Buderus Logano G315 Installation And Service Instructions Manual Download Page 32

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System start-up

Logano G315 – 6 720 817 939 (2017/02)

Removing flue gas baffles

For boilers with 7 – 11 boiler sections (819 – 1,553 MBH or 240 –
455 kW) an increase of the flue gas temperature can be achieved
through

pair-wise

removal of the upper or lower flue gas baffles.

11.6

Commissioning log

The Logano G315 can be used with an oil- or gas-fired burner. Fill in the
commissioning log for the appropriate type of oil or gas burner carefully.

▶ Sign all start-up work as completed and enter the relevant date.

Commissioning operations

Individual steps

Comments (signature)

Perform leak test of the entire system

Fill the heating system with water



page 31

Purge the heating system

Perform the leak test if the boiler was assembled on-site



page 17

Record the filling water quantity and composition in the
operator’s log (included with the technical documentation).

Check position of flue gas baffles



page 20

Check the fuel line for leaks

Start up the control panel



page 31

Initial burner start-up

See burner
documentation

10.

Check the flue gas temperature



page 31

11.

Check vent pipe for leaks

12.

Check the boiler on the hot gas side for leaks

13.

Enter the fuel used in the table provided in the operating
instructions

14.

Inform the owner and operator and hand over technical
documentation

15.

Confirm properly-completed commissioning

Company stamp/signature/date

Table 13

Summary of Contents for Logano G315

Page 1: ...d and certified installer or the gas supply company WARNING Theoperatinginstructionsarepartofthetechnicaldocumentsthatmust be handed over to the owner or operator of the heating system Explaintotheowneroroperatorhowtousetheheatingsystemusingthe operating instructions Make sure that they are familiar with all required information for the safe and proper operation of the heating system These instruc...

Page 2: ...ivery unassembled 10 5 Transporting the boiler 10 6 Positioning the boiler 11 6 1 Tools and auxiliary materials 11 6 1 1 Boiler assembly tool size 2 3 11 6 2 Recommended wall clearances 11 6 3 Installing the boiler on a boiler base or foundation 12 7 Boiler block assembly 12 7 1 Assembly of a boiler block from sections 13 7 2 Joining the boiler block assembly delivery unassembled 13 7 3 Setting up...

Page 3: ...Wet cleaning the boiler 35 13 5 Checking the operating pressure 35 13 6 Refilling with boiler water and purging the system 35 13 7 Inspection and maintenance reports 36 14 Troubleshooting burner faults 38 15 Spare parts 39 Index 53 Appendix 54 1 Key to symbols and safety instructions 1 1 Key to symbols Warnings The following keywords are defined and can be used in this document DANGER indicates a ...

Page 4: ...ioning units with vent to the outside 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 Only employ a trained and certified contractor to carry o...

Page 5: ...l jacket NOTICE Risk of system damage from use of incorrect burner Only use burners that meet the technical requirements of the oil gas fired boiler Logano G315 chapter 3 page 8 Observe all standards and guidelines applicable to the installation and operation of the system in your country Pleaseobservetheinformationontheboilerratingplate These are definitive and must be observed To prevent boiler ...

Page 6: ...ricalpowersupply servicingand repair may only be carried out by a trained or 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 thecompletesystemmustbetestedatthesametime Anyfaultsmustbe corrected immediately The design and mode of operation of this boiler must comply with the American Na...

Page 7: ... of eight 8 feetabovegradedirectlyinlinewiththeexhaustventterminalfor the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 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 unl...

Page 8: ...21 48 1o L LK 880 mm 34 41 64 1195 mm 47 3 64 106 mm 4 11 64 450 mm 17 23 32 155 mm 6 7 64 56 mm 2 13 64 EL RK VK VK 1035 mm 40 3 4 938 mm 36 59 64 818 mm 32 13 64 7 180 mm 34 41 64 2 13 64 17 23 32 40 3 4 47 3 64 36 59 64 32 13 64 4 11 64 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...

Page 9: ...78 Weight net1 lb kg 1 20 543 1 395 631 1 59 719 1 78 807 1 975 895 Boiler water content gal l 37 75 143 45 25 171 52 5 199 60 227 67 5 255 Gas capacity gal l 38 83 147 47 82 181 56 8 215 65 78 249 69 48 263 Flue gas temperature partial load 60 F C 178 6 137 280 4 138 176 8 136 269 6 132 285 8 141 Flue gas temperature full load F C 323 6 365 162 185 309 2 359 6 154 182 321 8 356 161 180 316 4 348 ...

Page 10: ...cket pack according to boiler rating 1 Cartons Thermal insulation 1 bag Table 5 Component Qty Packaging Front and rear section 3 intermediate sections as well as burner door 1 Pallet Intermediate sections depending on boiler size 1 Pallet Fittings and draft diverter 1 Box Tie rods and supply pipe 1 Bundle Jacket pack according to boiler rating 1 Cartons Thermal insulation 1 Bag Table 6 WARNING Ris...

Page 11: ...0 mm 6 2 Recommended wall clearances Fig 5 Installation room with boiler Observe the recommended wall clearances for complete opening of the burner door for boiler installation and for cleaning and maintenance Fig 5 The burner door can be hung with the hinges on the right or left When installing your boiler maintain the recommended minimum dimensions Select the recommended clearances between wall ...

Page 12: ...or with burner plate Depending on the type of delivery we distinguish between delivery unassembled and as a ready assembled block When delivered as a ready assembled block the boiler is assembled and checked for leaks prior to despatch If because of physical limitations a boiler block cannot be assembled as a complete unit delivery unassembled would enable assembly on site For details of assemblin...

Page 13: ...coat the hub sealing faces with sealant Fig 10 Preparing the packing grooves and hubs The next step involves preparing the nipples that will eventually seal the boiler sections Cleannipplewitharagsoakedinsolventsorgasolineandcoatevenly with sealant Insert the nipple straight into the upper Sz 2 119 50 and lower Sz 0 57 50 hub of the rear section and hammer home securely with alternate heavy blows ...

Page 14: ...l supplied Peel the backing paper from the sealant rope when inserting into the packing groove do not stretch Fig 13 Inserting sealant rope Preparation of the first intermediate section File down any burrs on the hubs as shown in Fig 9 The packing springs must be clean and dry Clean if necessary Clean the hub sealing faces with a rag soaked in solvents or gasoline Evenly coat the hub sealing faces...

Page 15: ...pressed using the boiler assembly tool NOTICE Theboilercanbedamagedbypullingtheboiler sections together incorrectly or due to excessive compression Ensure that the nipples are positioned straight in the boilerhubsafterbeingpoundedinandthattheyhave not been compromised Never compress more than one nipple joint at a time Stop compressing the sections when the boiler hubs meet NOTICE Assembly tool da...

Page 16: ...next step describes the installation of the supply pipe Chapter 7 4 page 17 7 3 Setting up the boiler block assembled block Cut the retaining band Fig 20 1 Remove the pallet prior to positioning the boiler block Fig 20 2 Fig 20 Boiler block on pallet Level the boiler block vertically and horizontally on the base foundation Chapter 6 3 page 12 The following pages describe the installation of the su...

Page 17: ...class 1 0 to measure the pressure Close off lower boiler hub Fig 23 3 at the front and rear To do this place corresponding seal Fig 23 1 on the relevant boiler hubandseal intherelevantsealingplug Inthiscase thesealingplug with the R tapped hole for the fill and drain connection Fig 23 2 is mounted on the rear of the boiler Install the on site fill and drain valve Closeoffsupplyandreturnconnections...

Page 18: ...he leak location by driving ponding in flat wedges or chisels between the sections at the designated points Fig 24 1 and 2 at the top and bottom Fig 24 Separating the boiler block 7 6 3 Supply flange with safety components return flange Fig 25 Return flange 1 Boiler connection 2 System connection Use new nipples and new sealant rope for the reassembly Pull the boiler back together and repeat the l...

Page 19: ...flat seal Fig 27 2 is required for connecting the supply at a later stage Fig 27 1 Fig 27 Fitting a flange 6 720 817 939 13 1T 6 5 2 3 4 7 1 NOTICE Risk of system damage from leaking connections All pipe connections to the boiler must be free of stress and tension NOTICE System damage from deposits local overheating and corrosion As a basic rule clean and flush existing systems before connecting t...

Page 20: ... gas baffles from the crate and insert into the flue gas passages as indicated by their inscription Fig 30 and Tab 10 Fig 30 Flue gas baffle plates 7 8 4 Fitting burner door panel In the factory the burner door is mounted with the hinges on the right hand side Fig 31 4 and 6 For left hand closing remove the hinges accordingly on the left hand side of the burner door Screw the hinge pins Fig 31 1 a...

Page 21: ... Thefoldededgeof the upper crosswise tier bar must point towards the front Screw the bottom crosswise tie bar Fig 33 2 to the feet of the rear section with two machine screws M 8 x x 15 The folded edge of the bottom crosswise tie bar must point towards the back Fig 33 Fitting the back profile rails 7 9 2 Attaching the thermal insulation The thermal insulation provided corresponds to the boiler siz...

Page 22: ...ls and top covers Attach side panel Fig 37 1 with the cut outs into the slots of the topconnectionplates Fig 37 2 andpushforwardsasfarasitwill go Screw the side panels at the bottom to the bottom profile rails using two self tapping screws in each case Fig 37 3 Fig 37 Fitting the side panels Place front cover Fig 38 1 between the side panels so the cut out Fig 38 3 fits over the tie bar Screw the ...

Page 23: ...eself tappingscrewineach case Fig 40 1 and 3 Fig 40 Fitting the front base rail Screwthetoprearboilerpanel Fig 41 2 tothebackofthecover Fig 41 1 and the side panels Fig 41 Fitting the rear boiler panel Screw the bottom rear boiler panel Fig 42 2 with the cut out for the fill and drain connection down onto the side panels Fig 42 1 and 3 Fig 42 Fitting the bottom rear boiler panel 6 720 642 621 33 1...

Page 24: ...top Place hose clamps Fig 45 4 over the vent pipe sealing collar One of the hose clamps must press onto the draft diverter outlet and and one onto the vent pipe Tighten hose clamps The vent pipe sealing collar must fit smoothly and firmly in place after tightening the hose clamps Fig 45 Installing the vent pipe 1 Vent pipe sealing collar 2 Flue gas temperature sensor 3 Sleeve 4 Vent pipe 5 hose cl...

Page 25: ...he capillary tubes through the cable entry and unroll to the required length Fig 47 Preparing the cable entry The sensor well has already been sealed in the flow connection socket Chapter 7 5 page 17 The temperature sensor set connected to the control panel consisting of three temperature sensors and one sensor blind piece Fig 48 1 is installed in the sensor well R Route capillary pipe sensor to t...

Page 26: ... panel installed 9 3 Installing the Hydrolevel Hydrostat Control and Hydrolevel Electro Well Slide temperature sensor bundle set with compensating spring all the way into the sensor well The plastic spiral is then pushed back automatically Push the sensor holder included with the control device over the side of the sensor well head Fig 52 Installing the temperature sensor set 1 Compensating spring...

Page 27: ...4 is 1 Amp In applications requiring CSD 1 compliance a manual safety high limit switch must be installed Interrupting power to the burner Fig 54 Installation of a high limit switch CAUTION Risk of system damage from incorrect connections Wrong connections can cause damage to the primary safety control Connect the hot black wire to the L terminal and the neutral white wire to the N terminal Do not...

Page 28: ...evel with Riello F15 for 120V burners only 1 Hydrolevel Hydrostat 2 Riello F15 burner L1 L2 C1 C2 B1 B2 I1 I2 Z T TV L B1 L B2 N N 120VAC G EQUIP GND TERMINAL 1 2 BLUE WHITE BLACK BROWN WHITE BLUE BROWN BLACK CAPACITOR VALVE MOTOR COIL 2 3 4 5 6 7 8 9 1 N L D5995 BLACK WHITE 6 720 817 939 07 1T ...

Page 29: ...level Hydrostat 2 Becket CF500 CF800 L1 Line 1 power hot L2 Line 2 power neutral LMT Limit control terminal MTR Motor control terminal S1 Oil valve S2 Oil valve on cleancut pump TRANS Ignition transformer VLV Valve control terminal Factory Wiring Wiring supplied by installer L1 L2 C1 C2 B1 B2 I1 I2 Z T TV L B1 L B2 N N 120VAC G EQUIP GND TERMINAL 1 2 LIMITS DETECTOR A K D A A C F LINE VOLTAGE SERV...

Page 30: ...ner plate onto the burner door seal with GP sealant rope diameter Ø 25 64 inches 10 mm Screw the burner to the burner plate Cut out insulating rings to match the burner tube diameter Fig 57 2 Fill the remaining gap between the burner door thermal insulation andtheburnertube Fig 57 4 usingtheappropriateinsulating rings Fig 57 3 Connect the vent connection to the burner to ensure the inspection wind...

Page 31: ...raise the flue gas temperature Chapter 11 5 page 31 11 5 Raising flue gas temperature Withanewboiler thefluegastemperaturewhentheboilertemperature is 176 F 80 C will be around 320 356 F 160 180 C depending on the boiler rating In two stage operation the temperature of the flue gas is lower Youcanincreasethefluegastemperaturefurtherbyremovingindividual hot gas check plates and hot gas baffle plates...

Page 32: ...the entire system 2 Fill the heating system with water page 31 3 Purge the heating system 4 Perform the leak test if the boiler was assembled on site page 17 5 Record the filling water quantity and composition in the operator s log included with the technical documentation 6 Check position of flue gas baffles page 20 7 Check the fuel line for leaks 8 Start up the control panel page 31 9 Initial bu...

Page 33: ...ng reasons to achieve a high level of efficiency and to operate the system economically low fuel consumption to achieve a high level of operational reliability to maintain a clean and environmentally friendly combustion 13 3 Cleaning the boiler with cleaning brushes Put the main power switch Fig 59 1 on the control panel in position 0 Isolate the fuel supply to the burner De energize the system Fi...

Page 34: ...er flue cleaning Undo the four self tapping screws on the rear boiler panel at the bottom Remove bottom rear boiler panel Loosen spring hooks below the flue outlet Fig 35 page 22 Fold both ends of the thermal insulation up Fig 64 1 and fasten in this position with the spring hooks Remove the cleanout covers from the rear section Fig 64 2 and on the draft diverter Fig 64 3 Remove all loose combusti...

Page 35: ... operating pressure The operating pressure must be at least 15 psi 1 bar Read the current operating pressure psi and temperature F C from the temperature pressure gauge If the operating pressure drops below 15 psi 1 bar refill boiler water Fig 66 Pressure temperature gauge 13 6 Refilling with boiler water and purging the system Slowly fill the heating system via the on site fill valve During filli...

Page 36: ...surfaces for contamination Shut down the heating system first 33 5 Check the burner burner documentation 6 Check the flue gas and venting system for proper operation and safety burner documentation 7 Checktheoperatingpressureandinletpressureofthe diaphragm expansion vessel for heating systems 35 8 Check the function of indirect fired heater and ionization rod tank documentation 9 Check the control...

Page 37: ...baffles 35 7 Check gaskets sealant ropes on the burner and burner door and replace if required see burner documentation 8 Commissioning the heating system 31 9 Record the final checks of the maintenance work incl measurements and test results 10 Check safe and proper operation Confirm professional inspection Company stamp signature Company stamp signature Table 15 Date ____________ Date __________...

Page 38: ...t after three attempts refer to the technical documentation provided with the burner to find out how to reset it NOTICE Risk of system damage from freezing Theheatingsystemcanfreezeupincoldweatherifithas been disabled due to a fault shutdown Rectify the fault immediately and restart the heating system If this is not possible drain the heating and DHW system side at the lowest point NOTICE Risk of ...

Page 39: ...ig 67 Designation Spare parts list 1 Group 1 boiler block front page 39 2 Group 2 boiler block draft diverter page 40 3 Group 3 burner door G315 page 45 4 Group 4 burner door G315 VM page 47 5 Group 5 jacket page 49 6 Group 6 not available 7 Group 7 not available 8 Group 8 safety group Logano G315 page 51 Table 17 Spare part groups Logano G315 6720817939 15 1T 2 8 6 5 3 4 7 1 ...

Page 40: ...ano G315 6 720 817 939 2017 02 40 Fig 68 Group 1 boiler block front Logano G315 6720906566 aa RS Kesselblock G315 2 3 23 24 9 5 4 20 21 22 13 14 15 15 14 13 18 19 19 11 6 7 10 8 10 12 17 16 13 14 15 1 25 27 26 14 7 26 27 ...

Page 41: ...0 20 KMVk Pack A 2 7 747 013 787 Sealant rope D15x5050 20 KMVk Pack B 3 7 747 013 788 12 Rear section G315 8 718 572 217 0 13 Threaded stud DIN939 M12x35 3 719 184 14 Reducer plugs G 1 3 4 x 3 4 5 317 732 16 Cleanout cover compl for rear section 5 371 905 17 Sealant rope GP10x1070 mm long 63 020 962 18 Gasket D33x44x2 mm 63 005 462 19 Plug G 1 5 317 712 Plug G 1 5 446 065 20 Tie rod M12x705 compl ...

Page 42: ... kg 7 747 027 148 Fittings G315 5 pc loose spare Fittings G315 6 pc loose spare Fittings G315 7 pc loose spare Fittings G315 8 pc loose spare Fittings G315 9 pc loose spare Primer 181 12 5 oz 370 ml in 17 oz 500 ml can Sealant graphite treated with linseed oil 450 g can Item Fig 68 Designation Order number Table 18 Group 1 boiler block front Logano G315 ...

Page 43: ...15 Spare parts Logano G315 6 720 817 939 2017 02 43 Fig 69 Group 2 boiler block draft diverter Logano G315 6720906567 aa RS Kesselblock Anbauteile G315 5 6 9 8 6 5 6 6 8 9 4 1 7 7 3 2 1 2 10 11 ...

Page 44: ...lue gas baffle bottom 380 mm G315 for 5 8 segments 5 265 196 Flue gas baffle bottom 460 mm G315 for 6 7 segments 5 265 198 3 Draft diverter compl G315 5 321 520 4 Sealant rope D15x4300 KMV pack 5 830 260 5 Washer DIN125 A13 A3K 5 883 276 6 Hexagon nut ISO4032 M12 8 5 090 068 7 Hex head bolt ISO4017 M12x55 5 090 262 8 Cleanout cover compl for 5 371 906 9 Sealant rope GP10x1070 mm long 63 020 962 10...

Page 45: ...15 Spare parts Logano G315 6 720 817 939 2017 02 45 Fig 70 Group 3 burner door Logano G315 M10x25 M12x35 6720906568 aa RS Brennertür G315 7 6 4 2 18 17 8 12 11 1 10 9 16 14 14 13 15 3 3 5 20 21 ...

Page 46: ...x270x10 mm 8 718 573 741 0 9 Burner plate 10x270x270 mm D 140 mm 5 431 312 10 Burner plate 10x270x270 mm D 160 mm 5 431 315 11 VE sealant rope GP 10x10000 5 830 584 VE sealant rope GP10x1070 mm long 63 020 962 12 Washer DIN125 pcs 10 5x2 0 mm 82 867 140 13 Inspection hole cover plate cpl 63 037 570 14 Gasket D42x52x1 5 mm 5 752 520 15 Countersunk screw M5x16 DIN963 Ms 5 555 760 16 Pressure testing...

Page 47: ...15 Spare parts Logano G315 6 720 817 939 2017 02 47 Fig 71 Group 4 burner door Logano G315 VM M12x35 6720906569 aa RS Brennertür VM Brenner G315 20 21 7 6 4 2 12 17 1 11 10 10 9 8 3 3 5 ...

Page 48: ...ing burner door G315 5 335 941 6 Hinge eye 70002675 8 718 570 844 0 7 Washer DIN125 A13 A3K 5 883 276 8 Inspection hole cover plate cpl 63 037 570 9 Countersunk screw M5x16 DIN963 Ms 5 555 760 10 Gasket D42x52x1 5 mm 5 752 520 11 Pressure testing nipple G1 8 5 481 194 12 Hex head bolt ISO4017 M12x45 10x 8 718 575 468 0 17 Washer DIN9021 A6 4 A3K 5 264 166 20 Sealing compound brown 63 014 361 21 Ra...

Page 49: ...ts Logano G315 6 720 817 939 2017 02 49 Fig 72 Group 5 jacket Logano G315 GE 31 5 Buderus 6720906570 aa RS Verkleidung G315 16 18 5 6 7 25 25 25 4 17 12 11 25 25 25 14 3 5 2 25 25 25 13 10 9 1 22 2 25 19 20 21 8 15 ...

Page 50: ...Top cover rear compl 824 mm long 6 sections G315 5 614 626 Top cover rear compl 984 mm long 7 sections G315 5 614 628 Top cover rear compl 1144 mm long 8 sections G315 5 614 630 Top cover rear compl 1304 mm long 9 sections G315 5 614 644 8 Front panel compl G315 5 614 632 9 Cover G315 63 011 714 10 Logano plus G315 name plate 63 014 097 Appliance insignia plate Buderus Logano G315 4 1999 67 902 82...

Page 51: ...e parts Logano G315 6 720 817 939 2017 02 51 Fig 73 Group 8 safety group Logano G315 M16x65 G1 27 5x17 G1 4 xG1 4 G1 4 M16x65 6720817939 14 1T 20 1 20 20 4 20 3 2 20 5 11 10 9 12 21 7 8 4 6 6 20 15 21 13 7 14 ...

Page 52: ...100 g1 2 0 120degrees C 100lg 5 639 604 6 Seal DIN2690 DN65 2 mm 81 363 040 7 Washer DIN125 A17 A3K 3 869 840 8 Pressure regulator with adapter for KSS 5181 616 9 Gasket D24x30 5x2 mm 5x 63 020 247 10 Gasket D6x11x2 mm AFM34 5x 8 718 571 893 0 11 O ring D10x2 mm PERBUNAN 5x 8 718 571 894 0 12 Double nipple G1 104 lg 5 681 062 13 Supply manifold 315SMFDK 14 Sensor well 7747022367 15 Return manifold...

Page 53: ...2 53 Index A Added water 31 B Boiler conditions of use 5 C Control Panel Assembly 5 F Fill water 31 Flow temperature 6 Fuels 5 O Operating pressure maximum 6 P Product description 5 T Temperature control 6 Thermal insulation 5 Transport 10 ...

Page 54: ... as provisions of the buildings inspectorate and any legislative requirements The technical documentation has been handed over to the user He has been familiarized with the safety instructions operation and maintenance of the system Date signature system installer Date signature user Type ______________________ User ______________________ Manufacturer no ______________________ Location ___________...

Page 55: ...Appendix Logano G315 6 720 817 939 2017 02 55 ...

Page 56: ......

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