Buderus Logano G615 Installation And Service Instructions Manual
For contractors
Read carefully prior to
installation and maintenance
WARNING: If installation, adjustment, modification, oper-
ation 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: In the Commonwealth of Massachusetts this
boiler must be installed by a licensed plumber or gas fitter.
This manual is available in the English and French language.
Please keep this manual for future reference.
Installation and Service
Instructions
Low-temperature oil/
gas boiler
Logano G615
6 720 642 625-00.1O
Boilers for oil/gas-fired power burners
6 720 647 207(2010/12) US/CA
Table of Contents
Logano G615 - Subject to technical modifications
2
About this manual
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 G615.
These service and installation 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 G615 is available in two
variants (disassembled and assembled).
These installation and service instructions explain the
installation and service of both boiler types.
Table of Contents
1 Guideline to symbols and safety instructions 4
1.1 Guideline to symbols . . . . . . . . . . . . . . . . . 4
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . 4
2 Product description . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Designated use . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Operating conditions . . . . . . . . . . . . . . . . . 8
2.3 Compliance with standards
and regulations . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Additional regulations for installations in
the Commonwealth of Massachusetts . .10
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Logano G615 – Delivery
as a pre-assembled block . . . . . . . . . . . . .14
4.2 Logano G615 – Delivery
in loose sections . . . . . . . . . . . . . . . . . . . .14
5 Transporting the boiler . . . . . . . . . . . . . . . . . . 14
6 Positioning the boiler . . . . . . . . . . . . . . . . . . . . 15
6.1 Tools and auxiliary materials . . . . . . . . . . 15
6.2 Recommended wall clearances . . . . . . . . 16
6.3 Installing the boiler on a boiler base or
foundation . . . . . . . . . . . . . . . . . . . . . . . . . .17
The appliance has been tested to meet all
national requirements in effect on the date of
manufacture. The certificates are on file with
the manufacturer.
Table of Contents
Logano G615 - Subject to technical modifications
3
7 Boiler block assembly . . . . . . . . . . . . . . . . . . . 18
7.1 Assembly of a boiler block from sections 18
7.2 Joining the boiler block assembly
(delivery as loose sections) . . . . . . . . . . . .19
7.3 Setting up the boiler block –
(assembled block) . . . . . . . . . . . . . . . . . . .23
7.4 Inserting the supply pipe (parts crate) . . 24
7.5 Installing sensor well (fittings crate) . . . . 24
7.6 Inserting the lower distribution tube
(fittings crate) . . . . . . . . . . . . . . . . . . . . . . .25
7.7 Leak test . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.7.1 Carrying out leak test . . . . . . . . . . . . . . . . 26
7.7.2 Seal leaks. . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.8 Boiler water connections . . . . . . . . . . . . . 27
7.9 Installing draft diverter, baffles,
and burner door . . . . . . . . . . . . . . . . . . . . .28
7.9.1 Positioning the draft diverter . . . . . . . . . . 28
7.9.2 Screwing cleanout cover
onto rear section . . . . . . . . . . . . . . . . . . . .28
7.9.3 Fitting burner door . . . . . . . . . . . . . . . . . . 29
7.9.4 Inserting the flue gas baffles . . . . . . . . . . 29
7.10 Installation of the boiler jacket . . . . . . . . . 30
7.10.1 Fitting the thermal insulation . . . . . . . . . . 30
7.10.2 Fitting the profile rails . . . . . . . . . . . . . . . . 32
7.10.3 Fitting side panels and top covers . . . . . 35
8 Connecting the boiler on the flue gas side . 38
8.1 Fitting the vent pipe sealing collar
(accessory) . . . . . . . . . . . . . . . . . . . . . . . . .38
8.2 Installing a flue gas temperature sensor
(option) . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
9 Installing the control panel . . . . . . . . . . . . . . . 39
9.1 Installing the control panel . . . . . . . . . . . . 39
9.2 Installing set of temperature sensors . . . 41
10 Mounting the burner . . . . . . . . . . . . . . . . . . . . . 42
11 System start-up . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.1 Filling the system . . . . . . . . . . . . . . . . . . . . 43
11.2 Commissioning the system . . . . . . . . . . . 44
11.3 Start up the control panel . . . . . . . . . . . . . 44
11.4 Initial burner start-up . . . . . . . . . . . . . . . . . 44
11.5 Commissioning log . . . . . . . . . . . . . . . . . . 45
12 Shutting down the system . . . . . . . . . . . . . . . 46
12.1 Shutting down the heating system
via the control panel . . . . . . . . . . . . . . . . . 46
12.2 Shutting down the system
in an emergency . . . . . . . . . . . . . . . . . . . . 46
13 System inspection and maintenance . . . . . . 47
13.1 General information . . . . . . . . . . . . . . . . . . 47
13.2 Why is regular maintenance important? . 47
13.3 Cleaning the boiler with cleaning
brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
13.4 Wet-cleaning the boiler . . . . . . . . . . . . . . . 50
13.5 Checking the operating pressure . . . . . . . 51
13.6 Refilling boiler water and purging
the system . . . . . . . . . . . . . . . . . . . . . . . . . 51
13.7 Inspection and maintenance logs . . . . . . 52
14 Troubleshooting burner faults . . . . . . . . . . . . 56
15 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1
Guideline to symbols and safety instructions
Logano G615 - Subject to technical modifications
4
1 Guideline to symbols and safety instructions
1.1 Guideline to symbols
Warnings
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
Additional symbols
1.2 Safety instructions
Danger from failing to consider your own safety in
an emergency such as a fire
B Never risk your own life. Your own safety must always
take the highest priority.
Risk due to oil leaks
B 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
B Close the gas shut-off valve.
B If you hear gas escaping, evacuate the affected area
immediately.
B Open the windows.
B Do not operate any electrical switches or equipment
such as telephones, power plugs and doorbells.
B Extinguish all open flames.
B Do not smoke.
Do not use lighters.
B Warn all occupants of the building, but do not ring
doorbells.
B 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
B Switch OFF the appliance.
B Open windows and doors.
B Inform a trained and certified heating contractor.
Danger of electric shock when the control panel is
open
B Always de-energize the control panel before working
on electrical parts (circuit breaker).
B Take provisions against unintentional reconnection.
Danger of poisoning due to flue gas if supply of
combustion air is insufficient
B Safeguard supply of combustion air.
B Do not cover or reduce the size of ventilation openings
in doors, windows and walls.
B 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.
Warnings are indicated in the text by a
warning triangle and a gray background.
In case of danger from electric shock, the
exclamation point on the warning triangle is
replaced with a lightning symbol.
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.
Symbol Explanation
B
Sequence of steps
Æ
Cross-reference to other points in this
document or to other documents
• Listing/list entry
– Listing/list entry (2nd level)
Tab. 1
1
Guideline to symbols and safety instructions
Logano G615 - Subject to technical modifications
5
B 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.
B 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.
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
B Instruct customers about the functions and operation
of the appliance.
B Inform the customer that they must not carry out any
modifications or repairs.
B Only use the boiler for its intended purpose and only
when it is in working order.
Disposal
B Dispose of packaging in an environmentally
responsible manner.
B All heating system components that have to be
replaced should be disposed of in environmentallyresponsible manner at an authorized disposal site.
Other important information
B 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.
2
Product description
Logano G615 - Subject to technical modifications
6
2 Product description
The boiler is a low-temperature boiler for oil or gas power
burners with constant or reset boiler water temperature
control without minimum return temperature.
The main components of the Logano G615 oil/gas-fired
boiler are:
• The boiler heat exchanger transfers the heat generated
by the burner to the boiler water.
• The boiler jacket and thermal insulation minimize
energy loss.
• The control panel serves to monitor and control all
electrical boiler components.
Fig. 1 Oil/gas-fired boiler Logano G615
1 Boiler shell (jacket)
2 Thermal insulation
3 Boiler heat exchanger
4 Control panel assembly
Fig. 2 Front jacket
1 Burner door panel
The Logano G615 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 Logano G615 with oil or gas-fired fanassisted burners.
NOTICE: Risk of system damage from use of
incorrect burner.
B Only use burners that meet the technical
requirements of the oil/gas-fired boiler
Logano G615 (Æ Chapter 3, page 11).
6 720 642 625-01.1o
3
4
2
1
1
During installation and operation of the
heating system, observe all national
standards and guidelines!
Also observe the details 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.
1
1
1
6 720 642 625-51.1o
2
Product description
Logano G615 - Subject to technical modifications
7
2.1 Designated use
The Logano G615 oil/gas-fired boilers have been
designed for the heating of boiler water.
The Logano G615 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.
Fuels
Logano G615
Heating oil Liquid propane (LPG) Natural Gas (NG)
Remark
The Logano G615 boiler can be operated with the specified fuels. Select a burner suitable for use with the
fuels specified for the Logano G615 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.
Tab. 2 Fuels
2
Product description
Logano G615 - Subject to technical modifications
8
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 (Æ 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.
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, closing the
motorized butterfly valves or by having a motorized valve
in the boiler return on a single boiler installation. The
Buderus 4000 series controls 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 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.
Control of all heating
zones with Buderus 4000
External controls (BMS) or
with Buderus 4212 with
ZM 427 or Aquastat control
Minimum flow rate none
Minimum return temperature °F ( °C) none
Minimum operating temperature oil boiler
1)
1) This temperature has to be reached within ten minutes of the burner starting and has to be maintained whilst the burner is firing.
°F ( °C) 122 (50)
Minimum operating temperature gas boiler
1)
°F ( °C) 122 (50)
2)
2) 65 with partial load < 60 % °C
140 (60)
2)
Maximum supply temperature °F ( °C) 2123)/2484) (1003)/1204))
3) The maximum supply temperature is 212 °F (100 °C), if the boiler is operated as hot water boiler.
4) The maximum supply temperature is 248 °F (120 °C), if the boiler is operated as a hot water generator.
Maximum operating pressure PSI (bar) 87 (6)
For operation with two-stageoil and gas bumers – Set the partial load stage to 60 %
Time constant of the temperature controller sec 40
Time constant of the monitor/limiter sec 40
Tab. 3
A heating zone with a mixing valve improves
controllability and is specifically
recommended for systems with differing
water temperature zones.
2
Product description
Logano G615 - Subject to technical modifications
9
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 a 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.
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
Product description
Logano G615 - Subject to technical modifications
10
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.
3
Specifications
Logano G615 - Subject to technical modifications
11
3 Specifications
The technical data provides information about the output
profile of the Logano G615 .
Fig. 3 Connections and dimensions
AA Flue gas spillage
EL Drain valve (Rp ¾)
1)
LKBoiler heat exchanger length
LGOverall boiler length
RK Return connection on the boiler
2)
VK Supply connection on the boiler
3)
(1390 mm)
54 23/32"
EL
RK
6 720 642 625-02.1o
L
G
VK
L
K
(125 mm)
4 59/64"
L
F
T
(750 mm)
29 17/32"
14 11/64"
(360 mm)
AA
(1826 mm)
71 57/64"
(1596 mm)
62 27/32"
(1281 mm)
50 7/16"
(350 mm)
13 25/32"
6"
(150 mm)
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).
3
Specifications
Logano G615 - Subject to technical modifications
12
Logano G615
Boiler
capacity
Unit 570 660 740 820 920 1020 1110 1200
Number of
boiler
sections
– 9 10 11 12 13 14 15 16
Nominal
output
Btu/hr
(kW)
1,743,604
–
1,944,921
(511 – 570)
1,948,333
–
2,252,014
(571 – 660)
2,255,426
–
2,524,984
(661 – 740)
2,528,397
–
2,797,956
(741 – 820)
2,801,368
–
3,139,170
(821 – 920)
3,142,582
–
3,480,385
(921 – 1020)
3,483,797
–
3,787,477
(1021 –
1110)
3,790,889
–
4,094,570
(1111 –
1200)
Thermal
output
Btu/hr
(kW)
1,865,077
–
2,102,562
(546.6 –
616.2)
2,083,795
–
2,434,563
(610.7 –
713.5)
2,412,384
–
2,729,713
(707.0 –
800.0)
2,704,122
–
3,024,864
(792.5 –
886.5)
2,996,202
–
3,393,716
(878.1 –
994.6)
3,360,960
–
3,760,180
(985.0 –
1102.0)
3,726,059
–
4,094,570
(1092.0 –
1200.0)
4,053,624
–
4,425,548
(1188.0 –
1297.0)
Overall boiler
length (L
G
)
inches
(mm)
75 53/64"
(1926)
82 33/64"
(2096)
89 7/32"
(2266)
95 29/32"
(2436)
102 19/32"
(2606)
109 19/64"
(2776)
115 63/64"
(2946)
122 43/64"
(3116)
Boiler block
length (L
K
)
inches
(mm)
71 1/64"
(1804)
77 23/32"
(1974)
84 13/32"
(2144)
91 7/64"
(2314)
97 51/64"
(2484)
104 31/64"
(2654)
111 3/16"
(2824)
117 7/8"
(2994)
Single boiler
section size
(B × H × T)
inches
(mm)
43 9/64" × 64 9/16" × 6 45/64"
(1096 × 1640 × 170)
Boiler block
transport
size
(B × H × L)
inches
(mm)
43 9/64" × 64 9/16" × L
K
(1096 × 1640 × LK)
Combustion
chamber
length (L
F
)
inches
(mm)
60 1/32"
(1525)
66 47/64"
(1695)
73 27/64"
(1865)
80 1/8"
(2035)
86 13/16"
(2205)
93 1/2"
(2375)
100 13/64"
(2545)
106 7/8"
(2715)
Combustion
chamber
diameter
inches
(mm)
26 49/64"
(680)
Burner door
thickness
inches
(mm)
5 4 5/64"
(145)
Weight, net 1)lbs.
(kg)
5.523
(2505)
6.056
(2747)
6.592
(2990)
7.125
(3232)
7.661
(3475)
8.179
(3710)
8.715
(3953)
9.143
(4147)
Boiler water
content
gal
(l)
148.25
(561)
164
(621)
180
(681)
195.75
(741)
211.5
(801)
227.5
(861)
243.25
(921)
259.25
(981)
Gas capacity
gal
(l)
243.5
(922)
271.25
(1027)
299
(1132)
326.75
(1237)
354.5
(1342)
382.25
(1447)
410
(1552)
437.75284
(1657)
Flue gas
temperature
partial load
60 %
°F
(°C)
284
(140)
Flue gas
temperature
full load
°F
(°C)
338 – 356
(170 – 180)
Flue gas
mass flow
rate, oil,
partial load
60 %
°F
(°C)
32.277
(0.1537)
32.32
(0.1778)
32.359
(0.1995)
32.397
(0.2207)
32.446
(0.2479)
32.495
(0.275)
32.539
(0.2992)
32.582
(0.3234)
Tab. 4 Technical data and dimensions
3
Specifications
Logano G615 - Subject to technical modifications
13
Flue gas
mass flow
rate oil, full
load
2)
lbs./s
(kg/s)
0.5115 –
0.5765
(0.232 –
0.2615)
0.5714 –
0.6676
(0.2592 –
0.3028)
0.6616 –
0.7487
(0.3001 –
0.3396)
0.7416 –
0.8296
(0.3364 –
0.3763)
0.8217 –
0.9308
(0.3727 –
0.4222)
0.9218 –
1.0313
(0.4181 –
0.4678)
1.0218 –
1.1228
(0.4635 –
0.5093)
1.1118 –
1.2136
(0.5043 –
0.5505)
Flue gas
mass flow
rate, gas,
partial load
60%
lbs./s
(kg/s)
0.34
(0.1542)
0.3935
(0.1785)
0.4414
(0.2002)
0.4883
(0.2215)
0.5485
(0.2488)
0.6085
(0.276)
00.662
(0.3003)
0.7156
(0.3246)
Flue gas
mass flow,
gas, full
load
2)
lbs./s
(kg/s)
0.5132 –
0.5787
(0.2328 –
0.2625)
0.5736 –
0.67
(0.2602 –
0.3039)
0.664 –
0.7513
(0.3012 –
0.3408)
0.7443 –
0.8325
(0.3376 –
0.3776)
0.8247 –
0.9341
(0.3741 –
0.4237)
0.9251 –
1.0348
(0.4196 –
0.4694)
1.0256 –
1.127
(0.4652 –
0.5112)
1.1158 –
1.2181
(0.5061 –
0.5525)
CO2 content,
oil
% 13
CO2 content,
gas
%10
Required flue
pressure
(draft
requirement)
PSI
(Pa)
0
(0)
Fireside
pressure
drop
in
W.C.
(mbar)
0.9624
(2.4)
1.3634
(3.4)
1.6842
(4.2)
1.6842
(4.2)
1.6441
(4.1)
1.8045
(4.5)
2.1654
(5.4)
2.3258
(5.8)
Permissible
supply
temperature
3)
°F
(°C)
212 – 248
(100 – 120
4)
Allowable
operating
water
pressure
PSI
(bar)
87
(6)
1) Weight not incl. packaging material approx. 4 – 5 % less.
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) Observe all gas regulations and requirements for your country.
Logano G615
Boiler
capacity
Unit 570 660 740 820 920 1020 1110 1200
Tab. 4 Technical data and dimensions
4
Scope of delivery
Logano G615 - Subject to technical modifications
14
4 Scope of delivery
The boiler can be delivered either as a pre-assembled
block or in loose sections.
B After delivery, check all packaging for perfect
condition.
B Check the delivery for completeness.
4.1 Logano G615 – Delivery as a preassembled block
4.2 Logano G615 – Delivery in loose
sections
5 Transporting the boiler
Use suitable equipment to transport the individual boiler
sections (delivery as loose sections) and other individual
parts.
Component Qty Packaging
Boiler heat exchanger 1 Pallet
Fittings 1 Crate
Assembly parts 1 Crate
Jacket pack A 1 Crate
Jacket pack B 1 Crate
Thermal insulation 1 Foil pouch
Tab. 5 Scope of delivery (block delivery)
Component Qty Packaging
Front, rear, intermediate
section with top supply
connection and burner door
1 Pallet
Central sections (depending
on boiler size)
2– 5 Pallet
Fittings basic unit, 9 – 16
pieces
1Crate
Additional fittings (content
depends on boiler size)
1 Crate
Assembly parts 1 Crate
Jacket pack A 1 Crate
Jacket pack B 1 Crate
Thermal insulation 1 Foil pouch
Tie rods set with spring
packages
Tab. 6 Scope of supply (loose sections)
WARNING: Risk of injury from improperly
secured boiler sections.
B Use only suitable means of transportation
when handling the boiler sections, e.g. a
sack truck with strap or heavy duty dolly.
B Secure the individual boiler sections to
prevent them from sliding off when
transporting them.
NOTICE: Risk of system damage from
impacts.
B The standard delivery of the Logano G615
oil/gas-fired boiler contains components
that are sensitive to shock.
B During handling protect all electronic and
other components against impact.
B Please observe the transport instructions
on the packaging.
NOTICE: Risk of system damage from
contamination.
B If you intend to keep the boiler in storage
once it has been assembled, observe the
following:
B Protect the boiler connections against
contamination by sealing them off or
covering them.
Dispose of packaging in an environmentally
responsible manner.
6
Positioning the boiler
Logano G615 - Subject to technical modifications
15
6 Positioning the boiler
This chapter describes how to properly position the
Logano G615.
6.1 Tools and auxiliary materials
The following tools and auxiliary materials are required for
the boiler assembly (the listed items are not contained in
the scope of delivery).
• Boiler assembly tool 2.3
• Installation kit (accessory)
• Steel hammer and wooden or rubber mallet
• Half-round bastard file
• Screwdriver (Philips and flat head)
• Flat chisel, support wedge, flat iron
• Metric wrenches
• Cleaning rags and cloth
• Fine emery cloth
•Wire brush
•3-in-1 oil
• Solvent (gasoline, mineral spirits)
• Level, tape measure, chalk, straight edge
Boiler assembly tool size 2.3
Fig. 4 Boiler assembly tool size 2.3 (dimensions in
mm)
1 Mating flange
2 Additional flange
3 Compression unit
4 Tie rod
5 Extension
6 Wedge (size 2.3)
L
1
121 1/4" (3080 mm)
L
2
31 1/2" (800 mm)
NOTICE: Risk of system damage from
freezing.
B Install the system in a room free from the
danger of freezing.
Boiler
sections
Assembly
tool(s) per
boiler hub
Extension
piece per
boiler hub
Length
(total) in
inches
(mm)
9– 16 1 3
121 1/4
(3080)
Tab. 7 Boiler assembly tool size 2.3 (complete in the
toolbox)
For the correct arrangement of the flange
when performing the assembly procedure,
refer to page 21.
6 720 642 623-03.1o
3 2 1
6
4 5
L
1
L
2
L
2
6
Positioning the boiler
Logano G615 - Subject to technical modifications
16
6.2 Recommended wall clearances
Fig. 5 Installation room with boiler
The burner door can be hung with the hinges on the right
or left.
The wall clearance on the hinge side must be at least the
burner projection (AB). A distance of AB + 4"
(AB + 100 mm) from the wall is recommended.
If you do not observe the recommended minimum wall
clearances, you will not be able to use the cleaning kit.
Alternatively shorter cleaning devices or wet cleaning may
be used.
Observe the recommended wall clearances
for complete opening of the burner door, for
boiler installation and for cleaning and
maintenance (Æ Fig. 5 and Tab. 8).
6 720 642 625-03.1o
L
K
(400 mm)
≥ 15 3/4"
(1281 mm)
50 7/16"
(AB+100 mm)
AB + 4"
AB
A
(~ 1150 mm)
45 1/4"
50 7/16"
≥
15 3/4"
45 1/4"
Boiler capacity Clearance A inch (mm)
BTU/h (kW) Sections Recommended minimum
1,944,921 –
2,797,956
(570 – 820)
9– 12 90 35/64"
(2300)
55 1/8"
(1400)
3,139,170 –
4,094,570
(920 – 1200)
13 – 16 118 7/64"
(3000)
59 1/16"
(1500)
Tab. 8 Recommended and minimum wall clearances
6
Positioning the boiler
Logano G615 - Subject to technical modifications
17
6.3 Installing the boiler on a boiler base
or foundation
Fig. 6 Base dimensions
Place the boiler on a 2 – 4 inch (450 – 100 mm) tall base
(observe wall clearances). The base must be flat and level.
The front edge of the boiler should be flush with the edge
of the base.
When pouring a foundation for the boiler, use the steel
inserts with the following dimensions:
3 15/16 × 1 31/32 × 5/16 inches (100 × 50 × 8 mm)
or sheet metal with the dimensions
3 15/16 × 13/64 inches (100 × 5 mm).
A silencing boiler base is available as an
accessory from Buderus.
6 720 642 621-01.1o
L
2
(820 mm)
(~ 100 mm)
(100 mm)
(~ 1160 mm)
(~ 50...100 mm)
2...4"
L
1
34 3/4"
1
4"
4"
32 9/32"
(410 mm)
16 9/64"
(100 mm)
4"
16 9/64"
34 3/4"
32 9/32"
Number of
boiler sections
L1 (base)
inch (mm)
L2 (steel section)
inch (mm)
9 65 3/4“ (1670) 57 7/8“ (1470)
10 72 7/16“ (1840) 64 9/16“ (1640)
11 79 9/64“ (2010) 71 1/4“ (1810)
12 85 53/6“4 (2180) 77 61/64“ (1980)
13 92 33/64“ (2350) 84 41/64“ (2150)
14 99 7/32“ (2520) 91 11/32“ (2320)
15 105 29/32“ (2690) 98 1/32“ (2490)
16 112 19/32“ (2860) 104 23/32“ (2660)
Tab. 9 Base dimensions for angle or sheet metal steel
lengths
7
Boiler block assembly
Logano G615 - Subject to technical modifications
18
7 Boiler block assembly
Fig. 7 Assembled boiler block
1 Boiler base or foundation
2 Draft diverter
3 Rear section
4 Intermediate section with supply connection
5 Intermediate section
6 Tie rod
7 Sequence of installation
8 Front section
9 Burner door with burner plate
A distinction is made between delivery as a preassembled block and delivered as disassembled
sections. 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.
The assembly of the boiler block from individual sections
is described below.
For details on final assembly of the remainder of the boiler,
Æ see Chapter 7.3, page 23.
7.1 Assembly of a boiler block from
sections
Fig. 8 Rear section
The assembly of the boiler block is always done from the
rear to the front, that is, the rear section (Æ Fig. 7, [3]) is
always mounted first and the front section (Æ Fig 7, [8])
is always mounted last.
Observe the installation direction arrows of the boiler
sections (Æ Fig. 7, [7]) during assembly!
Observe the correct positioning of the intermediate
section with top supply connection (Æ Fig. 7, [4])!
Mount the boiler block according to the instructions and
figures below!
WARNING: Risk of injury from improperly
secured boiler sections.
B 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.
B Secure the individual boiler sections to
prevent them from sliding off during
transport.
6 720 642 625-05.1o
1
2
3
4
6
6
7
9
8
5
WARNING: Risk of injury from insufficiently
secured boiler sections.
B Secure boiler sections during assembly
and take measures to prevent them from
tipping over. The installation aid
(accessory) is available from Buderus on
request.
6 720 642 621-04.1o
7
Boiler block assembly
Logano G615 - Subject to technical modifications
19
7.2 Joining the boiler block assembly
(delivery as loose sections)
Preparing boiler sections
B Remove nuts and washers from the studs on the hubs
of the boiler sections before attaching the rear section
and front section.
B Put the rear section in place and secure during
assembly taking measures to prevent tipping over (Æ
Fig 8 and separate instructions for installation).
B File down any burrs on the hubs if necessary.
Fig. 9 Filing down burrs on the hub
B Clean the packing grooves where required using a wire
brush and cloth.
B Clean the hub sealing faces with a rag soaked in
solvents or gasoline.
B Evenly coat the hub sealing faces with sealant.
Fig. 10 Coating the hub sealing faces
1 Sealing face of top hub
2 Sealing face of bottom hub
3 Packing groove
B Clean nipple with a rag soaked in solvents or gasoline
and coat evenly with sealant.
B Insert nipple directly into the top (size 4, 181/70) and
bottom (size 2, 119/50) hub on the rear section.
B Strike the nipple with hefty hammer strokes in a cross
pattern.
B Remove any burrs with a file.
WARNING: Danger of fire from combustible
cleaning agents.
B When using solvents, avoid open flames,
ambers and sparks.
B Please observe the safety instructions
regarding any solvents used.
The next step involves preparing the nipples
that will eventually seal the boiler sections.
6 720 642 625-07.1o
WARNING: Health hazard from noxious
vapors released during material handling,
such as solvents, primers or sealant.
B Ensure adequate ventilation of the
installation area.
B Please note the handling and safety
instructions of the product used.
The top nipple must protrude approx. 1 3/4"
(43 mm) and the bottom nipple approx. 1 1/4"
(32 mm) out of the corresponding hubs.
The packing grooves must be clean and dry
for the sealant rope to adhere properly.
6 720 642 621-06.1o
2
3
1
7
Boiler block assembly
Logano G615 - Subject to technical modifications
20
Fig. 11 Driving nipples home
B Coat the packing grooves with adhesive (primer).
Fig. 12 Coat the packing grooves with adhesive
(primer)
1 Packing grooves
B Insert the flexible sealant rope on the front of the rear
section, starting around the top hub, into the packing
grooves, and press in lightly.
B At the butt joints, overlap the sealant rope by approx.
3/4" (20 mm) and press firmly together.
B Do not let sealant rope overlap at the left and right of
the butt joints (Æ Fig. 13, [3]).
Fig. 13 Inserting sealant rope
1 Packing grooves
2 Sealant rope
3 Butt joints
Prepare the first intermediate section (with top
supply connection):
B File down any burrs on the hub.
B The packing springs must be clean and dry. Clean if
necessary.
B Clean the hub sealing faces with a rag soaked in
mineral spirit or gasoline.
Fig. 14 Preparing the center section
1 Sealing face of the hub
2 Packing springs
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).
6 720 642 625-09.1o
43
32
1-1/4"
(32 mm)
1-3/4" (43 mm)
6 720 642 621-08.1o
1
6 720 642 621-09.1o
2
1
6 720 642 625-12.1o
2
1
7
Boiler block assembly
Logano G615 - Subject to technical modifications
21
B Evenly coat the hub sealing faces with sealant.
B Coat the packing springs with primer.
B Position the intermediate section with the supply
connection so that the top and bottom hubs fit onto the
nipples in the rear section. The directional arrow must
point towards the rear.
B Drive first intermediate section onto the rear section
using a wooden or a rubber mallet.
Fig. 15 Pound intermediate section in place
1 Supply connection
2 Top hub
3 Directional arrow
4 Bottom hub
5 Wood or rubber mallet
B Push pressure flange with clamping nuts onto the tie
rods.
B Push a tie rod through the top and bottom hubs on the
boiler block.
B Push mating flanges onto the tie rods and secure each
with wedge.
B Hold the tie rod in the center of the hubs and slightly
draw together the compression tools using the
clamping nut.
Fig. 16 Using the boiler assembly tool
1 Boiler assembly tool (bottom hub)
2 Boiler assembly tool (top hub)
3 Pressure flange (top)
4 Pressure flange (bottom)
B Place ratchet wrench onto clamping nut and compress
boiler sections by tightening evenly.
To make installation easier, place the boiler
section to be fitted onto the nipple on the top
hub first. Then it is easier to align the boiler
section on the bottom hub.
Before the nipples are inserted in the next
intermediate section, the partly-assembled
boiler block must be compressed using the
boiler assembly tool.
Use boiler assembly tool 2.3 (Æ Fig. 4,
page 15).
6 720 642 625-13.1o
1
2
3
5
4
NOTICE: The boiler can be damaged by
pulling the boiler sections together
incorrectly or due to excessive compression.
B Ensure that the nipples are positioned
straight in the boiler hubs after being
pounded in and that they have not been
compromised.
B Never compress more than one nipple
joint at a time.
B Stop compressing the sections when the
boiler hubs meet.
6 720 642 621-12.1o
3
4
1
2
7
Boiler block assembly
Logano G615 - Subject to technical modifications
22
B Release and remove the boiler assembly tool.
B Check nipples are seated correctly.
Fig. 17 Boiler assembly tool 2.3
1 Screw connection of the tie rods (disassembled)
2 Screw connection of the tie rods (correctly positioned)
Fig. 18 shows the intermediate section with supply
connection. The nipples for mounting of the next
intermediate section are inserted into the corresponding
hubs. The sealant rope has already been inserted into the
packing groove. As shown for the rear section (Æ Fig. 13,
page 20), here too, the flexible sealant rope is interrupted.
The boiler section has been equipped with foot wedges
for ease of installation. The boiler section foot wedges are
also used later for final leveling of the boiler block.
Fig. 18 Using the boiler section foot wedges
1 Sealant rope (interrupted)
2 Boiler section foot wedge
Assemble all other boiler sections as described. The front
section is fitted last.
B Insert the tie rods (with spring packages fitted) into the
cast lugs on the top left and right, and bottom left and
right, next to the boiler block hubs.
B Turn and tighten each nut on the tie rods by hand.
B Now tighten the nuts on the tie rods 1 to 1½ turns.
B Level the boiler block vertically and horizontally on the
base/foundation (Æ see Chapter 6.3, page 17). Use
the boiler section foot wedges provided for this
purpose (Æ Fig. 18, page 22).
CAUTION: Danger of accident from material
fatigue. Improperly used or poorly maintained
assembly tools may fail.
B Never work directly in front of the
assembly tool while it is being tensioned.
B Ensure that no one is standing in front of
the assembly tool.
NOTICE: Assembly tool damage due to
loose screw connections of the tie rods.
B 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 (Æ Fig. 17,
[2]).
B Always keep the threads (Æ Fig. 17, [1])
clean. Dirty threads may damage the
assembly tool during compression.
6 720 642 623-18.1o
1
2
After the front section is attached, loosen the
assembly tool but do not remove it. First
insert the tie rods.
NOTICE: Damage to system through
excessively low contact pressure.
B Do not compress the spring pack. Only
use the spring pack in its original state.
6 720 642 625-15.1o
1
2
7
Boiler block assembly
Logano G615 - Subject to technical modifications
23
B Remove boiler assembly tool.
Fig. 19 Inserting the tie rods
1 Tie rods (bottom)
2 Tie rods (top)
3 Tie rod with spring package
The next step describes the installation of the supply pipe
(Æ see Chapter 7.4, page 24).
7.3 Setting up the boiler block –
(assembled block)
B Cut the straps.
B Remove pallet.
Fig. 20 Boiler block on pallet
1 Securing straps
2 Pallet
B Level the boiler block vertically and horizontally on the
base/foundation. Use the boiler section foot wedges
provided for this purpose.
B After leveling the boiler block, remove the transport
safety brace from the top and bottom hub.
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. 21 Removing the transport safety brace
1 Top hub
2 Bottom hub
3 Transport safety brace
DANGER: Risk of fatal injury from falling
objects.
B Provide a suitable means of supporting
the load.
B Observe all locally applicable
occupational health & safety regulations
regarding lifting equipment.
6 720 642 625-16.1o
1
2
3
6 720 642 625-17.1o
2
1
6 720 642 625-18.1o
3
1
2
Loading...