Buderus GB402-320-5 Installation And Maintenance Instructions For Contractors Download Page 64

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Summary of Contents for GB402-320-5

Page 1: ...Read carefully prior to installation and maintenance Installation and maintenance instructions for contractors Gas fired condensing boiler Logano plus GB402 6 720 820 700 2018 01 GB...

Page 2: ...linder 20 6 6 Filling the heating system and checking for leaks 21 6 7 Making the electrical connection 22 6 7 1 Fitting the control unit 22 6 7 2 Establishing the power supply connection 22 6 8 Provi...

Page 3: ...gas line to the gas valve 42 10 9 5 Fitting the ventilation air unit 42 10 10 Check for water leaks during operation 42 10 11 Checking the ionisation current 42 10 12 Completing inspection and mainten...

Page 4: ...not be inadvertently reconnected It is not enough to switch off the control unit Danger through short circuits To prevent short circuits Only use original Buderus cables Siting and adjustment Correcta...

Page 5: ...through their technical trainingandexperience areknowledgeableinhandlingheatingsystems and gas installations The following documents are available for the Logano plus GB402 Ower s manual Operating in...

Page 6: ...Gas burner burner rod 5 Boiler block with thermal insulation 6 Boiler casing 7 Condensate pan and siphon 8 Burner control unit The main components of the Logano plus GB402 Fig 1 are Control unit Appl...

Page 7: ...t control of your heating system available separately 2 6 Scope of delivery The Logano plus GB402 is supplied as standard with a Logamatic BC10 basic controller and the MC10 control unit in 3 separate...

Page 8: ...Condensate outlet EV Combustion air pipe inlet balanced flue operation only corresponding connections are available as accessories GAS Gas Supply MAG Optional connection for a diaphragm expansion vess...

Page 9: ...ull Load K 30 30 30 30 30 Partial load K 40 40 40 40 40 Maximum permitted flow rate through the boiler2 l h 34400 42463 50525 58588 66650 Pipework connections Gas connection inch 2 Heating water conne...

Page 10: ...formula signs used on the type plate 2 Is to be ensured by means of system sizing and it corresponds to a minimum differential between flow and return temperatures of 8 K Boiler size output no of sec...

Page 11: ...ply 2 Es and Ei are sub groups of gas group E 3 Gas group LL for Germany and subarea Ei of gas group E for France are supplied with a setting for an upper Wobbe index of 12 8 kWh m3 for 0 C 1013 mbar...

Page 12: ...e gas boiler installation Please note that regional approvals may be required for the flue system and the connection of the condensate outlet to the public sewerage system Prior to commencing installa...

Page 13: ...ations Modified regulations or supplements are also valid at the time of installation and must be observed 4 Transporting the boiler Theboilermaybetransportedtotheplaceofinstallationbycrane hoist fork...

Page 14: ...the installation location Fig 6 Transporting the boiler on rollers measurements in mm NOTICE Boiler damage through means of transport Withouttheinvertedcarton theboilerframewilldeform through lifting...

Page 15: ...NGER Danger posed by explosive and easily flammable materials Neveruseorstoreeasilyflammablematerials paper curtains clothing thinners paints etc in the vicinity of the boiler NOTICE Risk of boiler da...

Page 16: ...r systems Only ask qualified contractors to calculate and size flue gas combustion air systems for multi boiler systems Ask the manufacturer of the flue system to confirm and verifythecalculations The...

Page 17: ...parts Ensure that the insertion ends are free of burrs If chamfering on site is required only in accordance with the manufacturer s documentation Centrocerin scope of delivery must be used as a lubric...

Page 18: ...m Incascadearrangements ensurethattheboilerisequippedwith a separate ventilation air line Isolate the air supply pipe from power supply and construct it to adaptor using a standard air pipe system acc...

Page 19: ...connector with a suitable sealant Fig 15 Safety valve up to 3 bar 1 Safety valve NOTICE System damage due to leaking connections Install all lines free from stress to the boiler connections Use new ga...

Page 20: ...e return RK Connection the diaphragm expansion vessel DEV To safeguard individual boilers a DEV can be connected to the inch connection on the return in accordance with EN 12828 Install the DEV on sit...

Page 21: ...e heating system has been tested and no leaks have been found set the correct operating pressure NOTICE System damage through boiler scaling Observe the water quality requirements in accordance with t...

Page 22: ...al installation work isolate all poles of the mains power supply and secure against unintentional reconnection Observe the following points regarding the electrical connection Electrical work on heati...

Page 23: ...ng the cover 6 8 Providing the fuel supply Install gas tap R2 2 in the gas line GAS When doing so prevent the gas line inside the boiler from becoming twisted Connect compensator 1 recommended to the...

Page 24: ...e gas side for external gas tightness For higher gas supply pressures than shown in table 12 page 28 Buderus offers additional gas pressure regulators as accessories NOTICE Boiler damage through exces...

Page 25: ...tness testing Never allow the agent to come in contact with electrical cables If the boiler is to be replaced in existing systems Consult gas suppliers to ensure that the nominal gas pressure accordin...

Page 26: ...lied in a fault state Wait approx 1 minute to enable the EMS connection to the RC35 programming unit available separately to be established Fig 29 Logamatic BC10 basic controller 1 Set DHW temperature...

Page 27: ...outside the values in tab 12 shut down the boiler and notify the gas supplier Commissioning is not permitted The maximum permitted gas static pressure depends on the proper function of the gas pressur...

Page 28: ...til 20 of the load is reached Country Gas group reference gas Connection pressure 1 mbar 1 The gas supplier must ensure that the pressure conforms to country specific or local regulations The conditio...

Page 29: ...erating mode from the flue gas test Press to terminate the flue gas test Return to operating mode on the RC35 Close the flap on the RC35 If the boiler is designed for operation with the Logamatic 4000...

Page 30: ...ion 3 then raise slightly and hook in at the top Using locking screws secure the rear side panels to the boiler back panel 3 Hookinthefrontsidepanelsfirstatthebottom includinginsulation 2 then raise s...

Page 31: ...vel 25 8 Commissioning the control unit and burner 26 9 Set the gas type if required 28 10 Record actual values 29 Full Load Partial load Draught ______Pa ______Pa Gross flue gas temperature tA ______...

Page 32: ...ection and servicing Heating systems should be regularly serviced for the following reasons to maintain a high level of efficiency and to operate the system economically low fuel consumption to achiev...

Page 33: ...valve Determine the gas train volume Vgas train using table 14 Determine the pipe volume Vpipe using table 15 and table 16 Calculate the test volume Vtest according to the above equation Gas valve vo...

Page 34: ...perform a test as described in the following x Test volume in litres y Pressure drop in one minute in mbar Read off example test volume Vtest 5 litres and pressure drop 4 mbar min range 3 Tap leaking...

Page 35: ...e boiler to cool down Remove siphon 2 from the outlet of condensate pan 1 and position a bucket underneath the pan Fig 43 Removing the siphon 1 Condensate pan outlet 2 Siphon NOTICE Risk of system dam...

Page 36: ...e 4 screws from gas valve flange 1 and undo the gas connection Fig 45 Undoing the gas connection 1 Screws Undo all electrical plug in connections at the electrode block Fig 46 Undoing the electrical p...

Page 37: ...owpipecanbe used to blow them off from the inside and outside using a reasonable amount of compressed air max 3 bar Re install the burner rod with a new gasket 10 6 2 Clean heat exchangers Dry cleanin...

Page 38: ...uctions by the manufacturer of the cleaning agent Fig 54 Wet cleaning the heat exchanger Working on the heat exchanger during wet and dry cleaning Use a hose to flush any residues into the bucket or t...

Page 39: ...ing components 10 8 1 Removing the gas valve Shut down the heating system Chapter 8 1 page 32 Close the main gas shut off valve or gas isolator and secure against unintentional re opening Remove the f...

Page 40: ...ain gas shut off valve or gas isolator and secure against unintentional re opening Remove the front panel Chapter 10 1 page 32 Undo the electric plug in connections at the fan Pull out the burner Chap...

Page 41: ...the front semi shell with clips to the ventilation air collector Push the compensation hose onto the ventilation air collector Secure the gas valve with the nozzle plate on the studs 10 9 3 Fitting t...

Page 42: ...4 page 43 10 13 Replacing the gaskets subject to time in use Thefollowinggasketsmustbereplacedafterexpiryofthespecifiedtime in use NOTICE System damage through contaminated air Prior to fitting the ve...

Page 43: ...for this step 6 Check the siphon and condensation catch pan shut down the heating system for this step 7 Check the electrode block shut down the heating system for this step 39 8 Checking the gas supp...

Page 44: ...________Pa ________Pa ________Pa ________Pa ________Pa ________Pa ________Pa ________Pa ________Pa ________Pa ________Pa ________Pa ________ C ________ C ________ C ______ C ________ C ________ C ___...

Page 45: ...exchanger 37 4 Replace the electrode block 39 5 Cleaning the siphon 39 6 Clean the condensation catch pan 39 7 Replace the mixture manifold gasket O ring 39 8 Carry out a function check Confirm profes...

Page 46: ...the fault has been cleared Should the fault reoccur repeat the reset two or three times Fig 64 Clearing a fault with the Reset key 11 2 Emergency mode The burner control unit automatically goes to em...

Page 47: ...stem conditions OH The appliance is in standby there is no heat demand The boiler is ready to operate and has no heat demand from the heating circuit OY The current boiler water temperature is higher...

Page 48: ...e Replace boiler sensor high limit safety cut out STB Replace ignition monitoring electrode V 3C 537 No speed The SAFe receives no speed feedback although the fan is supposed to be running Check cabli...

Page 49: ...ce the temperature sensor if there are any deviations from the table Check the voltage at the temperature sensor according to table Replace the SAFe in case of deviations V 4Y 523 Interruptioninthe bo...

Page 50: ...emperature Replace the SAFe if the boiler does not start Make replacements to check whether it is the SAFe or the MC10 that is faulty Replace the SAFe or MC10 If the SAFe remains dark wait a short tim...

Page 51: ...bling between the ignition transformer and ignition electrode for contact separation on electrode and transformer breaks and damage Establish the contacts correctly Replace cable if required SAFe burn...

Page 52: ...he control unit receives unrealistic values from the return sensor Check cabling between SAFe and return sensor Checkelectricalconnectionofthe SAFe cable Replace cable if required Remedy contact probl...

Page 53: ...ure sensor Replace cable if required Checkelectricalconnectionofthe SAFe cable Remedy contact problem if required Checktheresistancevaluesofthe temperature sensor against the table Replace temperature...

Page 54: ...y deviations from the table Check the voltage at the temperature sensor according to table Replace the SAFe in case of deviations V EE 612 Return temperature sensor measurement Successive measurements...

Page 55: ...EEN Operation state Colour code Lighting of the reset button Burner control unit is in operation On The burner control unit is in the locked out fault status Flashes slowly The boiler control unit is...

Page 56: ...62 60 50 3866 90 3958 00 4049 10 55 3239 10 3312 00 3384 90 60 2730 20 2786 00 2841 80 65 2314 50 2357 00 2399 50 70 1969 90 2004 00 2038 10 75 1683 30 1709 00 1734 70 80 1444 90 1464 00 1483 10 85 12...

Page 57: ...12 Appendix Logano plus GB402 6 720 820 700 2018 01 57 Fig 67 MC10 connection diagram 1 The total current of all externally connected components must not exceed 5 A...

Page 58: ...PH HK1 Heating pump 13 WA Heat demand external 14 FA Outside temperature sensor 15 FW DHW temperature sensor 16 EV External interlock remove the jumper when connected 17 RC Room controller 18 EMS BUS...

Page 59: ...m Fig 69 SAFe connection diagram 1 Fan pulse width modulation signal 2 Ignition transformer 3 Ionisation 4 Gas solenoid valve MV1 MV2 5 Gas pressure switch 6 Mains entry 7 Water pressure sensor 8 Flue...

Page 60: ...l Result O2 5 1 vol O2 20 95 CO2max CO2 CO2max O2 20 95 12 9 1 12 5 1 Nominal CO2 max for the distributed gas vol 11 4 11 5 11 6 11 7 11 8 11 9 12 12 1 12 2 12 3 CO2 default value for the burner setti...

Page 61: ...15 Fuels 9 G Gas category 9 Gas tightness test 42 Guidelines 12 I Installation location 15 Ionisation current 42 L Levelling 15 O Operating pressure maximum 9 P Packaging 7 32 Product Description 6 P...

Page 62: ...Logano plus GB402 6 720 820 700 2018 01 62 Notes...

Page 63: ...Logano plus GB402 6 720 820 700 2018 01 63 Notes...

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