result in severe personal
					in writing.Elektroanschluss nur durch eine Elektrofachkraft ausführen
	injury or death.
					lassen.
	• DANGER indicates a situation that will result in severe injury or death.
				When working on the flue gas venting equipment or vent damper leakage
	Important information
				of flue gases may endanger the lives of people.
				B Carefully observe proper operation of the vent damper. Do not start
			This symbol indicates important information where
					up the boiler unless the vent damper is operating properly.
			there is no risk of personal injury or property damage.
				B	Use only original parts when replacing parts.
				B When replacing the vent damper, install the new one in the specified
	Additional symbols				position.
				Risk to life by poisoning by spillage of flue gases
	Symbol Explanation
				B	If the blocked vent switch trips frequently the fault must be corrected
	B		Step in an action sequence
					and proper operation of the blocked vent switch test must be
	Æ		Cross-reference to another part of the document
					conducted.
	•		List entry	Risk to life by poisoning by leakage of flue gases
	–		List entry (second level)
				B	Make sure that the	boiler is not equipped with a thermally controlled
	Table 1
					flue gas vent damper after the open draft hood.

1.2Safety instructions

Observe these instructions for your safety.

The burner and control must be correctly installed and adjusted to ensure safe and economical operation of the gas boiler.

Read this installation and maintenance manual carefully and note the details on the boiler nameplate before placing the boiler in operation.

Risk of fatal injury from explosion of flammable gases

If you smell gas there is a danger of explosion.

B Never work on gas lines unless you are licensed for this type of work.

BMake sure that a qualified company installs the boiler, connects gas and ventplaces the boiler in operation, connects the electrical power, and maintains and repairs the boiler.

B No open flame! No smoking! Do not use lighters

BPrevent spark formation. Do not operate electrical switches, including telephones, plugs or door bells.

B Close main gas valve.

B Open doors and windows.

B Warn other occupants of the building, but do not use door bells. B Call gas company from outside the building.

BIf gas can be heard escaping, leave the building immediately, prevent other people from entering, notify police and fire departments from outside the building.

Risk of fatal injury from neglecting your own safety in case of emergency, such as with a fire

B Never put yourself at risk. Your own safety must always take priority.

Fire danger due to flammable materials or liquids

BMake sure that there are no flammable materials or liquids in the immediate vicinity of the boiler.

B Maintain a minimum distance of 15 inches from the boiler.

Installation and maintenance

BObserve all current standards and guidelines applicable to the installation and operation of the boiler heating system as applicable in your state or local jurisdiction.

BClean and service the boiler system once a year. Check that the complete heating system operates correctly.

B Immediately correct all faults to prevent system damage.

BOnly use original Buderus spare parts. Losses caused by the use of parts not supplied by Buderus are excluded from the Buderus warranty.

GC 124 II – 6 720 804 440 (2012/07)

3

2 Product Description

2 Product Description

The boiler is a low temperature gas boiler.

The boiler consists of the following main components:

•Ignition module and adjustable boiler temperature controller

•Boiler jacket and front door

•Boiler block with insulation

•Burner

The ignition module and adjustable boiler temperature controller monitor and control all electrical and operational components of the boiler.

The boiler jacket prevents energy loss and acts as soundproofing.

The boiler block transfers the heat generated by the burner to the heating water. The insulation reduces energy loss.

1

2

3 6

4

5

6 720 804 440-01.1T

Fig. 1 Logano GC124 II gas boiler

[1]Boiler front door

[2]Boiler temperature controller

[3]Ignition module

[4]Boiler block with insulation

[5]Burner

[6]Boiler jacket

2.1Correct use

The Logano GC124 II atmospheric gas boiler is designed to heat water for a hot water heating system for heating single or multiple occupancy buildings.

2.2National regulations

The heating system must comply with the relevant regulations issued by national authorities, or the regulations issued by the National Fuel Gas Code, ANSI Z 223.1.

If specified by the local regulatory authorities the heating system must comply with the regulations of the "Standard for Controls and Safety Devices for Automatically Fired Boilers," ANSI/ASME CSD-1.

Carbon monoxide detectors must be installed as specified by the local regulations. The boiler must be serviced annually (Æchapter 15, page 20).

2.3Boiler Operating Conditions

The hot water piping system must comply with the current legislation and local regulations. If an existing boiler is replaced, the complete hot water piping system must be inspected to ensure that it is in perfect condition to ensure safe operation.

Maximum boiler temperature:	220 °F
Maximum operating pressure:	58 psi

Table 2 Boiler Operating Conditions

2.4Tools, materials and accessories

You need standard tools for the installation and maintenance of the boiler as used in boiler heating system installation and oil, gas and water installations.

The following additional items will also be useful:

•Boiler cart with strap.

•Cleaning brushes and/or chemical cleaning agents for wet cleaning of the cast iron heat exchanger.

2.5Disposal

BDispose of the packaging material in an environmentally prudent fashion.

BDispose of any components of the heating system that require replacement in an environmentally prudent fashion.

4	GC 124 II – 6 720 804 440 (2012/07)

Dimensions and Connections	3

3 Dimensions and Connections

	2
	VK 1¼"
3/8	GAS ½"	(GAS ½")*
EL ¾"	RK 1¼"
		6 720 804 440-02.1T

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

* optional connection
VK	Boiler supply
RK	Boiler return
EL	Boiler drain
GAS	Gas connection
Dimensions
		Boiler			Vent	Min. relief	Number of	Water
		input						volume
Boiler size			A	B	connection II	valve capacity	Orifices		Dry weight
		Btu/hr	Inches	Inches	Inches	lb/hr	Qty.	US Gal.	lbs
18/3		74000	13 1/8"	8"	5"	62	2	2.4	228
25/4		103000	16 3/4"	8 2/3"	5"	86	3	2.9	287
32/5		132500	20 3/8"	9 1/2"	6"	110	4	3.4	349.5

Table 3 Dimensions/specs for GC124 II

For the size and dimensions of the main gas orifices, refer to Æchapter 16, page 29.

6 720 804 440-03.1T

Fig. 3 Pressure drop/boiler

GC 124 II – 6 720 804 440 (2012/07)

5

4 Scope of delivery

4	Scope of delivery
B	Check packaging upon receipt of delivery for damage.
B Check delivery for completeness.
Component		Qty	Packaging method
Boiler, complete		1	1 palette
B-kit components:		1	1 cardboard box1)
•	1-1/4" supply
	manifold
•	30 psi relief valve
•	long shank boiler
	drain (¾")
•	¼" pressure/
	temperature gauge
•	90°-elbow
	(1¼" x 1" NPT)
•	90°-elbow
	(1¼" x 1¼" NPT)
•	90°-elbow (¾" NPT
	nipple)
•	nipple1" NPT
•	nipple 1¼" NPT
Vent damper		1	1 cardboard box1)
Circulator with whip		1	1 cardboard box1)
Technical documents			1 plastic package

Table 4	Scope of delivery
1) On Palette
Accessory		Qty
Cleaning Brush		1
Table 5	Scope of delivery

5 Moving the boiler

This chapter describes how to move the boiler safely into place.

NOTICE: System damage due to uneven and rough surfaces.

BObserve the transport diagrams on the packaging to protect the sensitive components from damage due to rough surfaces. Handle the product with care.

Protect all boiler connections from dirt if the boiler is not installed immediately following removal from packaging.

Dispose of the packaging material in an environmentally prudent fashion.

5.1Moving the boiler with boiler cart

Move the boiler with packaging in tact and on its pallet as much as possible.

B Remove packaging straps and cardboard box from pallet.

B Remove screws that secure the boiler base to the wood pallet.

BPick up boiler base from one side and slide to the edge of the pallet. Place a steel pipe as roller under the boiler base. Place additional steel pipes under the boiler base and roll the boiler to its final destination.

6 720 804 440-04.1T

Fig. 4 Moving the boiler with rollers

CAUTION: Risk of injury due to improper securing of the boiler during transport.

BUse a boiler coart or dolley and strap for moving the boiler

B Secure boiler on the boiler cart.

BRemove the front door during lifting or transport to prevent unintentional opening.

BSet the boiler cart or dolley on the front side of the boiler and put a piece of cardboard between the two to prevent scratches.

1

6 720 804 440-05.1T

Fig. 5 Moving the boiler with dolley or boiler cart.

[1] Additional card board for protection.

6	GC 124 II – 6 720 804 440 (2012/07)

B Secure boiler on the boiler cart.

B Move boiler to desired location.

B Place the boiler at its final postion.

5.2Lifting and carrying the boiler

The boiler can be picked up at the both long sides of the boiler as shown.

CAUTION: Risk of injury due to carrying heavy loads.

BLift and carry the boiler with at least four people at the designated side panel locations.

6 720 804 440-06.1T

Fig. 6 Lifting and carrying the boiler

6 Placing the boiler

This chapter explains how to place the boiler and position it in the boiler room.

NOTICE: System damage due to frost.

B Place the boiler in a frost-free room.

The boiler is very heavy when filled with water. Check that the floor can bear the weight before installation.

6.1Clearances

The GC124 boiler is approved for closet installation. The following minimum distances must then be maintained:

•front: 2",

•sides: 2",

•behind open draft hood: 6",

•above boiler top panel: 30".

A space of at least 33 inches is recommended in front of the boiler with the door removed to allow sufficient access space for operation and maintenance. When the door is closed, a minimum clearance of 2 inches is required at the front and sides, 2 inches clearance is also required for the flue pipe and 30 inches clearance to the ceiling. The installation location and the base must be smooth and horizontal.The boiler may be installed on a flammable base, but not on carpet.

		6
Placing the boiler

1

2

3

6 720 804 440-07.1T

Fig. 7 Required clearances in the boiler room

[1]Recommended service clearances

[2]Required minimum clearances

[3]Burner tray access door with combustion air opening as required per ANSI Z.223.1

6.2Leveling the boiler

Level the boiler in both horizontal directions.

BLevel the boiler using a level and place small wedges (not supplied) for leveling purposes.

7 Boiler installation

This chapter describes how to install the boiler. This includes the following tasks:

•Connecting the heating system

•Electrical connection

•Gas supply piping connection

7.1Preparing for installation

BUnpack all boxes and containers and check all parts against the packing lists to make sure that everything has been supplied.

Every boiler is carefully inspected and tested before it leaves the factory. However, if you discover any damage or missing parts, please inform your supplier immediately. Before disposing of packing material, make sure that no parts are still in it.

For better access remove the front door.

GC 124 II – 6 720 804 440 (2012/07)

7

7	Boiler installation
7.2	Connecting the heating system
	NOTICE: Boiler damage due to moisture.		3
	B Protect the components of the gas ignition system
	from moisture (dripping, spray, rain) during
	installation of the boiler, during operation and during
	maintenance work (such as replacing the pump,
	replacing the control, etc.).
	NOTICE: System damage due to overheating as a result	1	2
	of a low water condition.
	B Note that a boiler installed above the level of the
	heating system must be equipped with a low-water
	cut-off. The low-water cut-off must be installed during
	installation of the boiler and placed above the water	2	2
	level in the boiler without any means of shutting the
	water off between the boiler and low water cut-off
	(Æfigure 8).
	NOTICE: System damage due to high temperature		4
	variations in the heating system.
	B If the boiler is operated in connection with a
	refrigeration system, make sure that the pipes for the
	refrigerated liquid are connected in parallel to the
	boiler system with suitable valves to prevent the
	refrigerated liquid from entering the boiler.
	B The piping system of a boiler connected to the heating
	coils of hydro-air heating systems that may be	2	2
	exposed to the circulation of cooled air must be
	equipped with a flow-control valve or some other
	automatic system for preventing the boiler water from
	circulating by gravity during the cooling cycle.	1	2
			6 720 804 440-08.1T
		Fig. 8 Low-water cut-off installation

[1] Boiler [2] Radiator

[3] Heating system with low-water cut-of [4] Heating system without low-water cut-off

8	GC 124 II – 6 720 804 440 (2012/07)

Boiler installation	7

Installation of B-kit

The relief valve and the pressure/temperature gauge are mounted on the boiler supply manifold which is attached to the VK (supply) connection of the boiler (included in B-kit).

Installing boiler supply VK:

BRemove factory installed plastic inserts from boiler supply (VK), boiler return (RK) and boiler drain (EL) connections.

BInstall the 1¼"NPT nipple into boiler supply, the 1" NPT nipple into boiler return and ¾" male NPT drain valve into boiler drain connection.

BInstall 90° 1¼" x 1¼"NPT on 1¼" NPT supply nipple and face upward and install 90° 1¼" x 1"NPT elbow on return nipple and face in desired direction.

BInstall GC124 1¼" x 1¼"NPT supply manifold into supply connection (VK) of the boiler. Do NOT place on return connection of the boiler!

BInstall first 90° ¾" street elbow in upper ¾" NPT tapping of GC124 1- 1/4" supply manifold and install pressure relief valve into this ¾" tapping. Make sure to orient the discharge of the relief valve horizontally. Install the temperature/pressure gauge in the lower 3/4" tapping of the supply manifold.

	1
	2
	3		VK
	4
			6
	5
		EL
	7
		RK
	8
		9	6 720 804 440-09.1T
	Fig. 9 Installation of B-kit

[1]Pressure relief valve ¾"

[2]90° 3/4" street elbow

[3]GC124 1-1/4" supply manifold

[4]Pressure & temperature gauge

[5]90° 1-1/4" NPT elbow

[6]1-1/4" x 1" NPT nipple

[7]Boiler drain ¾" NPT (backside of boiler)

[8]90° 1-1/4" NPT elbow

[9]1" NPT nipple

Install the relief valve after the leak test. (Æchapter 7.5, page 11).

The relief valve must be installed in a vertical position. The relief valve must also be installed in accordance with the requirements of the ANSI/ASME Boiler and Pressure Vessel Code, Section IV.

We recommend installing a y-strainer (accessory) in the boiler return connection to reduce build-up of debris on the water side inside the boiler.

Ensure compliance with all state and local regulations pertaining to the installation of boiler systems.

WARNING: Fire danger due to exposure to hot water pipes.

BMaintain a minimum clearance of two inches between non-insulated pipes carrying hot water and combustible walls and surfaces in the boiler room.

A minimum of 1" high quality pipe insulation is required to permit direct contact with combustible surfaces.

7.3Electrical connections

The electrical connections of the boiler must be made as specified by the local codes and the current regulations of the National Electrical Code, ANSI/NFPA–70.

The boiler must be grounded as specified by the regulations of the relevant local authorities; otherwise follow the regulations of the National Electrical Code, ANSI/NFPA–70.

The boiler is fully functional with the factory installed aquastat and the field installed vent damper and heating system circulation pump.

When making the electrical connections please observe the following guidelines:

BPerform only electrical work, if you possess the required certification for such work. When you do not have the required certification, have the electrical work performed by a certified electrician.

B Observe all local and state installation regulations.

Power supply connection.

Install incoming power to the boiler per local and state codes.

B Install an ON/OFF switch near the boiler per local code requirements.

6 720 804 440-10.1T

Fig. 10 ON/OFF switch (emergency shutoff switch)

GC 124 II – 6 720 804 440 (2012/07)

9

7 Boiler installation

Description of field installed wiring connections using factory supplied junction box.

BRemove two knock-outs from the left side of boiler panel to route electrical feed and pump power into junction box.

B Route electrical power from the outside into junction box.

BInstall a metal strain relief for the incoming power line on outside of left boiler jacket panel. (Æfigure 12).

BJust use supplied wiring nuts and double proper wiring before powering up the boiler.

When making the electrical connections use only wires that are approved for electrical use.

Refer to the wiring diagrams for electrical details (Æchapter 17, page 30) .

WARNING: Risk to life from electrical shock.

BWhen conducting maintenance work label all cables before disconnecting them.

BIf cables are connected incorrectly the system may not operate correctly with possibly dangerous consequences.

BCheck that the heating system functions correctly after any maintenance work.

WARNING: Fire danger.

Hot boiler components may damage electrical wiring.

BMake sure that all cables are routed in the ducts or on the boiler insulation.

1

2

3

6 720 804 440-11.1T

Fig. 11 Electrical junction box

[1]Electrical junction box (Inside of jacket cabinet)

[2]Incoming line voltage wiring

[3]Furnished wiring nuts.

6 720 804 440-12.1T

Fig. 12 Strain relief for shielded electrical wiring

7.4Fuel gas supply connection

7.4.1 Gas connections

For the gas pipe diameter required for the installation please see table 6 and table 7 (Æpage 11). Make sure that the pipe fitting has the correct thread size.

Make sure that a sediment trap is installed at the inlet for the gas supply pipe to the boiler. A manual stop valve must be installed outside the boiler jacket if required by the local code. We recommend installing a manual shut-off valve in the main gas pipe to the boiler. The gas pipe must be fastened outside the boiler.

The local codes must be observed during installation of the gas piping connections, otherwise the regulations of the National Fuel Gas Code, ANSI Z 223.1 must be followed.

B Install gas piping without any undue stress on the piping.

BThe Commonwealth of Massachusettes prohibits the use of copper tubing for the gas line.

WARNING: Danger of explosion.

Leakage from the gas pipes and gas connections may cause an explosion.

B Use soap solution to find leaks.

1

2

3

6 720 804 440-13.1T

Fig. 13 Gas piping connection to gas valve – right or left side

[1]Gas feed

[2]Manual shut-off valve

[3]Sediment trap

10	GC 124 II – 6 720 804 440 (2012/07)

Boiler installation	7

Gas carrying capacity (Æchapter 16, page 29)

Nominal	Equivalent lengths for pipe fittings in feet
	Pipe fitting type
diameter
of iron	90°-	T-piece	Shut-off	Gas shut-off
pipe	angle		valve
(inches)	Equivalent lengths in feet
1/2	1.4	2.7	0.3	0.80
3/4	2.1	4.1	0.5	1.25
1	2.6	5.2	0.6	1.6
1 1/4	3.5	6.9	0.8	2.15
1 1/2	4.0	8.0	0.9	2.50
Table 6 Equivalent lengths for pipe fittings
Length of	Gas pipe supply volume in cubic feet of gas per hour1
pipe in
feet	1/2	3/4	1	1 1/4	1 1/2
10	132	278	520	1060	1600
20	92	190	350	730	1100
30	73	152	285	590	890
40	63	130	245	500	760
50	56	115	215	440	670
75	45	93	175	360	545
100	38	79	160	305	480
150	31	64	120	250	380

Table 7 Gas pipe supply volume

1Maximum gas supply volume in cubic feet per hour, based on

a specific gas weight of 0.60 and a gas pressure of 0.5 psi or less and a pressure gradient corresponding to a water column of 0.3 inches.

Disconnect the boiler with the manual shut-off valve and physically separate the boiler from the gas piping if the gas piping system is pressure tested with a test pressure greater than 1/2 psi.

If the gas supply pipe system is pressure tested at a test pressure of 1/2 psi or less, it is sufficient to disconnect the boiler from the gas pipe system by closing the manual shut-off valve.

Use only sealant that is resistant to corrosion by LPG for pipe connection. Only a small amount of sealant must be applied to the external thread of the pipe connections.

If you wish to convert the boiler to propane, please contact Buderus for the required conversion components. Do not attempt to convert the boiler without the approved Buderus propane conversion parts and the relevant technical documentation. The technical documentation is included with the propane conversion parts.

7.4.2 Installation at high altitudes

The boiler is designed for installation at altitudes below 8500 feet above sea level.

If the installation location is over 8500 feet above sea level, please contact Buderus for another product option as the GC124 is not approved above 8500 feet operation.

NOTICE: System damage due to dirt.

If the boiler is assembled and not in use, note the following:

BProtect the boiler connections from dirt by closing the connections.

7.5Filling heating system and checking for leaks

The boiler is tested for leaks at the factory. Before placing the heating system into use, check the entire system for soundness to avoid leaks occurring during operation.

Water treatment

Have the water analyzed before filling the heating system. The water may require treatment as a result of the analysis.

Please consult the local water supply company if the water is extremely hard or has a pH level below 7.0.

NOTICE: System damage due to overpressure during the leak test. Pressure, control or safety components may be damaged by high pressure.

BBefore conducting the leak test make sure that no pressure, control or safety components that cannot be disconnected from the water compartment of the boiler are installed.

Carry out the leak test at 1.5 times the normal operating pressure and as specified by the local codes as follows:

Maximum operating pressure		Maximum test pressure
30 psi	(based on supplied relief	45 psi
	valve)
58 psi	(with special relief valve)	75 psi

Table 8 Pressure Test

BClose connection for relief valve (Æfigure 14, page 12) and all other open connections with plugs.

BDisconnect the expansion tank from the system by closing the expansion tank shut-off valve.

B Open mixing and shut-off valves on hot water side.

B Fill boiler slowly with water from the feed water connection. B Open automatic vents slightly to allow the air to escape.

BSlowly fill heating system. Observe pressure display on pressure gauge during this process.

B Check connections and pipes for leaks.

BBleed heating system through the bleed valves on the radiators or other air elimination components or high points in the system.

B If the pressure drops during air bleeding, water must be added. B Install pressure relief valve (Æfigure 14, page 12).

GC 124 II – 6 720 804 440 (2012/07)

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