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9

 

Boiler inspection and maintenance

Logano G234X – 6 720 811 233 (2014/05)

27

9.5.3

Wet cleaning the boiler (chemical cleaning)

▶ For wet cleaning, use a cleaning agent appropriate for the degree of 

soiling (e. g. soot or scale). 

▶ Remove the boiler casing and thermal insulation; check for damage.
▶ Unscrew cleaning cover from the draft diverter.
▶ Cover the control panel with foil to prevent spray getting into the 

control panel.

▶ Ventilate boiler room well.
▶ Spray cleaning agent evenly from the top into the hot gas flues 

(

Fig. 34).

▶ Install the burner in reverse order of removal (

Section 9.5.1).

Fig. 34 Wet cleaning the boiler 

▶ Place the heating system in operation.
▶ Heat the boiler to a temperature of at least 122 °F (55 °C).
▶ Shut down the heating system.
▶ Allow boiler to cool.
▶ Remove burner (

Section 9.5.1).

▶ Brush out the hot gas flues.
▶ Clean combustion chamber and bottom panel.
▶ Ventilate boiler room well again.
▶ Install or clean the burner (

Section 9.6).

▶ Screw cleaning cover into place and replace insulation.
▶ Install boiler cover.

9.6

Cleaning the burner

▶ Remove burner (

Section 9.5.1).

▶ Check burner rods for dirt. 

If necessary, clean burner as described below:
▶ Unscrew pilot burner unit (

 Fig. 35 [1]) from burner.

▶ Disconnect pilot gas line [3] from pilot burner unit.
▶ Remove and blow out pilot orifice [2].
▶ Immerse burner rods in water with cleaning agent and brush off.

Fig. 35 Pilot burner 

[1]

Pilot burner unit 

[2]

Pilot orifice

[3]

Pilot gas line

[4]

Ignitor sensor cable

▶ Rinse off the burner rods under a stream of water. Hold burner so that 

water enters all slots of the burner rods and drains out again.

▶ Remove remaining water by swinging the burner (

 Fig. 36).

Fig. 36 Swinging burner

▶ Check that the burner rods are free. 
▶ Remove water and dirt residue in the slots. 
▶ If slots are damaged: Replace burner.
▶ Install the burner in reverse order of removal (

Section 9.5.1).

▶ Place boiler in operation as directed in Section 6, starting on 

page 18.

▶ Check that the AquaSmart

TM

 functions properly.

In some circumstances, you may need to proceed 
differently from the method described here.
▶ For wet cleaning (chemical cleaning), observe the 

operating instructions of the relevant cleaning 
equipment and cleaning agent.

6 720 806 028-20.1T

▶ Make sure that the insulation on the burner shield 

does not get wet.

Summary of Contents for Logano G234X

Page 1: ...atal injury or property damage Follow the instructions in this installation and maintenance manual exactly If you require assistance or further information contact a qualified contractor an suitable service provider or the gas supply company DANGER These instructionsare partofthetechnical documents that must be handed over to the owner operator of the heating system Discuss the content of this man...

Page 2: ...cting the flue connector 14 5 7 1 Check openings for combustion air supply and venting 14 5 7 2 Requirements for connection to chimneys or flue gas systems 15 5 7 3 Installing the flue pipe 16 5 7 4 Connecting flue pipe 16 5 7 5 Installing a vent damper 16 5 7 6 Electrically connecting the vent damper 17 6 Placing the heating system in operation 18 6 1 Testing the safety valve 18 6 2 Making the he...

Page 3: ...er is not be fitted with a barometric damper or a thermally controlled vent damper downstream of the flue connector Do not tamper with remove or attempt to repair the flue gas shutoff switch When replacing the flue gas shutoffswitch install the new part inthe original location Afluegasshutoffswitchtrippingmorethanonceindicatesaproblem with the flue gas system or chimney which must be repaired imme...

Page 4: ...perator that they must never carry out any modifications or repairs 2 Product Description This installation and maintenance manual contains important information for the safe and correct installation initial commissioning and maintenance of this boiler The Logano G234X floor standing gas boiler is generally referred to below as a boiler The installation and maintenance manual is provided for techn...

Page 5: ...e fashion Dispose of any components of the heating system that require replacement in an environmentally responsible fashion at an approved landfill Notice regarding environmental protection and disposal Section 8 page 24 2 6 Product Description The boiler is a low temperature gas boiler with an atmospheric gas burner The boiler consists of the following main components Fig 1 Ignition module and a...

Page 6: ... 16 40 11 16 25 10 16 2 10 16 38 7 16 729 465 137 147 348 650 66 1034 975 6 720 806 028 02 1T Boiler size Unit 38 5 45 5 55 6 64 7 Ignition heat load MBTU hr 160 187 228 266 kW 46 9 54 8 66 8 78 0 Nominal output MBTU hr 130 154 188 219 kW 38 45 55 64 Dimension A inches 25 6 25 6 29 1 32 7 mm 650 650 739 831 Dimension B inches 7 7 7 8 mm 178 178 178 203 Minimum capacity of the safety relief valve l...

Page 7: ...er of injectors Main gas orifice identification Rated orifice pressure for natural gas 0 8500 ft 0 2591 m In W C mbar 38 3 3 70 3 0 7 6 45 3 3 70 4 1 10 4 55 4 3 50 4 6 11 5 64 4 3 80 4 4 10 9 Table 4 Main gas orifice identification and rated orifice pressure for natural gas Boiler size Number of injectors Main gas orifice identification Rated orifice pressure for propane gas 0 8500 ft 0 2591 m In...

Page 8: ... boiler and roll it on additional pipes to the installation location Fig 5 Place the boiler in its final position Fig 5 Transporting the boiler on rollers NOTICE Risk of system damage from impact shocks Fragile components could be damaged Observe the transport instructionsonthe packaging NOTICE System damage due to improper transport Protect sheet metal parts flue gas pipe burner and control unit ...

Page 9: ...el the boiler both horizontally and vertically using a spirit level Insert metal shims underneath if necessary Fig 7 Leveling the boiler example DANGER Danger posed by explosive and combustible materials Neveruseorstoreeasilyflammablematerials paper curtains clothing thinners paints etc near the boiler Maintainaclearanceof16 inches 415 mm fromthe boiler NOTICE Risk of system damage due to freezing...

Page 10: ...ht side NOTICE Risk of boiler damage due to moisture Protect the individual components of the control system and the ignition system from damp dripping water water spray rain during installation operation and servicing e g pump replacement programmer replacement etc NOTICE Risk of system damage due tooverheating as a result of lack of water Make sure that if the boiler is located above the level o...

Page 11: ...able regulations Mount an ON OFF switch near the boiler Fig 10 Main power switch by customer DANGER Risk of fire from flammable materials Maintainaclearanceof2inches 51 mm frompipes carrying hot water and flammable walls at the installation location We recommend installing a dirt trap and a dirt separator accessory in the heating return connection to reduce build up of debris on the water side Obs...

Page 12: ...al code We recommend installing a manual shutoff valve in the main gas pipe to the boiler The gas pipes must be fastened outside the boiler The gas supply pipe is designed for a gas connection on the right side For conversion to a left side gas connection see Section 5 1 Topreventstrainonthegasvalves extensionsofthegas supply line must be supported 1 2 3 4 6 720 806 028 07 1T Pipe length Flow rate...

Page 13: ...versionkitsforconvertingtheboilerfromnaturalgas to propane gas can be obtained from Bosch Do not attempt to convert the appliance without the approved Buderus parts and the relevant technical documentation The technical documentation is included with the conversion parts For information about the identification of the main gas orifice and the nominal gas orifice pressure for natural gas and propan...

Page 14: ...al building codes In Canada the regulations in accordance with CAN CSA B 149 1 and 2 Installation Codes apply NOTICE System damage due to faulty safety valve Do not install the safety valve until the leak test Section 5 5 has been completed Install the safety valve vertically Install the safety valve in accordance with the requirements of the ANSI ASME Boiler and Pressure Vessel Code Section IV Ob...

Page 15: ... to the outside through vertical ventilation ducts each opening must have a minimum cross section of one square inch per 2000 Btu h 1100 mm2 kW of the total burner output of all gas fired appliances inside the closed room If the openings are connected to ventilation ducts the ducts must have the same cross section area as the openings to which they connected 5 7 2 Requirements for connection to ch...

Page 16: ...les provided in the vent damper 1 Fasten vent damper to the flue connector adapter with three 3 corrosion resistant sheet metal screws A Seal all unused openings of the common flue gas system B Perform a visual inspection of the flue gas system to ensure that it has the correct dimensions and longitudinal inclination Make sure that the system is not blocked leaking corroded or has any other faults...

Page 17: ...ns are permitted to carry out electrical work Beforeopeningtheappliance Disconnectitfromthe power supply via the ON OFF switch or the appropriate building fuse Take measures to ensure that the heating system cannot be accidentally reactivated Please observe all installation instructions DANGER Fire hazard from hot boiler components Hot boiler components may damage electrical cables Ensurethattheel...

Page 18: ...cted close the gas shutoff valve seal the leaks and repeat step 6 8 Close the gas shutoff valve Remove the screw plug from the gas supply pressure test point 2 on the gas valve in order to measure the gas supply pressure Install pressure test port and attach a pressure gauge 9 To measure the orifice pressure remove the screw plug from the orifice pressure test point 3 on the gas valve Install pres...

Page 19: ... and subsequent incorrect operation Risk of fire and explosion from failure to observe the startup instructions Read the startup instructions carefully before commissioning DANGER Risk of fatal injury from gas explosion If you smell gas there is a danger of explosion Close the gas shutoff valve Open windows and doors Donotoperateanyelectricalswitchesortelephones Do not use any sockets Extinguish a...

Page 20: ... 17 4 26 2 mbar and between 11 13 W C for propane gas 27 4 32 4 mbar Record the measured values in the commissioning report page 23 11 Check nozzle pressure Set the orifice pressure according to Table 11 while the boiler is operating To do so remove the safety screw for adjusting the orifice pressure Fig 23 3 from the gas valve Turn the adjustment screw clockwise to increase the orifice pressure T...

Page 21: ...trollermustswitchtolockedstatus and stop generating sparks 21 Disconnecttheheatingsystemfromthepowersupply Openthegas shutoff valve Switch on the power supply for the appliance A normal operating cycle must follow If the gas valve operates correctly Proceed to step 25 22 If the gas valve does not operate correctly Immediately turn the ON OFF knob on the gas valve 1 clockwise to the OFF position Cl...

Page 22: ...Checking temperature control 1 Adjustment keypad 6 6 Shutting off gas supply to boiler Set the room thermostats to the lowest setting Disconnect the heating system from the power supply before carrying out maintenance work Turn the gas valve ON OFF knob Fig 26 1 clockwise to the OFF position Do not use excessive force 6 7 Inform owner operator hand over technical documentation Familiarize the owne...

Page 23: ...orifice pressure and adjust if necessary inches W C or mbar Page 20 Meas value _____________________________ Unit _____________________________________ 7 Leak test during operation Check ignition flame Check main burner flame Check that flue gas system is functioning properly Page 18 Page 20 Page 20 Page 16 8 Check maximum AquaSmartTM setting Page 22 9 Install front wall of boiler Page 14 10 Infor...

Page 24: ... regulations are strictly observed To protect the environment we use the best possible technology and materials taking into account economic points of view Packaging method For the packaging we participate in the country specific recycling systems which guarantees optimal recycling All packaging materials used are environmentally friendly and recyclable Old appliances Old appliances contain materi...

Page 25: ...he boiler for cleaning Shut down the heating system Section 7 1 page 24 Remove front wall of boiler Fig 18 page 18 Turn the gas valve ON OFF knob 1 clockwise to the OFF position Do not use excessive force Fig 30 Gas valve in OFF position 1 ON OFF knob OFF position DANGER Danger to life from electric shock When performing maintenance label all connection cables before disconnecting them If cables a...

Page 26: ... on the studs Fig 32 Removing the burner 1 Retaining nuts 2 Studs with spacers 9 5 2 Cleaning the boiler with brushes mechanical cleaning Remove the boiler casing and thermal insulation check for damage Unscrew cleaning cover from the draft diverter Cover control unit with foil to prevent entry of metal dust into the control unit Use cleaning brushes 1 to brush out hot gas flues Clean combustion c...

Page 27: ...aning the burner Remove burner Section 9 5 1 Check burner rods for dirt If necessary clean burner as described below Unscrew pilot burner unit Fig 35 1 from burner Disconnect pilot gas line 3 from pilot burner unit Remove and blow out pilot orifice 2 Immerse burner rods in water with cleaning agent and brush off Fig 35 Pilot burner 1 Pilot burner unit 2 Pilot orifice 3 Pilot gas line 4 Ignitor sen...

Page 28: ...r any other flammable or corrosive vapors and liquids Complete the maintenance log to confirm that all maintenance work has been carried out page 31 Sign the maintenance log and familiarize the owner with how the heating system operates DANGER Risk of fatal injury from explosion of flammable gases Gas lines and their fittings may leak after maintenance has been performed Carry out a proper leak te...

Page 29: ...t the If everything is OK replace pilot assembly No Heat requirement ended system switches off flue baffle closes End of troubleshooting Repeat procedure until heating system operates properly On models with vent damper check that it operates and limit switches are present If necessary replace vent damper Check ignition wiring ceramic insulator of ignition electrode and ignition gap adjust if nece...

Page 30: ...on flame Specified thermostat value control reached Main and ignition gas valves close gas burners ex tinguished vent damper if installed closes Ignition burner operation Ignition flame burns automatic ignition signals steady ignition flame or ignition flame does not burn pilot assembly starts ignition at tempt switches off after 90 seconds END PHASE 1 Ignition attempt PHASE 2 Main burner operatin...

Page 31: ...age 18 ___________ inches W C ___________ inches W C 8 Check for leaks during operation Page 18 9 Check the pilot burner flame Page 20 10 Check the main burner flame Page 21 11 Check the vent damper Page 17 12 Check high temperature limit controller Page 22 13 Check the area around the boiler for flammable materials gasoline or corrosive liquids Page 3 14 Confirm maintenance Confirmation of proper...

Page 32: ... Blocked vent switch Intermittent pilot dual valve combination gas control VR8304 Pilot burner Honeywell Main valve Pilot valve green blue white red GND MV MV PV GND PV MV PV MV 24V 24V 4 3 2 1 Ref no Drwg no Reviewed Edition Wiring diagram Optional Vent Damper Plug R W L2 Circulator N L 1 Emergency Shut off Switch by others L1 C1 C2 ZC ZR B1 B2 2 Boiler Sensor Plug 3 Fuse 1 25AT 24V AWG 18 WIRE 1...

Page 33: ...culator To Pilot Burner Spark Gas valve Main Pilot PV PV MV GND MV S8600H GND PV PV MV MV 24V 24VGND K1 TR High Limit Flame roll out safety shutoff switch K2 B2 L2 N L 24V AWG 18 WIRE 120 VAC Wiring Schematic G234X Circuit breaker Emergency shut off switch C2 Fuse 1 25AT Wiring diagram gas boiler G234X USA CDN Intermittent pilot 8469 8718588667 2012 11 GAW 034 USA Ref no Drwg no Reviewed Edition W...

Page 34: ...10 Logano G234X 6 720 811 233 2014 05 34 Notes ...

Page 35: ...10 Logano G234X 6 720 811 233 2014 05 35 Notes ...

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