Buderus Logano GC 124 II, LoganoUS GC 144 II, LoganoCA GC 144 II Installation And Service Instructions Manual
Installation and Service
Instructions
Gas boiler
WARNING!
Installation, adjustment, modification, operation
or maintenance of the heating system carried out
by unqualified personnel may result in property
damage, personal injury, and loss of life.
The directions of this installation and maintenance
manual must be followed precisely.
Contact a qualified service company, service provider or the gas company if support or additional
information is required.
CAUTION!
Before placing this boiler in operation observe the
safety instructions of this installation and maintenance manual.
CAUTION!
The operating manual is a component of the technical documentation handed over to the operator
of the heating system. Discuss the instructions in
this manual with the owner or operator of the heating system and ensure that they are familiar with all
information required for operation of the heating
system.
In the Commonwealth of Massachusetts
this boiler must be installed by a licensed
plumber or gas fitter.
Keep this installation and maintenance manual
available for future reference.
In the Commonwealth of Massachusetts this boiler
must be installed by a licensed plumber or gas fitter.
Logano GC 124 II
6 720 804 440 (2012/11) EN-US
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Contents
Contents
1 Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 National regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Boiler Operating Conditions . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Tools, materials and accessories . . . . . . . . . . . . . . . . . . . 4
2.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Dimensions and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Moving the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Moving the boiler with boiler cart . . . . . . . . . . . . . . . . . . 6
5.2 Lifting and carrying the boiler . . . . . . . . . . . . . . . . . . . . . 7
6 Placing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2 Leveling the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13 Start-up protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
14 Taking the heating system out of operation . . . . . . . . . . . . . 20
14.1 Normal system shut-down . . . . . . . . . . . . . . . . . . . . . . . 20
14.2 Emergency shut-down procedures . . . . . . . . . . . . . . . . 20
15 Boiler inspection and maintenance . . . . . . . . . . . . . . . . . . . . . 20
15.1 Why is regular maintenance important? . . . . . . . . . . . . 20
15.2 Testing the flue system, including combustion air,
air inlets and Ventilation openings . . . . . . . . . . . . . . . . 20
15.3 Inspection of the boiler and burner . . . . . . . . . . . . . . . . 20
15.4 Preparing boiler for cleaning . . . . . . . . . . . . . . . . . . . . . 20
15.5 Cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
15.5.1 Cleaning the boiler with brushes . . . . . . . . . . . . . . . . . . 21
15.5.2 Wet cleaning (chemical cleaning) . . . . . . . . . . . . . . . . . 22
15.6 Cleaning the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15.7 Maintenance protocol . . . . . . . . . . . . . . . . . . . . . . . . . . 25
15.8 Troubleshooting the GC124 II . . . . . . . . . . . . . . . . . . . . 27
16 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
17 Electrical circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7 Boiler installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.1 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.2 Connecting the heating system . . . . . . . . . . . . . . . . . . . . 8
7.3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.4 Fuel gas supply connection . . . . . . . . . . . . . . . . . . . . . . 10
7.4.1 Gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.4.2 Installation at high altitudes . . . . . . . . . . . . . . . . . . . . . . 11
7.5 Filling heating system and checking for leaks . . . . . . . . 11
8 Check openings for combustion air supply and venting . . . . 12
9 Requirements for connection to chimneys or venting
systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 Flue pipe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11 Placing the heating system in operation . . . . . . . . . . . . . . . . . 14
11.1 Starting up the GC124 II . . . . . . . . . . . . . . . . . . . . . . . . 15
11.1.1 Prepare pressure measurement . . . . . . . . . . . . . . . . . . 15
11.1.2 Turning on heating system . . . . . . . . . . . . . . . . . . . . . . . 16
12 Final start-up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Logano GC 124 II – 6 720 804 440 (2012/11)2
1 Safety considerations
1.1 Key to symbols
Warnings
Warnings in this document are identified by a warning
triangle printed against a grey background.
Keywords at the start of a warning indicate the type and
seriousness of the ensuing risk if measures to prevent
the risk are not taken.
The following keywords are defined and can be used in this document:
• NOTE indicates a situation that could result in damage to property or
equipment.
• CAUTION indicates a situation that could result in minor to medium
personal injury.
• WARNING indicates a situation that could result in severe personal
injury or death.
• DANGER indicates a situation that will result in severe injury or death.
Important information
This symbol indicates important information where
there is no risk of personal injury or property damage.
Additional symbols
Symbol Explanation
▶ Step in an action sequence
Cross-reference to another part of the document
• List entry
– List entry (second level)
Table 1
1.2 Safety instructions
Observe these instructions for your safety.
The burner and control must be correctly installed and adjusted to
ensure safe and economical operation of the gas boiler.
Read this installation and maintenance manual carefully and note the
details on the boiler nameplate before placing the boiler in operation.
Risk of fatal injury from explosion of flammable gases
If you smell gas there is a danger of explosion.
▶ Never work on gas lines unless you are licensed for this type of work.
▶ Make sure that a qualified company installs the boiler, connects gas
and ventplaces the boiler in operation, connects the electrical power,
and maintains and repairs the boiler.
▶ No open flame! No smoking! Do not use lighters
▶ Prevent spark formation. Do not operate electrical switches,
including telephones, plugs or door bells.
▶ Close main gas valve.
▶ Open doors and windows.
▶ Warn other occupants of the building, but do not use door bells.
▶ Call gas company from outside the building.
▶ If gas can be heard escaping, leave the building immediately, prevent
other people from entering, notify police and fire departments from
outside the building.
Safety considerations
Risk to life from electrical shock.
▶ Disconnect the power supply to the boiler heating system before
conducting any work on it, e.g. turn off the heating system emergency
switch outside the boiler room.
▶ It is not sufficient just to turn off the control.
▶ Do not carry out electrical work unless you are qualified for this type
of work.
▶ Before disconnect electrical power completely and pad lock to
prevent accidental reconnection.
▶ Observe the local installation regulations.
Risk of fatal injury from flue gas poisoning
Insufficient ventilation or combustion air availability may cause
dangerous flue gas leaks or formation.
▶ Make sure that inlets and outlets are not reduced in size or closed.
▶ If faults are not corrected immediately, the boiler must not be
operated until all faults have been corrected.
▶ Inform the system operator and/or owner of the fault and the danger
in writing.Elektroanschluss nur durch eine Elektrof achkraft ausführen
lassen.
When working on the flue gas venting equipment or vent damper leakage
of flue gases may endanger the lives of people.
▶ Carefully observe proper operation of the vent damper. Do not start
up the boiler unless the vent damper is operating properly.
▶ Use only original parts when replacing parts.
▶ When replacing the vent damper, install the new one in the specified
position.
Risk to life by poisoning by spillage of flue gases
▶ If the blocked vent switch trips frequently the fault must be corrected
and proper operation of the blocked vent switch test must be
conducted.
Risk to life by poisoning by leakage of flue gases
▶ Make sure that the boiler is not equipped with a thermally controlled
flue gas vent damper after the open draft hood.
Risk of fatal injury from neglecting your own safety in case of
emergency, such as with a fire
▶ Never put yourself at risk. Your own safety must always take priority.
Fire danger due to flammable materials or liquids
▶ Make sure that there are no flammable materials or liquids in the
immediate vicinity of the boiler.
▶ Maintain a minimum distance of 15 inches from the boiler.
Installation and maintenance
▶ Observe all current standards and guidelines applicable to the
installation and operation of the boiler heating system as applicable in
your state or local jurisdiction.
▶ Clean and service the boiler system once a year. Check that the
complete heating system operates correctly.
▶ Immediately correct all faults to prevent system damage.
▶ Only use original Buderus spare parts. Losses caused by the use of
parts not supplied by Buderus are excluded from the Buderus
warranty.
1
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Product Description
2 Product Description
The boiler is a low temperature gas boiler.
The boiler consists of the following main components:
• Ignition module and adjustable boiler temperature controller
• Boiler jacket and front door
• Boiler block with insulation
•Burner
The ignition module and adjustable boiler temperature controller
monitor and control all electrical and operational components of the
boiler.The boiler jacket prevents energy loss and acts as soundproofing.
The boiler block transfers the heat generated by the burner to the
heating water. The insulation reduces energy loss.
2.3 Boiler Operating Conditions
The hot water piping system must comply with the current legislation
and local regulations. If an existing boiler is replaced, the complete hot
water piping system must be inspected to ensure that it is in perfect
condition to ensure safe operation.
Maximum boiler temperature: 220 °F
Maximum operating pressure: 58 psi
Table 2 Boiler Operating Conditions
2.4 Tools, materials and accessories
You need standard tools for the installation and maintenance of the
boiler as used in boiler heating system installation and oil, gas and water
installations.
The following additional items will also be useful:
• Boiler cart with strap.
• Cleaning brushes and/or chemical cleaning agents for wet cleaning of
the cast iron heat exchanger.
2.5 Disposal
▶ Dispose of the packaging material in an environmentally prudent
fashion.
▶ Dispose of any components of the heating system that require
replacement in an environmentally prudent fashion.
Fig. 1 Logano GC124 II gas boiler
[1] Boiler front door
[2] Boiler temperature controller
[3] Ignition module
[4] Boiler block with insulation
[5] Burner
[6] Boiler jacket
2.1 Correct use
The Logano GC124 II atmospheric gas boiler is designed to heat water
for a hot water heating system for heating single or multiple occupancy
buildings.
2.2 National regulations
The heating system must comply with the relevant regulations issued by
national authorities, or the regulations issued by the National Fuel Gas
Code, ANSI Z 223.1.
If specified by the local regulatory authorities the heating system must
comply with the regulations of the "Standard for Controls and Safety
Devices for Automatically Fired Boilers," ANSI/ASME CSD-1.Carbon
monoxide detectors must be installed as specified by the local
regulations. The boiler must be serviced annually ( chapter 15,
page 20).
Logano GC 124 II – 6 720 804 440 (2012/11)4
3 Dimensions and Connections
VK 1¼"
Dimensions and Connections
3
EL ¾"
GAS ½"
RK 1¼"
(GAS ½")*
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Fig. 2 Back, side and front view, measurements in inches
* optional connection
VK Boiler supply
RK Boiler return
EL Boiler drain
GAS Gas connection
Dimensions
Boiler size Boilerinput A B
Vent
connection II
Min. relief
valve capacity
Number of
Orifices
Water volume Dry weight
Btu/hr Inches Inches Inches lb/hr Qty. US Gal. lbs
18/3 74000 13 1/8" 8" 5" 62 2 2.4 228
25/4 103000 16 3/4" 8 2/3" 5" 86 3 2.9 287
32/5 132500 20 3/8" 9 1/2" 6" 110 4 3.4 349.5
Table 3 Dimensions/specs for GC124 II
For the size and dimensions of the main gas orifices,
refer to chapter 16, page 29.
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Fig. 3 Pressure drop/boiler
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Scope of delivery
4 Scope of delivery
▶ Check packaging upon receipt of delivery for damage.
▶ Check delivery for completeness.
Component Qty Packaging method
Boiler, complete 1 1 palette
B-kit components:
• 1-1/4" supply
manifold
• 30 psi relief valve
•long shank boiler
drain (¾")
•¼" pressure/
temperature gauge
• 90°-elbow
(1¼" x 1" NPT)
• 90°-elbow
(1¼"x1¼"NPT)
• 90°-elbow (¾" NPT
nipple)
• nipple1" NPT
• nipple 1¼" NPT
Vent damper 1 1 cardboard box
Circulator with whip 1 1 cardboard box
Technical documents 1 plastic package
Table 4 Scope of delivery
1) On Palette
Accessory Qty
Cleaning Brush 1
Table 5 Scope of delivery
1 1 cardboard box
5.1 Moving the boiler with boiler cart
Move the boiler with packaging in tact and on its pallet as much as
possible.
▶ Remove packaging straps and cardboard box from pallet.
▶ Remove screws that secure the boiler base to the wood pallet.
▶ Pick up boiler base from one side and slide to the edge of the pallet.
1)
1)
1)
Place a steel pipe as roller under the boiler base. Place additional steel
pipes under the boiler base and roll the boiler to its final destination.
Fig. 4 Moving the boiler with rollers
CAUTION: Ris k of inj ury due to i mpr ope r se cu rin g of the
boiler during transport.
▶ Use a boiler coart or dolley and strap for moving the
boiler
▶ Secure boiler on the boiler cart.
▶ Remove the front door during lifting or transport to
prevent unintentional opening.
5 Moving the boiler
This chapter describes how to move the boiler safely into place.
NOTICE: System damage due to uneven and rough
surfaces.
▶ Observe the transport diagrams on the packaging to
protect the sensitive components from damage due
to rough surfaces. Handle the product with care.
Protect all boiler connections from dirt if the boiler is not
installed immediately following removal from packaging.
Dispose of the packaging material in an environmentally
prudent fashion.
▶ Set the boiler cart or dolley on the front side of the boiler and put a
piece of cardboard between the two to prevent scratches.
Fig. 5 Moving the boiler with dolley or boiler cart.
[1] Additional card board for protection.
Logano GC 124 II – 6 720 804 440 (2012/11)6
▶ Secure boiler on the boiler cart.
6 720 804 440-06.1T
▶ Move boiler to desired location.
▶ Place the boiler at its final postion.
5.2 Lifting and carrying the boiler
The boiler can be picked up at the both long sides of the boiler as shown.
CAUTION: Risk of injury due to carrying heavy loads.
▶ Lift and carry the boiler with at least four people at the
designated side panel locations.
Placing the boiler
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Fig. 7 Required clearances in the boiler room
[1] Recommended service clearances
[2] Required minimum clearances
[3] Burner tray access door with combustion air opening as required
per ANSI Z.223.1
Fig. 6 Lifting and carrying the boiler
6 Placing the boiler
This chapter explains how to place the boiler and position it in the boiler
room.
NOTICE: System damage due to frost.
▶ Place the boiler in a frost-free room.
The boiler is very heavy when filled with water. Check that the floor can
bear the weight before installation.
6.1 Clearances
The GC124 boiler is approved for closet installation. The following
minimum distances must then be maintained:
• front: 2",
• sides: 2",
• behind open draft hood: 6",
• above boiler top panel: 30".
A space of at least 33 inches is recommended in front of the boiler with
the door removed to allow sufficient access space for operation and
maintenance. When the door is closed, a minimum clearance of 2 inches
is required at the front and sides, 2 inches clearance is also required for
the flue pipe and 30 inches clearance to the ceiling. The installation
location and the base must be smooth and horizontal.The boiler may be
installed on a flammable base, but not on carpet.
6.2 Leveling the boiler
Level the boiler in both horizontal directions.
▶ Level the boiler using a level and place small wedges (not supplied) for
leveling purposes.
7 Boiler installation
This chapter describes how to install the boiler. This includes the
following tasks:
• Connecting the heating system
• Electrical connection
• Gas supply piping connection
7.1 Preparing for installation
▶ Unpack all boxes and containers and check all parts against the
packing lists to make sure that everything has been supplied.
Every boiler is carefully inspected and tested before it
leaves the factory. However, if you discover any damage
or missing parts, please inform your supplier
immediately. Before disposing of packing material,
make sure that no parts are still in it.
For better access remove the front door.
Logano GC 124 II – 6 720 804 440 (2012/11) 7
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Boiler installation
7.2 Connecting the heating system
NOTICE: Boiler damage due to moisture.
▶ Protect the components of the gas ignition system
from moisture (dripping, spray, rain) during
installation of the boiler, during operation and during
maintenance work (such as replacing the pump,
replacing the control, etc.).
NOTICE: System damage due to overheating as a result
of a low water condition.
▶ Note that a boiler installed above the level of the
heating system must be equipped with a low-water
cut-off. The low-water cut-off must be installed during
installation of the boiler and placed above the water
level in the boiler without any means of shutting the
water off between the boiler and low water cut-off
( figure 8).
NOTICE: System damage due to high temperature
variations in the heating system.
▶ If the boiler is operated in connection with a
refrigeration system, make sure that the pipes for the
refrigerated liquid are connected in parallel to the
boiler system with suitable valves to prevent the
refrigerated liquid from entering the boiler.
▶ The piping system of a boiler connected to the heating
coils of hydro-air heating systems that may be
exposed to the circulation of cooled air must be
equipped with a flow-control valve or some other
automatic system for preventing the boiler water from
circulating by gravity during the cooling cycle.
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Fig. 8 Low-water cut-off installation
[1] Boiler
[2] Radiator
[3] Heating system with low-water cut-of
[4] Heating system without low-water cut-off
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Boiler installation
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Installation of B-kit
The relief valve and the pressure/temperature gauge are mounted on the
boiler supply manifold which is attached to the VK (supply) connection
of the boiler (included in B-kit).
Installing boiler supply VK:
▶ Remove factory installed plastic inserts from boiler supply (VK), boiler
return (RK) and boiler drain (EL) connections.
▶ Install the 1¼"NPT nipple into boiler supply, the 1" NPT nipple into
boiler return and ¾" male NPT drain valve into boiler drain connection.
▶ Install 90° 1¼" x 1¼"NPT on 1¼" NPT supply nipple and face upward
and install 90° 1¼" x 1"NPT elbow on return nipple and face in desired
direction.
▶ Install GC124 1¼" x 1¼"NPT supply manifold into supply connection
(VK) of the boiler. Do NOT place on return connection of the boiler!
▶ Install first 90° ¾" street elbow in upper ¾" NPT tapping of GC124 1-
1/4" supply manifold and install pressure relief valve into this ¾"
tapping. Make sure to orient the discharge of the relief valve
horizontally. Install the temperature/pressure gauge in the lower 3/4"
tapping of the supply manifold.
We recommend installing a y-strainer (accessory) in the
boiler return connection to reduce build-up of debris on
the water side inside the boiler.
Ensure compliance with all state and local regulations
pertaining to the installation of boiler systems.
WARNING: Fire danger due to exposure to hot water
pipes.
▶ Maintain a minimum clearance of two inches between
non-insulated pipes carrying hot water and
combustible walls and surfaces in the boiler room.
A minimum of 1" high quality pipe insulation is
required to permit direct contact with combustible
surfaces.
7.3 Electrical connections
The electrical connections of the boiler must be made as specified by the
local codes and the current regulations of the National Electrical Code,
ANSI/NFPA–70.
The boiler must be grounded as specified by the regulations of the
relevant local authorities; otherwise follow the regulations of the
National Electrical Code, ANSI/NFPA–70.
The boiler is fully functional with the factory installed aquastat and the
field installed vent damper and heating system circulation pump.
Fig. 9 Installation of B-kit
[1] Pressure relief valve ¾"
[2] 90° 3/4" street elbow
[3] GC124 1-1/4" supply manifold
[4] Pressure & temperature gauge
[5] 90° 1-1/4" NPT elbow
[6] 1-1/4" x 1" NPT nipple
[7] Boiler drain ¾" NPT (backside of boiler)
[8] 90° 1-1/4" NPT elbow
[9] 1" NPT nipple
Install the relief valve after the leak test. ( chapter 7.5,
page 11).
The relief valve must be installed in a vertical position.
The relief valve must also be installed in accordance with
the requirements of the ANSI/ASME Boiler and Pressure
Vessel Code, Section IV.
Logano GC 124 II – 6 720 804 440 (2012/11) 9
When making the electrical connections please observe
the following guidelines:
▶ Perform only electrical work, if you possess the
required certification for such work. When you do not
have the required certification, have the electrical
work performed by a certified electrician.
▶ Observe all local and state installation regulations.
Power supply connection.
Install incoming power to the boiler per local and state codes.
▶ Install an ON/OFF switch near the boiler per local code requirements.
Fig. 10 ON/OFF switch (emergency shutoff switch)
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Boiler installation
Description of field installed wiring connections using factory
supplied junction box.
▶ Remove two knock-outs from the left side of boiler panel to route
electrical feed and pump power into junction box.
▶ Route electrical power from the outside into junction box.
▶ Install a metal strain relief for the incoming power line on outside of
left boiler jacket panel. ( figure 12).
▶ Just use supplied wiring nuts and double proper wiring before
powering up the boiler.
When making the electrical connections use only wires
that are approved for electrical use.
Refer to the wiring diagrams for electrical details
( chapter 17, page 30) .
WARNING: Risk to life from electrical shock.
▶ When conducting maintenance work label all cables
before disconnecting them.
▶ If cables are connected incorrectly the system may
not operate correctly with possibly dangerous
consequences.
▶ Check that the heating system functions correctly after any
maintenance work.
WARNING: Fire danger.
Hot boiler components may damage electrical wiring.
▶ Make sure that all cables are routed in the ducts or on
the boiler insulation.
Fig. 12 Strain relief for shielded electrical wiring
7.4 Fuel gas supply connection
7.4.1 Gas connections
For the gas pipe diameter required for the installation please see table 6
and table 7 ( page 11). Make sure that the pipe fitting has the correct
thread size.
Make sure that a sediment trap is installed at the inlet for the gas supply
pipe to the boiler. A manual stop valve must be installed outside the
boiler jacket if required by the local code. We recommend installing a
manual shut-off valve in the main gas pipe to the boiler. The gas pipe
must be fastened outside the boiler.
The local codes must be observed during installation of the gas piping
connections, otherwise the regulations of the National Fuel Gas Code,
ANSI Z 223.1 must be followed.
▶ Install gas piping without any undue stress on the piping.
▶The Commonwealth of Massachusettes prohibits the use of copper
tubing for the gas line.
WARNING: Danger of explosion.
Leakage from the gas pipes and gas connections may
cause an explosion.
▶ Use soap solution to find leaks.
Fig. 11 Electrical junction box
[1] Electrical junction box (Inside of jacket cabinet)
[2] Incoming line voltage wiring
[3] Furnished wiring nuts.
Fig. 13 Gas piping connection to gas valve – right or left side
[1] Gas feed
[2] Manual shut-off valve
[3] Sediment trap
Logano GC 124 II – 6 720 804 440 (2012/11)10
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