Buderus SB735 Series Installation And Maintenance Manual
6302 2320 – 10/2003 US/CA For installers
Please read these instructions carefully!
Boiler Installation and
Maintenance Manual
Condensing Gas Boiler SB735
Series
2
Introduction
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Technical Changes!
Buderus Hydronic Systems, Inc. reserves the right to
this make changes due to continued technological and
engineering improvments.
Updating Technical Informations
Please contact us if you have suggestions for improving
this manual or when you have noticed incorrect
information.
Manufacturers Address:
Buderus Hydronic Systems, Inc.
50 Wentworth Ave
Londonderry, New Hampshire 03053
www.buderus.net
Document number: 6302 2320
Issue: 10/2003
F
This equipment conforms to the following
European and US requirements:
– 90/396/EWG European gas fired
guidelines
Standards: EN 677, EN 303-1,
EN 303-3, DIN 4702-6
– 92/42/EWG
European efficiency
guidelines
– 73/23/EWG
European low voltage
guidelines
– 89/336/EWG
EMV- European
electromechanical code
guidelines
– 97/23/EG European pressure
vessel guidelines
Standard: TRD 702
– ASME Boiler and Vessel Pressure
Code
Confirmation regarding confirmity with
respect to these guidelines can be obtained
upon request from Buderus Hydronic
Systems, Inc.
TABLE OF CONTENTS
3
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735• Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Regulations and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Hydrostatic test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Packaging and Components . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical Data, Dimensions and Water Connections . . . . . . . . . 6
4 Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Anti-Vibration Supports . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Boiler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 Installation of the Thermal Insulation
and Jacket Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2 Boiler Jacket - Pack A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Boiler Jacket - Pack B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4 Installation of the Control Panel
and Sensor Well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.5 Burner Door and Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.6 Boiler Jacket - Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.7 Rating Tag Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.8 Boiler Jacket - Pack C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.9 Venting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.10 Neutralization Equipment and Water Controls Installation. . . . . . . . . . 23
7 Placing the Boiler in Operation . . . . . . . . . . . . . . . . . . . . 24
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2 Cleaning of the Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
General Information1
4
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
1 General Information
1.1 General Information
This Boiler Installation and Maintenance Manual
contains important information regarding proper and
safe assembly, start-up and operating and maintenance
procedures for the SB735 series boilers!
The assembly and maintenance instructions are
designed for the installing contractor, who, due to
vocational training, is familiar, knowledgeable and
experienced in heating system and gas piping
installations.
1.2 Regulations and Guidelines
This document also makes reference to additional
accessories that may be used in conjunction with the
SB735 boilers. Observe the proper installation
instructions when installing these accessories.
The installation must conform to the requirements of the
authority having jurisdiction or, in absence of such
requirements, to the latest edition of the National Fuel
Code, ANSI Z223.1.
ADANGER!
due to combustion products.
Route flue gases via venting system to the
atmosphere. Use only approved venting
materials.
Have the system inspected by an authorized
person prior to start-up. Only start-up the
system after approval.
Check system for leaks.
The Buderus SB735 boiler is a condensing boiler
suitable for firing with natural gas or propane only.
The installation of a low water cut-off and pressure relief
valve must be based on local code requirements. Please
install these components per manufacturer’s
instructions and per detail on page 23.
JNOTICE
To avoid build-up of debris inside the heat
exchanger of the boiler, it is recommended to
install a filter on the boiler return connection(s).
1.3 Hydrostatic test
Perform a hydrostatic test. The test pressure should be
1.5 times the actual operating pressure in the heating
system, however a minimum of 14 psi.
JNOTICE!
Observe the listed boiler output ratings as
shown on the boiler rating plate.
Maximum Temperature and Pressure Ratings:
Permissible Fuels:
Logano SB735: Fuel Natural Gas or L.P
Please observe the guidelines of the gas supply
company!
Maximum Temperature and Pressure Ratings
Maximum Supply Temperature: 210 °F
Allowed System Pressure
(Models)
790 43.5 psi
970 43.5 psi
1200 43.5 psi
Maximum Time constant:
- Manual Reset High Limit 40 sec
- Adjustable High Limit 40 sec
Table. 1 Maximum Temperature and Pressure Ratings
Packaging and Components 2
5
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
2 Packaging and Components
The complete product is shipped in the following
components:
– Boiler vessel, bolted on transport woods
– Supply manifold, packaged with hydronic control
package
– Technical documentation, secured to the boiler
– VE insulation rings for burner and PVC condensate
drain (Siphon) secured to the boiler
– Boiler jacket panels and installation components,
packaged in a wooden crate and cardboard. The
assembly components are located in Pack A.
– The insulation blankets are packaged in 2 plastic
bags.
– A sound attenuating boiler base is supplied standard
with the SB735/1200 model.
– Electronic control panel, in cardboard box (optional).
– A condensate neutralization package can be ordered
separately.
– Hydronic control package, consisting of aquastat,
low water cut-off, relief valve and temperature
pressure gauge (when ordered from Buderus).
– Gas burner and gas train components, if ordered
from Buderus.
– Pre-cut burner mounting plate, if ordered from
Buderus.
Above mentioned components may differ slightly based
on the particular boiler model.
Technical Data, Dimensions and Water Connections3
6
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
3 Technical Data, Dimensions and Water Connections
Fig. 1 Technical Data, Dimensions and Water Connections
VK = Boiler Supply Connection
RK1 = Low Temperature Return Connection
RK2 = High Temperature Return Connection
H* = Boiler Height with Logamatic 2107/2109=H+6 inch
AKO = Condensate Drain
EK = Water Feed
EL = Boiler Drain
M = Sensing Port for Temperature Sensor
Ø AA = Vent Pipe Diameter
L
L
K
H
B
H
AA
Ø AA
M
VK
RK
2
AKO
RK
1
EK/EL
Boiler Model 790 970 1200
Max. Input [MBH] 2751 3378 4179
Max. Output [MBH] 2605 3251 4079
IBR Net [MBH] 2265 2827 3547
Thermal Efficiency [%] 96.9 96.3 97.6
Combustion Efficiency [%] 94.7 95.6 96.5
Length L Inch 91 ½ 108 ¼ 108 ¼
Length L
K
Inch 75 ½ 92 92
Hight H Inch 81 ¼ 81 ¼ 81 ¼
Width BInch545454
Boiler Widthless Jacket Inch 44 ¼ 44 ¼ 46 ¼
Vent Connection-Ø inside Ø AA Inch 14 14 14
Vent Height H
AA
Inch 19 19 19
Weight Lbs. 4330 5441 5534
Boiler supply
1. First Return Connection
VK
RK
1
Inch
Inch
4
4
5
5
5
5
2. Second Return Connection RK
2
Inch 3 4 4
Boiler Drain/Water Feed EK/EL Inch 1½ 1½ 1½
Table. 2 Technical Data, Dimensions and Water Connections
Boiler Installation 4
7
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
4 Boiler Installation
It is required to have a floor drain available near the
boiler.
It is recommended to place the boiler on solid foundation
of 2" to 4 " height. Use dimension B and L (Table 3) to
size this foundation.
The supporting floor must be level and of sufficient
strength.
Observe the indicated side clearances when placing the
boiler (Fig. 2). Dimensions shown indicate minimum
clearances to combustibles or space needed to swing
open burner door.
Place the boiler horizontally on the supporting
foundation.
JNOTICE!
Make sure to install the base supplied with the
SB735/1200.
Fig. 2 Clearance dimensions for SB735 boilers
Boiler
Model
L
[Inch]
BK
[Inch]
A
[Inch]
790 91 43 ¾ 98“(43“)*
970 107 ½ 43 ¾ 98“(43“)*
1200 107 ½ 46 98“(43“)*
Table. 3 Minimum Boiler Pad
Please observe the burner length L
Br
with respect to the front
clearance.
AL
8“
32“
1)
L
Br
(0)
B
k
(4“)
(40“)
Anti-Vibration Supports5
8
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
5 Anti-Vibration Supports
z Anti-vibration supports are standard equipment on
the SB735/1200 model; they can be ordered
separately for the other models.
z Insert the longer part of the longitudinal anti-vibration
bracket (Fig. 3, Item. 4) from the front and the
shorter part (Fig. 3, Item. 3) from the rear into the
channel sections (Fig. 3, Item. 2).
z Position both rails of the anti-vibration boiler support,
in accordance with dimensions shown in Table 4, on
the floor where the boiler is to be installed.
JNOTICE!
Prepare the foundation, where the anti-vibration
supports are to be located, with a smooth trowel
of ±1/8“ per linear foot and with a slight rise to
the back. This ensures an even load distribution
over the longitudinal anti-vibration brackets,
and adequate boiler ventilation.
z Position, align and place the boiler on the supports.
The boiler support should be flush with the boiler
back wall. The end-stop plates (Fig. 3, Item. 1)
should contact the channel section of the boiler.
Fig. 3 Anti-vibration support
Item. 1: End-stop plates
Item. 2: Channel section
Item. 3: Short anti-vibration bracket
Item. 4: Long anti-vibration bracket
Table. 4 Support dimensions
1)
Standard delivery
2)
Accessories
Boiler
Type
Boiler-
Model
Length
F
[Inch]
Distance
C
[Inch]
1200
1)
90 46
SB735
970
2)
90 43 ¾
790
2)
73 ½ 44
F
C
2
4
3
1
Boiler Assembly 6
9
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
6 Boiler Assembly
JNOTICE!
Make sure, that when fitting the front thermal
insulation, the burner door of the combustion
chamber is closed, to prevent damage to the
stainless steel combustion chamber from
welding or grinding activities.
Order of installation:
1. Thermal insulation/Pack A
2. Pack B
3. Pack C
6.1 Installation of the Thermal Insulation
and Jacket Panels
JNOTICE!
Ensure that the fabric is on the outside when
fitting the insulation blankets.
z Position the insulation blankets for the boiler body so
that the cut-outs are located over the cross brackets
plates (Fig. 5, Item. 1).
JNOTICE!
Position the narrow insulation blanket for boiler
model 790 at the rear, and note the drain cutouts.
JNOTICE!
Note the cut-outs for the low water indicator and
the cross bracket holder
(Fig. 7, Item. 1 + 5)!
z Position the front insulation blanket with its cut-out,
over the cross bracket holder.
z Tuck the insulation blanket in underneath the boiler
(Fig. 5).
Fig. 4 Connections
M = Sensing port for temperature sensor
VK = Boiler supply and relief valve connection
RK2 = High temperature boiler return
RK1 = Low temperature boiler return
AA = Vent connection
AKO = Condensate drain
EK/EL = Water feed/boiler drain
Fig. 5 Insulation blanket
M
VK
RK2
RK1
AA
AKO
EK/EL
1
Boiler Assembly6
10
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
z Overlap the insulation blankets on the side and wrap
around the boiler body, then fasten with 8 clips.
z Unscrew four hexagon bolts (Fig. 6, Item. 1) from the
right side of the boiler door (Fig. 7, Item. 1) and four
from the left side.
ADANGER OF INJURY!
through falling parts.
Ensure that the hinge bolts (Fig. 21, Item. 1)
are in the boiler door before opening it.
JNOTICE!
The recesses (Fig. 6, Item. 2) in the boiler door
(2 on the left and 2 on the right side) have been
provided for lifting with a crane or hoist, for
example for the complete removal of the door.
z Open the burner door (Fig. 7, Item. 1)
z Place the insulation blanket with round cut-out
(Fig. 7, Item. 2), with its wide edge facing upwards,
on the left front of the boiler body (wide edge up) and
secure with four clips (2 left, 2 right) on the
surrounding thermal insulation.
ACAUTION!
Ensure that the wide edge is at the top at the
hinge bolts!
z Close the burner door and re-secure with eight
hexagon bolts.
z Position the thermal insulation strip (Fig. 7, Item. 3)
laminated on the front of the reversing door.
z Position the thermal insulation strips (Fig. 7, Item. 4)
for the reversing door from below around the side of
the reversing door and secure with two clips.
JNOTICE!
Observe the hinge bolt cut-outs!
z Locate the rear side thermal insulation (Fig. 8,
Item. 2) in accordance with the cut-outs on the rear
side of the boiler and secure with six clips (Fig. 8,
Item. 1, 3 left and 3 right) on the surrounding thermal
insulation (Fig. 8, Item. 3).
Fig. 6 Screws for opening the burner door
Fig. 7 Burner door insulation blanket
Fig. 8 Rear side insulation blanket
1
1
2
2
1
2
3
4
5
1
2
3
Loading...