Buderus Logano G515 Installation And Service Instructions Manual
Low-temperature
oil/gas boiler
WARNING: If installation, adjustment, modification,
operation or maintenance of the heating system is carried
out by an unqualified person, this may result in personal
injury or property damage.
The directions of this installation manual must be followed
precisely.
If support or additional information is required, contact a
qualified service company, service provider or the gas
company.
WARNING:
Observe the safety instructions of this installation manual
before placing the heating appliance in operation.
The operating manual is a component of the technical
documentation and must be handed over to the operator
of the heating system. Explain to the owner or operator
how to use the heating system using the operating instructions. Make sure that he has been familiarized with all
information required for the operation of the heating system..
NOTICE: If the storage tank will be installed in Massachusetts, it must be installed by an installer or dealer who is
registered there.
This manual is available in the English and French lan-
6 720 642 624-00.1O
guage.
Please keep this manual for future reference.
Installation and Service Instructions
Logano G515
Boilers for oil/gas-fired power burners
6 720 647 208 (2014/09) US/CA
Read carefully prior to installation and maintenance.
Contents
About this manual
The appliance conforms to the basic requirements of the
relevant directives.
The conformity has been confirmed.
The corresponding documentation and the original
Declaration of Conformity are on file with the
manufacturer.
Contents
1 Guideline to symbols and safety instructions . . . . . . . . . . . . . 3
1.1 Guideline to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
This installation and maintenance instructions contain important
information for the safe and proper installation, initial start-up and
maintenance of the oil/gas-fired boiler Logano G515.
These installation and maintenance instructions are designed for
specialists, who, due to their vocational training and experience, are
knowledgeable in handling heating systems and oil and gas installations.
The oil/gas-fired boiler Logano G515 is available in two variants
(disassembled and assembled).
These installation and maintenance instructions explain the installation
and maintenance of both boiler types.
2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Compliance with standards and regulations . . . . . . . . . 6
2.4 Additional regulations for installations in the
Commonwealth of Massachusetts . . . . . . . . . . . . . . . . . .7
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Logano G515 – Delivery as a pre-assembled block . . 10
4.2 Logano G515 – Delivery in loose sections . . . . . . . . . . 10
5 Transporting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Positioning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1 Tools and auxiliary materials . . . . . . . . . . . . . . . . . . . . . 11
6.1.1 Boiler assembly tool size 2.2 . . . . . . . . . . . . . . . . . . . . . 11
6.1.2 Boiler assembly tool size 2.3 (
complete in the toolbox) . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Recommended wall clearances . . . . . . . . . . . . . . . . . . . 12
6.3 Installing the boiler on a boiler base or foundation . . . 12
7 Boiler block assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.1 Assembly of a boiler block from sections . . . . . . . . . . . 13
7.2 Joining the boiler block assembly
(delivery as loose sections) . . . . . . . . . . . . . . . . . . . . . 14
7.3 Setting up the boiler block – (assembled block) . . . . . 18
7.4 Inserting the supply pipe (parts crate) . . . . . . . . . . . . . 18
7.5 Installing the sensor well . . . . . . . . . . . . . . . . . . . . . . . . 18
7.6 Leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.6.1 Carrying out leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.6.2 Sealing leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.7 Boiler water connections . . . . . . . . . . . . . . . . . . . . . . . . 20
7.8 Installing draft diverter, baffles and burner door . . . . . 20
7.8.1 Positioning the draft diverter . . . . . . . . . . . . . . . . . . . . 20
7.8.2 Screwing cleanout cover onto rear section . . . . . . . . . 20
7.8.3 Fitting the burner door . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.8.4 Hot gas check plates on front section . . . . . . . . . . . . . . 21
7.8.5 Insert the flue gas baffle plates . . . . . . . . . . . . . . . . . . . 22
7.9 Installation of the boiler jacket . . . . . . . . . . . . . . . . . . . 22
7.9.1 Mount the brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.9.2 Fitting the profile rails . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.9.3 Fitting the thermal insulation . . . . . . . . . . . . . . . . . . . . 24
7.9.4 Fitting side panels and top covers . . . . . . . . . . . . . . . . 27
Logano G515 – 6 720 647 208 (2014/09)2
Guideline to symbols and safety instructions
1
8 Connecting the boiler on the flue gas side . . . . . . . . . . . . . . . 31
8.1 Fitting the vent pipe sealing collar (accessory) . . . . . . 31
8.2 Installing a flue gas temperature sensor (accessory) . 31
9 Installing the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.1 Installing the control panel . . . . . . . . . . . . . . . . . . . . . . 32
9.2 Fitting temperature sensor assembly
and burner cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 Mounting the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
11 System start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.1 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.2 Commissioning the system . . . . . . . . . . . . . . . . . . . . . . 35
11.3 Start up the control panel . . . . . . . . . . . . . . . . . . . . . . . 35
11.4 Initial burner start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.5 Raising flue gas temperature . . . . . . . . . . . . . . . . . . . . . 36
11.5.1 Removing heat exchanger baffles . . . . . . . . . . . . . . . . . 36
11.5.2 Removing hot gas check plates . . . . . . . . . . . . . . . . . . . 36
11.5.3 Increasing the flue gas temperature slightly . . . . . . . . . 36
11.6 Commissioning log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12 Shutting down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
12.1 Shutting down the heating system
via the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
12.2 Shutting down the system in an emergency . . . . . . . . . 38
13 System inspection and maintenance . . . . . . . . . . . . . . . . . . . 39
13.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.2 Why is regular maintenance important? . . . . . . . . . . . . 39
13.3 Cleaning the boiler with cleaning brushes . . . . . . . . . . 39
13.4 Wet-cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 41
13.5 Checking the operating pressure . . . . . . . . . . . . . . . . . 41
13.6 Filling with boiler water and purging the system . . . . . 41
13.7 Inspection and maintenance logs . . . . . . . . . . . . . . . . . 42
1 Guideline to symbols and safety instructions
1.1 Guideline to symbols
Warnings
Warnings are indicated in the text by a warning triangle
and a gray background.
Signal words at the beginning of a warning are used to indicate the type
and seriousness of the ensuing risk if measures for minimizing damage
are not taken.
• NOTICE indicates that damage to property may occur.
• CAUTION indicates possible minor to medium personal injury.
• WARNING indicates possible severe personal injury.
• DANGER indicates a potential for loss of life.
Important Information
Important information neither indicating personal injury
nor damage to property are marked with this symbol.
They are separated by lines above and below the text.
Additional symbols
Symbol Explanation
▶ Sequence of steps
Cross-reference to other points in this document or to
other documents
• Listing/list entry
– Listing/list entry (2nd level)
Table 1
14 Troubleshooting burner faults . . . . . . . . . . . . . . . . . . . . . . . . . 45
15 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Logano G515 – 6 720 647 208 (2014/09) 3
1
Guideline to symbols and safety instructions
1.2 Safety instructions
Danger from failing to consider your own safety in an emergency
such as a fire
▶ Never risk your own life. Your own safety must always take the
highest priority.
Risk due to oil leaks
▶ When using oil as the fuel, national regulations hold the operator
responsible for immediately asking a specialist contractor to remedy
oil leaks the moment they are discovered.
If you smell gas
▶ Close the gas shut-off valve.
▶ If you hear gas escaping, evacuate the affected area immediately.
▶ Open the windows.
▶ Do not operate any electrical switches or equipment such as
telephones, power plugs and doorbells.
▶ Extinguish all open flames.
▶ Do not smoke.
Do not use lighters.
▶ Warn all occupants of the building, but do not ring doorbells.
▶ Call your gas utility company and your local heating contractor from
outside the building. If necessary, notify police or the fire
department.
If you smell flue gas
▶ Switch OFF the appliance.
▶ Open windows and doors.
▶ Inform a trained and certified heating contractor.
Danger of electric shock when the control panel is open
▶ Always de-energize the connection before working on electrical parts
(circuit breaker).
▶ Take provisions against unintentional reconnection.
Installation, conversion
Only have the appliance installed or modified by a trained and certified
heating contractor.
Never modify any parts that carry flue gas.
Never close the outlet of safety valves. Water may be expelled from any
safety valve during heat-up.
Inspection and maintenance
The operator is responsible for safety and environmental compliance of
the heating system.
Sign a maintenance and inspection contract with a trained and certified
contractor, covering an annual inspection and demand-dependent
maintenance. This guarantees high efficiency and environmentally
sound combustion.
Instructing the customer
▶ Instruct customers about the functions and operation of the
appliance.
▶ Inform the customer that they must not carry out any modifications
or repairs.
▶ Only use the boiler for its intended purpose and only when it is in
working order.
Disposal
▶ Dispose of packaging in an environmentally responsible manner.
▶ All heating system components that have to be replaced should be
disposed of in environmentally-responsible manner at an authorized
disposal site.
Other important information
▶ If the system overheats or the gas supply does not shut off, do not
switch off or disconnect the power supply to the pump. Instead, shut
off the gas supply somewhere else separate from the heating system.
Danger of poisoning from flue gas if supply of combustion air is
insufficient
▶ Safeguard supply of combustion air.
▶ Do not cover or reduce the size of ventilation openings in doors,
windows and walls.
▶ Safeguard sufficient supply of combustion air also for appliances
installed at a later date, e.g. kitchen exhaust fans, clothes dryers, and
air conditioning units with vent to the outside.
▶ Never operate the appliance if the supply of combustion air is
insufficient.
Combustion air / room air
To prevent corrosion, keep the supply of combustion air / room air free
of corrosive substances (e.g. halogenated hydrocarbons that contain
chlorine or fluorine compounds).
Danger of explosion of flammable gases
▶ Only employ a trained and certified contractor to carry out work on
the gas train.
Explosive and easily combustible materials
Never use or store easily combustible materials (paper, thinners, paints,
etc.) near the appliance.
Logano G515 – 6 720 647 208 (2014/09)4
2 Product description
4
Product description
The Logano G515 oil/gas-fired boiler is supplied with or without a burner
You can obtain undrilled or predrilled burner plates (hole pattern
depends on burner) as accessories from Buderus.
The predrilled burner plate is included in the scope of delivery for the
1
Logano G515 with oil or gas-fired fan-assisted burners.
NOTICE: Risk of system damage from use of incorrect
burner.
▶ Only use burners that meet the technical
requirements of the oil/gas-fired boiler Logano
G515 ( Chapter 3, page 8).
2
2
3
1
Fig. 1 Oil/gas-fired boiler Logano G515
[1] Boiler shell (jacket)
[2] Thermal insulation
[3] Boiler heat exchanger
[4] Control panel assembly
1
1
6 720 642 624-01.1O
The main components of the Logano G515 oil/gas-fired boiler are:
•Boiler block ( Fig. 1, [3]) The boiler heat exchanger transfers the
heat generated by the burner to the boiler water.
• Boiler shell (jacket, ( Fig. 1 [1] and Fig. 2, [1]), thermal insulation
( Fig. 1, [2]). The boiler jacket and thermal insulation minimize
energy loss.
•Control panel ( Fig. 1, [4]). The control panel is designed to
monitor and control all electrical components of the Logano G515
oil/gas-fired boiler.
Observe all standards and guidelines applicable to the
installation and operation of the system in your country.
Please observe the information on the boiler rating plate.
To prevent boiler contamination, we recommend
installing a dirt trap in the water system.
As a basic rule, flush existing systems before connecting
the boiler.
Install a desludging unit in the boiler return to prevent
damage to the boiler.
1
Fig. 2 Front jacket
[1] Boiler shell (jacket)
Logano G515 Heating oil Liquid propane (LPG) Natural gas (NG)
Remarks The Logano G515 boiler can be operated with the specified fuels. Select a burner suitable for use with the fuels specified for the
Logano G515 boiler.
The output figures shown in the Tab. “Technical Data” are nominal power figures.
Carry out maintenance and cleaning procedures annually. Check that the entire system is functioning correctly.
Immediately remedy faults.
If heating oil is used, shorter maintenance intervals may be necessary depending on the operating time.
Table 2
Logano G515 – 6 720 647 208 (2014/09) 5
6 720 642 624-02.1O
Fuels
2
Product description
2.1 Designated use
The Logano G515 oil/gas-fired boilers have been designed for the
heating of water.
The Logano G515 can be operated with oil, gas, and combination
burners. For a list of the approved burners, please contact Bosch
Thermotechnology Corp.
This boiler can be operated with an aquastat, the Logamatic 4000, and
other control systems.
2.2 Operating conditions
Thermostream technology is a unique feature of Buderus cast iron
boilers. Return water is preheated and mixed within the boiler before it
comes in contact with the heating surface of the combustion chamber.
The Thermostream technology ensures there is an even temperature
distribution in the boiler and avoids condensate forming within the
combustion chamber. This unique feature reduces thermal stress, the
main cause of failure of traditional cast iron boilers. The advantage of
this technology is the maintenance of the minimum operating
temperature of the boiler ( Tab. 3); this makes the installation of a
shunt pump unnecessary. This way, the costs for the pump itself and its
power consumption, as well as possible failure costs are saved. The
minimum boiler operating temperature as shown in the table below must
be reached within 10 minutes and then be maintained while the burner
is running.
Control of all heating zones
with Buderus 4000
Minimum flow rate none
Minimum return temperature °F ( °C) none
Minimum operating temperature oil boiler
Minimum operating temperature gas boiler
Maximum supply temperature °F ( °C) 212
Maximum operating pressure PSI (bar) 87 (6)
1)
1)
°F ( °C) 122 (50)
°F ( °C) 122 (50) 140 (60)
2)
/2483) (1002)/1203))
External controls (BMS)
or Aquastat control
Time constant of the temperature controller sec 40
Time constant of the monitor/limiter sec 40
Table 3
1) This temperature has to be reached within ten minutes of the burner starting and has to be maintained whilst the burner is firing.
2) The maximum supply temperature is 212 °F (100 °C), if the boiler is operated as hot water boiler.
3) The maximum supply temperature is 248 °F (120 °C), if the boiler is operated as a hot water generator.
This operating condition can be easily achieved by the controls
monitoring the boiler temperature and reducing the flow rate through
the boiler until the required temperature is reached. This is then
maintained by continuing to control flow based on the boiler water
temperature. The controls can reduce the flow rate by closing the valves
on the mixed heating circuits, modulating the boiler primary pumps or by
closing the motorized butterfly valves or by having a motorized valve in
the boiler return on a single boiler installation. The Buderus 4000 series
control panel can manage this process or it can be completed by the
BMS.
If it is not possible for the control panel to regulate the flow sufficiently to
meet this operating condition, then a shunt pump circuit must be fitted
to avoid the type of thermal stress that all boilers would experience in
these conditions. This shunt pump circuit can be controlled either with a
Buderus 4000 control panel or with a third-party controller. Failure to
ensure that the operating condition is maintained may lead to thermal
stress in the boiler and eventual failure of the sections which would be
outside the scope of the warranty.
2.3 Compliance with standards and regulations
Installation and operation of the system must comply with all applicable
codes, regulations and statutory requirements.
Installation, connection of the fuel supply and flue connector,
commissioning, connection of the electrical power supply, servicing and
repair may only be carried out by trained and certified heating
contractor. Only registered gas fitters may carry out work on the gas
train.
The system must be cleaned and serviced once a year. The operation of
the complete system must be tested at the same time. Any faults must be
corrected immediately.
The design and mode of operation of this boiler comply with the
American National Standard ANSI Z21.13/CSA4.9, latest edition for
Gas Fired Low Pressure Steam and Hot Water Boilers.
Other confirmed approvals and certifications are indicated by labels on
the boiler.
The heat exchanger has been designed and certified in accordance with
the ASME Boiler and Vessel Code, Section IV.
Logano G515 – 6 720 647 208 (2014/09)6
Product description
2
Installation of the wall mounted condensing gas boiler must comply with
all applicable codes and regulations imposed by the national, Federal or
local authorities and bodies. If no specific requirements are defined, in
the USA, the latest edition of the National Fuel Gas Code ANSI Z223.1/
NFPA 54 applies. In Canada, installation must comply in all respects with
the latest edition of the Installation Code for Gas Burning Appliances and
Equipment, CAN/CSA-B.149 and the applicable local regulations and
requirements for the appliance category. The relevant authorities and
regulatory bodies must be informed before installation starts.
Where required by local regulations, the system must comply with the
American Society of Mechanical Engineers Safety Code for Controls and
Safety Devices for Automatically Fired Boilers (ASME CSD-1).
The hot water distribution system must comply with all applicable codes
and regulations. When replacing an existing boiler, it is important to
check the condition of the entire hot water distribution system to ensure
safe operation.
In the Commonwealth of Massachusetts, this appliance must be
installed by a licensed plumber and gas fitter. Valves external to the
boiler must be fitted with T-handles and condensate piping must be
installed in accordance with the State Plumbing Code.
2.4 Additional regulations for installations in the
Commonwealth of Massachusetts
(a) For all side wall horizontally vented gas fueled equipment installed in
every dwelling, building or structure used in whole or in part for
residential purposes, including those owned or operated by the
Commonwealth and where the side wall exhaust vent termination is less
than seven (7) feet above finished grade in the area of the venting,
including but not limited to decks and porches, the following
requirements shall be satisfied:
• INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of
installation of the side wall horizontal vented gas fueled equipment,
the installing plumber or gasfitter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed.
In addition, the installing plumber or gasfitter shall observe that a
battery operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling, building or
structure served by the side wall horizontal vented gas fueled
equipment. It shall be the responsibility of the property owner to
secure the services of qualified licensed professionals for the
installation of hard wired carbon monoxide detectors.
– In the event that the side wall horizontally vented gas fueled
equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may
be installed on the next adjacent floor level.
– In the event that the requirements of this subdivision cannot be
met at the time of completion of installation, the owner shall have
a period of thirty (30) days to comply with the above
requirements; provided, however, that during said thirty (30)
day period, a battery operated carbon monoxide detector with an
alarm shall be installed.
• APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above
provisions shall comply with NPA 720 and be ANSI/UL 2034 listed
and IAS certified.
• SIGNAGE. A metal or plastic identification plate shall be permanently
mounted to the exterior of the building at a minimum height of eight
(8) feet above grade directly in line with the exhaust vent terminal for
the horizontally vented gas fueled heating appliance or equipment.
The sign shall read, in print size no less than one-half (½) inch in size,
“GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS”.
• INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspections, the inspector observes carbon
monoxide detectors and signage installed in accordance with the
provisions of 248 CRM 5.08(2)(a) 1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CRM
5.08(2)(a) 1 through 4:
• The equipment listed in Section 10 entitled “Equipment Not
Required To Be Vented” in the most current edition of NFPA 54 as
adopted by the board; and
• Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential
purposes.
(c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM REQUIRED. When the manufacturer of Product Approved side
wall horizontally mounted gas equipment provides a venting system
design or venting system components with the equipment, the
instructions provided by the manufacturer for the installation of the
equipment and venting shall include:
• Detailed instructions for the installation of the venting system or the
venting system components; and
• A complete parts list for the venting system design or venting system.
(d) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED. When the manufacturer of Product Approved
side wall horizontally vented gas fueled equipment does not provide the
parts for the venting of flue gases, but identifies “special venting
systems”, the following requirements shall be satisfied by the
manufacturer:
• The referenced “special venting systems” shall be included with the
appliance or equipment installation instructions; and
• The “special venting systems” shall be Product Approved by the
Board, and the instructions for that system shall include a parts list
and detailed installation instructions.
(e) A copy of all instructions for all Product Approved side wall
horizontally vented gas fueled equipment, all venting instructions, all
parts lists for venting instructions, and/or venting design instructions
shall remain with the appliance or equipment at the completion of the
installation.
Logano G515 – 6 720 647 208 (2014/09) 7
3
38-9/16"
61-1/4"
2-23/64"
4-31/64"
52-11/64"
51-49/64"
23-1/16"
3-5/32"
4-1/2"
44-3/32"
23-1/32"
10-5/8"
Specifications
3Specifications
The technical data provides information about the output profile of the
Logano G515.
28 37/64"
(980 mm)
23 1/16"
Ø ≤ 10 5/8"
(270 mm)
61 1/4"
52 11/64"
(1325 mm)
(586 mm)
(1556 mm)
51 49/64"
(1315 mm)
3 5/32"
(80 mm)
2 23/64"
(60 mm)
4 31/64"
(114 mm)
VK
4 1/2"
(115 mm)
44 3/32"
(1120 mm)
23 1/32"
(585 mm)
EL
RK
10"
(250 mm)
Fig. 3 Technical data for Logano G515 (dimensions in inches (mm))
[EL] Drain valve (Rp ¾)
[LK] Boiler heat exchanger length
[L] Overall boiler length
[RK] Return connection on the boiler
[VK] Supply connection on the boiler
1)
2)
3)
1) With the drain valve (EL), you may only drain the system, not fill it.
2) The filling of the boiler and the system must be undertaken on a separate
connector on the return line.
3) The flange corresponds to the order reduced to 212 (DN100), 176 (DN80) or
149 (DN65).
L
K
L
6 720 642 623-01.1o
Logano G515 – 6 720 647 208 (2014/09)8
Specifications
Logano G515
Boiler capacity Unit 240 295 350 400 455 510
Number of boiler sections – 7 8 9 10 11 12
Nominal output MBH
(kW )
Combustion output MBH
(kW)
Boiler overall length (L) inches
(mm)
Boiler block length (L
) inches
K
(mm)
Fitting clearance, boiler section
(width × height × depth)
Fitting clearance, boiler block
(width × height × length)
inches
(mm)
inches
(mm)
Combustion chamber length inches
(mm)
Combustion chamber diameter inches
(mm)
Burner door thickness inches
(mm)
Weight, net
1)
lb.
(kg)
Boiler water content gal.
(l)
Gas capacity gal.
(l)
Flue gas temperature, partial load
(60%)
(°C)
Flue gas temperature, full load °F
(°C)
Flue gas mass flow rate, oil, partial
load (60%)
Flue gas mass flow rate oil,
2)
full load
lb./s
(kg/s)
lb./s
(kg/s)
Flue gas mass flow rate, gas, partial
load (60%)
Flue gas mass flow, gas, full load
lb./s
(kg/s)
2)
lb./s
(kg/s)
CO2 content, oil % 13
CO
content, gas % 10
2
Required draft PSI
(Pa)
Flue gas resistance PSI
(mbar)– (0.5 – 0.6)
Table 4
°F
685.8 - 818.9
(201 – 240)
735.7 - 886.1
(215.6 – 259.7)
62 – 7/32
(1580)
53 – 35/64
(1360)
45 – 55/64
(1165)
2.80
(1270)
68.2
(258)
111.2
(421)
281
(138)
328 – 362
(164 – 183)
0.143
(0.065)
0.203 – 0.243
(0.092 – 0.11)
0.143
(0.065)
0.203 – 0.245
(0.092 – 0.111)
822.3 - 1.006.6
(241 – 295)
879.7 - 1.088.5
(257.8 – 319.0)
68 – 29/32
(1750)
60 – 15/64
(1530)
52 – 9/16
(1335)
3.153
(1430)
77.7
(294)
128.6
(487)
281
(138)
322 – 362
(161 – 183)
0.176
(0.080)
0.241 – 0.298
(0.109 – 0.135)
0.176
(0.080)
0.243 – 0.300
(0.11 – 0.136)
–
(1.0 – 1.4)
1.010.0 -
1.194.2
(296 – 350)
1.080.3 -
1.286.7
(316.6 – 377.1)
75 – 19/32
(1920)
66 – 59/64
(1700)
1.197.7 -
1.364.9
(351 – 400)
1.278.2 -
1.465.9
(374.6 – 429.6)
82 – 9/32
(2090)
73 – 5/8
(1870)
32 7/8 × 51 49/64 × 6 45/64
(835 × 1315 × 170)
32 7/8 × 51 49/64 × L
(835 × 1315 × LK)
59 – 1/4
(1505)
65 – 15/16
(1675)
20 – 17/64
(515)
5 – 19/32
(142)
3.506
(1590)
(1753)
87.2
(330)
145.5
(551)
284
(140)
322 – 351
(161 – 177)
315 – 340
(157 – 171)
0.207
(0.094)
0.296 – 0.353
(0.134 – 0.16)
(0.108)
0.351 – 0.401
(0.159 – 0.182)
00.209
(0.095)
0.298 – 0.355
(0.135 – 0.161)
(0.108)
0.353 – 0.403
(0.16 – 0.183)
0
(0)
–
(1.1 – 1.6)
(2.1 – 2.9)
3.865
96.7
(366)
162.7
(616)
265
(129)
0.238
0.238
–
K
1.368.3 -
1.552.5
(401 – 455)
1.461.8 -
1.669.2
(428.4 – 489.2)
88 – 31/32
(2260)
80 – 5/16
(2040)
72 – 41/64
(1845)
4.189
(1900)
106.2
(402)
179.9
(681)
266
(130)
319 – 342
(159 – 172)
0.271
(0.123)
0.401 – 0.459
(0.182 – 0.208)
0.271
(0.123)
0.403 – 0.459
(0.183 – 0.208)
–
(2.5 – 3.3)
1.555.9 - 1.74.2
(456 – 510)
1.665.8 -
1.869.2
(488.2 – 547.8)
95 – 23/32
(2430)
(2210)
79 – 21/64
(2015)
4.542
(2060)
115.7
(438)
196.8
(745)
284
(140)
328 – 346
(164 – 174)
0.302
(0.137)
0.457 – 0.514
(0.207 – 0.233)
0.304
(0.138)
0.459 – 0.233
(0.208 – 0.233)
(2.4 – 3.1)
3
87
–
Logano G515 – 6 720 647 208 (2014/09) 9
4
Scope of delivery
Logano G515
Boiler capacity Unit 240 295 350 400 455 510
Maximum permissible supply
temperature
Maximum permissible operating
pressure
3)
°F
(°C)
PSI
(bar)
248
(120)
87
(6)
Table 4
1) Weight with packaging approx. 6–8% higher.
2) The details relate to the upper and lower rated output range.
3) Safety limit (high limit safety cut-out). Maximum possible supply temperature = safety limit (STB) – 32 °F (–18 K).
Example: Safety limit (STB): = 212 °F (100 °C), max. possible supply temperature = 212–32 = 180 °F (100–18 = 82 °C).
4 Scope of delivery
The Logano G515 can be delivered either as a pre-assembled block or in
loose sections.
▶ Check that the packaging is undamaged on delivery.
▶ Check that the delivery is complete.
4.1 Logano G515 – Delivery as a pre-assembled block
Component Qty Packaging
Boiler block with burner door and draft
diverter
Assembly components (longitudinal rails
and supply pipe)
Jacket Pack A, B, C (according to boiler
rating)
Thermal insulation 1 PU bag
Table 5
4.2 Logano G515 – Delivery in loose sections
Component Qty Packaging
Front and rear section as well as burner
door
Intermediate sections – (depending on
boiler size)
Fittings 1 Box
Exhaust manifold 1 Box
1 Pallet
1 Box
1– 3 Cartons
1 Pallet
1– 2 Pallet
5 Transporting the boiler
Use suitable equipment to transport the individual boiler sections
(delivery as loose sections) and other individual parts.
WARNING: Risk of injury from improperly secured
boiler sections.
▶ Use only suitable means of transportation when
handling the boiler sections, e.g. a heavy duty hand
truck.
▶ Secure the individual boiler sections to prevent them
from sliding off during transport.
NOTICE: Risk of system damage from impacts.
▶ The standard delivery of the Logano G515 oil/gas-
fired boiler contains components that are sensitive
to shock.
▶ During handling protect all electronic and other
components against impact.
▶ Please observe the transport instructions on the
packaging.
NOTICE: Risk of system damage from contamination.
▶ If you intend to keep the boiler in storage once it has
been assembled, observe the following:
▶ Protect the boiler connections against
contamination by sealing them off or covering them.
Tie rods 1 bundle
Assembly components (longitudinal rails
and supply pipe)
Jacket Pack A, B, C (according to boiler
rating)
Thermal insulation 1 PU bag
1 Box
1– 3 Cartons
Table 6
Dispose of packaging in an environmentally responsible
manner.
Logano G515 – 6 720 647 208 (2014/09)10
6 Positioning the boiler
This chapter describes how to properly position the Logano G515.
NOTICE: Risk of system damage from freezing.
▶ Install the system in a room free from the danger of
freezing.
6.1 Tools and auxiliary materials
The following tools and auxiliary materials are required for the boiler
assembly (the listed items must be provided by the installer):
• Boiler assembly tool 2.2 ( Fig. 4, page 11) or 2.3 ( Fig. 5,
page 11)
• Boiler block support for fitting the boiler sections together
• Steel hammer and wooden or rubber mallet
• Half-round bastard file
• Screwdriver (Philips and flat head)
•Flat chisel
• Metric wrenches
• Support wedge, flat iron
• Cleaning rags and cloth
• Fine emery cloth
•Wire brush
• 3-in-1 oil
• Solvent (gasoline, mineral spirits)
• Spirit level, tape measure, chalk, straight edge
• Blanking flange with vent facility (for pressure test)
6.1.1 Boiler assembly tool size 2.2
Positioning the boiler
Boiler
sections
7 – 10 1 0 85 – 3/64 (2 160)
11 – 12 1 1 108 – 21/32
Assembly tool(s)
per boiler hub
Extension piece
per boiler hub
Length (total) in
inches (mm)
6
(2760)
Table 7
For the correct arrangement of the flange during
assembly, refer to page 17.
6.1.2 Boiler assembly tool size 2.3 (complete in the toolbox)
4 5
L
2
L
1
L
2
6
4 5
L
1
3 2 1
Fig. 4 Boiler assembly tool size 2.2
[1] Mating flange
[2] Additional flange
[3] Compression unit
[4] Tie rod
[5] Extension
[6] Dowel pin (size 2.2)
[L
] 85" (2160 mm)
1
] 23 – 5/8" (600 mm)
[L
2
L
2
6
6 720 642 623-02.1o
3 2 1
6 720 642 623-03.1o
Fig. 5 Boiler assembly tool size 2.3
[1] Mating flange
[2] Additional flange
[3] Compression unit
[4] Tie rod
[5] Extension
[6] Wedge (size 2.3)
] 121– 1/4" (3080 mm)
[L
1
[L2] 31 – 1/2" (800 mm)
Boiler
sections
7 – 12 1 3 121 – 1/4 (3080)
Assembly tool(s)
per boiler hub
Extension piece
per boiler hub
Length (total) in
inches (mm)
Table 8
For the correct arrangement of the flange during
assembly, refer to page 17.
Logano G515 – 6 720 647 208 (2014/09) 11
6
15-3/4"
38-9/16"
35-1/2"
33-1/2"
21-1/4"
3-1/2"
Positioning the boiler
6.2 Recommended wall clearances
38 37/64"
≥ 15 3/4" (980 mm)
(400 mm)
35 1/2"
AB + 4"
K
L
(AB+100 mm)
AB
A
6 720 642 623-04.1o
Fig. 6 Installation room with boiler
Observe the recommended wall clearances for complete
opening of the burner door, for boiler installation and for
cleaning and maintenance ( Fig. 6 and Tab. 9).
The burner door can be right or left hung/opening (the boiler is always
supplied with the door attached on the right).
When installing your boiler maintain the recommended minimum
dimensions. Select the recommended clearances between wall and
boiler for easy access for installation, maintenance and service work.
The wall clearance on the hinge side must be at least the burner
projection (AB). A distance of AB + 3 – 15/16" (AB + 100 mm) from the
wall is recommended.
Boiler capacity Clearance A in inches (mm)
MBH (kW)
819 – 1.194
(240 – 350)
1,365 – 1,740
(400 – 510)
Table 9
If you do not observe the recommended minimum clearance ( Fig. 6),
you will not be able to use the cleaning kit (accessory). Alternatively,
shorter cleaning devices or wet cleaning may be used. Alternatively
shorter cleaning devices or wet cleaning may be used.
Boiler
sections
7 – 9 66 –15/16" (1700) 39 – 3/8" (1 000)
10 – 12 86 – 39/64" (2200) 39 – 3/8" (1 000)
Recommended minimum
(~ 900 mm)
6.3 Installing the boiler on a boiler base or foundation
1
33 1/2"
(850 mm)
2...4"
(~ 50...80 mm)
1
2
L
L
4"
(100 mm)
21 1/4"
(540 mm)
Fig. 7 Base dimensions (dimensions in inches (mm))
A silencing boiler base is available as an accessory from
Buderus.
If this boiler base is not used, a concrete foundation can be constructed
on-site. When building the base, a
3 – 15/16 × 1 – 31/32 × 5/16 inches (100 × 50 × 8 mm) steel angle
or 3 – 15/16 × 13/64 inches (100 × 5 mm) steel flat should be
incorporated, to ensure that the boiler sections can slide when the boiler
is installed ( Fig. 7 and Tab. 10).
When building the bases, consider to which side the
burner swings out (left or right-hand burner door stop
( Fig. 6, page 12).
It is advisable to place the boiler on a 2 – 4 inch (50 – 80 mm) tall base
( Fig. 7, [1]). The installation area must be completely flat and level.
The front edge of the boiler should be flush with the edge of the base.
Number of boiler
sections
7 53 – 35/64 (1360) 46 – 27/32 (1 190)
8 60 – 15/64 (1530) 53 – 35/64 (1360)
9 66 – 59/64 (1700) 60 – 15/64 (1 530)
10 73 – 5/8 (1870) 66 – 59/64 (1700)
11 80 – 5/16 (2040) 73 – 5/8 (1870)
12 87 (2210) 80 – 5/16 (2040)
Table 10
L1
(base) in inch (mm)L2 (steel section) in inch (mm)
3 1/2"
(~ 90 mm)
6 720 642 623-05.1o
Logano G515 – 6 720 647 208 (2014/09)12
Boiler block assembly
6 720 642 623-06.1o
7
10
9
8
7
4
1
2
3
5 6
6 720 642 621-04.1o
7
7 Boiler block assembly
WARNING: Risk of injury from improperly secured
boiler sections.
▶ Use only suitable means of transportation when
handling the boiler sections, e.g. a heavy duty hand
truck with strap or a heavy duty hand truck.
▶ Secure the individual boiler sections to prevent them
from sliding off during transport.
7.1 Assembly of a boiler block from sections
WARNING: Risk of injury from inadequately secured
boiler sections.
▶ Secure boiler sections during assembly and take
measures to prevent them from tipping over. The
installation aid (accessory) is available from Buderus
on request.
Fig. 9 Rear section
The boiler block is always installed starting from the rear with the rear
Fig. 8 Boiler heat exchanger
[1] Boiler base or foundation
[2] Exhaust manifold
[3] Rear section
[4] Return connection
[5] Supply connection
[6] Intermediate section
[7] Tie rod
[8] Sequence of installation
[9] Front section
[10] Burner door with burner plate
Depending on the type of delivery, we distinguish between delivery as
disassembled sections and as ready assembled block. When delivered
as a block, the boiler sections are already fully assembled and checked
for leaks prior to delivery. If the assembled boiler is too large or too
heavy to be brought to its final installation location in the building,
delivery of the disassembled boiler in sections offers a solution.
For the further installation of a pre-assembled boiler block, see
Chapter 7.3, page 18.
section ( Fig. 8, [3], page 13) and working toward the front. The front
section ( Fig. 8, [9], page 13) is always fitted last.
Observe the directional arrows ( Fig. 8, [8]) during assembly and
carry this out in accordance with the following instructions and
illustrations.
Logano G515 – 6 720 647 208 (2014/09) 13
7
6 720 642 623-08.1o
1
2
6 720 642 621-05.1o
Boiler block assembly
7.2 Joining the boiler block assembly (delivery as loose
sections)
Remove nuts and washers from the studs on the hubs of the boiler
sections before attaching the rear section and front section.
If you are using the installation aid, you will need to
remove the cleaning access cover before you can attach
it to the rear section.
▶ Unscrew cleanout cover on rear section ( Fig. 10, [1 and 2]).
Fig. 10 Removing the cleanout cover.
▶ Set up the rear section and secure with the installation aid to prevent
it from tipping ( Fig. 11 and Fig. 9 and separate installation
instructions for installation aid).
▶ File down any burrs on the hubs ( Fig. 12).
▶ Clean the packing grooves where required using a wire brush and
cloth ( Fig. 13, [3]).
Fig. 12 Remove burrs
WARNING: Danger of fire from combustible cleaning
agents.
▶ When using solvents, avoid open flames, ambers,
and sparks.
▶ Please observe the safety instructions regarding any
solvents used.
▶ Clean the hub sealing faces ( Fig. 13, [1 and 2]) with a rag soaked
in solvents or gasoline.
WARNING: Health hazard from noxious vapors released
during material handling.
▶ Ensure adequate ventilation of the installation area.
▶ Please note the handling and safety instructions of
the product used.
Fig. 11 Fastening the installation aid
▶ Evenly coat the hub sealing faces with sealant.
6 720 642 623-09.1o
Logano G515 – 6 720 647 208 (2014/09)14
Boiler block assembly
6 720 642 621-06.1o
2
3
1
6 720 642 621-07.1o
1
2
6 720 642 621-08.1o
1
6 720 642 621-09.1o
2
1
7
Fig. 13 Prepare packing grooves and hubs
The next step involves preparing the nipples that will eventually seal the
boiler sections.
▶ Clean nipple with a rag soaked in solvents or gasoline and coat evenly
with sealant.
▶ Insert the nipple straight into the upper (Sz. 4.181.70) and lower
(Sz. 1, 82/50) hub of the rear section and pound home securely with
alternate heavy blows. Once pounded in, the upper nipple
( Fig. 14, [1]) must protrude approx. 1 – 49/64 inches (45 mm)
and the lower nipple approx. 1 – 3/8 inches (35 mm) out of the
corresponding hubs.
▶ Remove any burrs with a file.
Fig. 15 Coat the packing grooves with adhesive (primer)
▶ Insert the flexible sealant rope ( Fig. 16, [2]) on the front of the
rear section, starting around the upper hub, into the packing gro oves
( Fig. 16, [1]) and press in lightly. At the butt joints, overlap the
sealant rope by approx. 3/4" (20 mm) and press firmly together.
▶ Unroll the required length of sealant rope from the spool supplied.
▶ Peel the backing paper from the sealant rope when inserting into the
packing groove (do not stretch).
Fig. 14 Driving nipples home
The packing grooves ( Fig. 15, [1]) must be clean and dry to enable
the sealant rope to adhere properly.
▶ Coat the packing grooves with adhesive (primer)
Logano G515 – 6 720 647 208 (2014/09) 15
Fig. 16 Inserting sealant rope
Preparation of the first intermediate section:
▶File down any burrs on the hubs ( Fig. 12, page 14).
7
6 720 642 623-15.1o
1
2
6 720 642 621-11.1o
2
3
4
1
6 720 642 623-18.1o
1
2
Boiler block assembly
The packing springs must be clean and dry. Clean if necessary.
▶ Clean the hub sealing faces with a rag soaked in solvents or gasoline.
▶ Evenly coat the hub sealing faces with sealant ( Fig. 17, [1]).
▶ Coat the packing springs with primer ( Fig. 17, [2]).
Fig. 17 Preparing the intermediate section
Before the nipples are inserted in the next intermediate
section, the part-assembled boiler block must be
compressed using the boiler assembly tool.
NOTICE: The boiler can be damaged by pulling the boiler
sections together incorrectly or from excessive
compression.
▶ Ensure that the nipples are positioned straight in the
boiler hubs after being pounded in and that they have
not been compromised.
▶ Never compress more than one nipple joint at a time.
▶ Stop compressing the sections when the boiler hubs
meet.
NOTICE: Assembly tool damage from loose screw
connections of the tie rods.
▶ Always check the tie rods before each use and
retighten as necessary. The tie rod is correctly
positioned if it is fully inserted and no threads are
showing ( Fig. 19, [2]).
▶ Always keep the threads ( Fig. 19, [1]) clean.
Dirty threads may damage the assembly tool during
assembly.
To make installation easier, place the boiler section to be
fitted onto the nipple on the upper hub first. Once this
has been done, the boiler section can be aligned with the
lower hub.
The directional arrow ( Fig. 18, [3]) must point toward the rear.
▶ Position the intermediate section so that the upper and lower hubs
( Fig. 18, [2 and 4]) fit onto the nipples in the rear section.
▶ Drive first intermediate section onto the rear section using a wooden
or a rubber mallet ( Fig. 18, [1]).
Fig. 19 Boiler assembly tool 2.3
CAUTION: Danger of accident from material fatigue.
Improperly used or poorly maintained assembly tools
may fail.
▶ Never work directly in front of the assembly tool
while it is being tensioned.
▶ Ensure that no one is standing in front of the
assembly tool.
Fig. 18 Pound intermediate section in place
Logano G515 – 6 720 647 208 (2014/09)16
Use a size 2.2 or 2.3 boiler assembly tool ( Fig. 4, Fig. 5 and Fig. 20
6 720 642 621-12.1o
3
4
1
2
6 720 642 623-19.1o
1
[1 and 2]).
▶ Push pressure flanges ( Fig. 20, [3]) with clamping nuts onto the
tie rods ( Fig. 4, page 11 and Fig. 5, [4]).
▶ Push a tie rod through the upper and lower hubs on the boiler.
▶ Push mating flanges onto the tie rods and secure each with wedge
(dowel pin for assembly tool 2.2).
▶ Hold the tie rod in the center of the boiler hubs and slightly draw
together the assembly tools using the clamping nut.
▶ Place ratchet wrench onto clamping nuts and compress boiler
sections by tightening evenly.
Boiler block assembly
Fig. 21 Using the boiler section foot wedges
Assemble all other boiler sections as described. The front section is
fitted last.
After the front section is installed, loosen the assembly
tool – but do not remove it. Fit the tie rods first.
7
Fig. 20 Using the boiler assembly tool
▶ Release and remove the boiler assembly tool.
▶ Check nipples are seated correctly.
WARNING: Risk of injury from falling boiler sections.
▶ Remove the installation aid first if the partly-
assembled boiler consists of at least three boiler
sections.
Fig. 21 shows the rear section with intermediate section fitted. The
preparations for fitting the next intermediate section have also been
made.
The boiler section has been equipped with foot wedges for ease of
installation ( Fig. 21, [1]).
The boiler section foot wedges are also used later for final leveling of the
boiler block.
▶ Insert the tie rods (with spring packs fitted) into the cast lugs on the
top left and right, and bottom left and right, next to the boiler hubs
( Fig. 22, [1 to 4]).
NOTICE: Damage to system through excessively low
contact pressure.
▶ Do not compress the spring pack. Only use the spring
pack in its original state.
▶ Tighten the nuts hand-tight.
▶ Tighten the nuts on the tie rods 1 to 1½ turns.
▶ Level the boiler block vertically and horizontally on the base/
foundation ( see Chapter 6, page 11).
▶ Remove boiler assembly tool.
Logano G515 – 6 720 647 208 (2014/09) 17
7
6 720 642 623-20.1o
1
2
3
4
6 720 642 623-21.1o
2
1
6 720 642 623-22.1o
1
2
3 4 5
6 720 642 623-23.1o
1
Boiler block assembly
Fig. 22 Fitting the tie rods
The next step describes the installation of the supply pipe
( Chapter 7.4, page 18).
7.4 Inserting the supply pipe (parts crate)
The supply pipe ( Fig. 24, [4]) consists of 2 pieces for boilers with
10 – 12 boiler sections.
▶ Push the flat gasket over the supply pipe ( Fig. 24, [1]).
▶ Push the supply pipe from the front into the top boiler hub.
▶ Close off with flange cover ( Fig. 24, [2]).
The supply pipe must be fixed in such a way that the
holes on the supply pipe are positioned at the correct
angle. This ensures optimum distribution of water in the
area of the top boiler hub (Thermostream principle).
▶ Make sure that the cam [3] on the end plate of the
supply pipe ( Fig. 24, [3]) fits in the notch in the
top boiler hub ( Fig 24, [5]).
7.3 Setting up the boiler block – (assembled block)
DANGER: Risk of fatal injury from falling objects.
▶ Provide a suitable means of supporting the load.
▶ Observe all locally applicable occupational health &
safety regulations regarding lifting equipment.
▶ Cut the straps ( Fig. 23, [1]).
▶ Remove the pallet prior to positioning the boiler block
( Fig. 23, [2]).
Fig. 24 Installing the supply pipe
7.5 Installing the sensor well
▶ Seal and install the sensor well R ¾ from the rear of the boiler (length:
110 mm) into the R ¾ tapped hole of the supply connection
( Fig. 25, [1]).
Fig. 23 Boiler block on pallet
▶ Level the boiler block vertically and horizontally on the base/impact
sound-absorbing base ( Chapter 6.3, page 12). Use the boiler
section foot wedges provided for this purpose.
The following pages describe the installation of the supply pipe and
sensor well. You must do both irrespective of whether the boiler is
supplied pre-assembled or in separate sections.
Fig. 25 Fitting the sensor well
Logano G515 – 6 720 647 208 (2014/09)18
7.6 Leak test
6 720 642 623-24.1o
3
2
1
6 720 642 623-25.1o
1
2
Conduct a leak test of the boiler block only when the boiler was delivered
disassembled. Pre-assembled sections are leak tested in the factory.
For details of assembling the remainder of the boiler if the block is
delivered pre-assembled, see Chapter 10, page 34.
7.6.1 Carrying out leak test
NOTICE: Risk of system damage from overpressure.
▶ Ensure that no pressure, control or safety equipment
is fitted during leak tests.
The leak test must be performed with a test pressure of 125 psi (8.6
bar). Use a pressure gauge class 1.0 to measure the pressure.
▶ Close off lower boiler hub ( Fig. 26, [3]) at the front and rear. To
do this, place corresponding seal ( Fig. 26, [1]) on the relevant
boiler hub and screw on flange cover with edge length 4 21/64
inches (110 mm). In this case, the flange with the tapped hole (R ¾)
for the fill and drain connection ( Fig. 26, [2]) is mounted on the
rear of the boiler.
▶ Install the on-site fill and drain valve.
▶ Close off supply and return connections (supply connection flange
with purger valve).
Fig. 27 Separating the boiler block
▶ Use new nipples and new sealant rope for
reassembly.
▶ Pull the boiler back together and repeat the leak test.
Boiler block assembly
7
Fig. 26 Fitting the flange
▶ Slowly fill the boiler with water via the fill and drain connection. While
doing this, purge the air from the boiler via the boiler supply
connection with purger.
7.6.2 Sealing leaks
▶ If a hub connection is leaking, first drain the water through the fill/
drain valves.
▶ Remove supply pipe.
▶ Undo nuts on tie rods and remove tie rods.
▶ Separate the boiler at the leak location by driving (knocking) in flat
wedges or chisels between the sections at the points provided at the
top and bottom ( Fig. 27, [1 and 2], between the sections).
Logano G515 – 6 720 647 208 (2014/09) 19
7
6 720 642 623-28.1o
1
2
Boiler block assembly
7.7 Boiler water connections
Please observe the following information regarding the boiler
connection to the system side. These instructions are important for
trouble-free operation.
NOTICE: Risk of system damage from leaking
connections.
▶ All pipe connections to the boiler must be free of
stress and tension.
NOTICE: System damage from deposits, local
overheating, and corrosion.
▶ As a basic rule, clean and flush existing systems
thoroughly before connecting the new boiler.
▶ Install a desludging unit in the boiler return to
prevent damage to the boiler.
The weld neck flange is fitted to the upper boiler hub ( Fig. 28, [3] –
return connection) if the return is connected at a later stage.
The weld neck flange and flat gasket are shown ( Fig. 28, [4 and 5]).
▶ The supply connection flange ( Fig. 28, [1]) with flat gasket
( Fig. 28, [2]) is required for connecting the supply at a later
stage.
7.8 Installing draft diverter, baffles and burner door
Next step in the assembly process is to install the burner door and draft
diverter. The pre-assembled boiler comes with these components
already installed.
7.8.1 Positioning the draft diverter
The GP sealant rope (fiberglass cord with silicon casing) which forms a
seal is inserted in the draft diverter at the factory.
▶ Place the draft diverter onto the four threaded studs on the rear
section ( Fig. 29 [1 to 4]) and secure using washers and nuts.
Fig. 28 Fitting a flange
The boiler supply and return manifolds are included in
the Buderus scope of delivery.
NOTICE: Risk of system damage from temperature
stresses.
▶ Install a fill valve on the system side.
▶ When the heating system is in operation, do not fill it
via the boiler fill & drain valve. Instead, use the fill
valve on the system side.
Fig. 29 Fitting the draft diverter
7.8.2 Screwing cleanout cover onto rear section
If the cleanout covers have been removed in order to attach the
installation aid to the rear section:
▶ Screw the cleanout covers with washers and nuts back onto the rear
section ( Fig. 30, [1 and 2]).
Fig. 30 Fitting the cleanout cover
Logano G515 – 6 720 647 208 (2014/09)20
7.8.3 Fitting the burner door
6 720 642 623-29.1o
4
5
1
2
3
6 720 642 623-30.1o
34
1
2
5 6
6 720 642 623-31.1o
1
2
▶ Place a few drops of Silastic adhesive 6 inches – 8 inches (15 –
20 cm) apart in the packing grooves ( Fig. 31, [2]) on the front
section ( Fig. 31).
▶ Insert GP sealant rope into the packing groove on the front section.
The sealant rope joint should be located at the side ( Fig. 31, [2]).
Boiler block assembly
Fig. 32 Hooking in the burner door
7.8.4 Hot gas check plates on front section
The hot gas check plates ( Fig. 33, [1 and 2]) are each screwed with
one hexagon socket screw to the front section at the factory.
7
Fig. 31 Fitting the hinge pins and locking brackets
In the factory, both burner door hinge lobes are fitted on the right-hand
side ( Fig. 32 [1 and 2]). For left-hand closing, dismantle the hinge
lobes from the right-hand side and reassemble them on the left-hand
side of the burner door.
▶ Screw the hinge pins (right-hand) to the boiler front section with 2
machine screws M12 × 55 in each case ( Fig. 31, [1 and 3]). For
left-hand closing, secure accordingly on the left-hand side.
▶ Screw on locking brackets with run-on slopes for the burner door
(right-hand closing) to the front section with 2 machine
screws M12 × 55 ( Fig. 31, [4 and 5]). For left-hand closing,
secure accordingly on the right-hand side.
Make sure the run-on slopes of the locking brackets are
on the inside of the boiler.
▶ Hook the burner door with the hinge lobes into the hinge pins.
Fig. 33 Position of hot gas check plates
Logano G515 – 6 720 647 208 (2014/09) 21
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