Buderus Logano G615 Installation And Service Instructions Manual Download Page 53 | Manualshive

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System inspection and maintenance

Logano G615 - Subject to technical modifications

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Summary of Contents for Logano G615

Page 1: ...g appliance in operation The operating manual is a component of the technical documentation and must be handed over to the operator of the heating system Explain to the owner or operator how to use th...

Page 2: ...service of both boiler types Table of Contents 1 Guideline to symbols and safety instructions 4 1 1 Guideline to symbols 4 1 2 Safety instructions 4 2 Product description 6 2 1 Designated use 7 2 2 O...

Page 3: ...itting side panels and top covers 35 8 Connecting the boiler on the flue gas side 38 8 1 Fitting the vent pipe sealing collar accessory 38 8 2 Installing a flue gas temperature sensor option 38 9 Inst...

Page 4: ...lighters B Warn all occupants of the building but do not ring doorbells B Call your gas utility company and your local heating contractor from outside the building If necessary notify police or the f...

Page 5: ...ve during heat up Inspection and maintenance The operator is responsible for safety and environmental compliance of the heating system Sign a maintenance and inspection contract with a trained and cer...

Page 6: ...Front jacket 1 Burner door panel The Logano G615 oil gas fired boiler is supplied with or without a burner You can obtain undrilled or predrilled burner plates hole pattern depends on burner as access...

Page 7: ...tic 4000 and other control systems Fuels Logano G615 Heating oil Liquid propane LPG Natural Gas NG Remark The Logano G615 boiler can be operated with the specified fuels Select a burner suitable for u...

Page 8: ...lation The Buderus 4000 series controls can manage this process or it can be completed by the BMS If it is not possible for the control panel to regulate the flow sufficiently to meet this operating c...

Page 9: ...ted condensing gas boiler must comply with all applicable codes and regulations imposed by the national Federal or local authorities and bodies If no specific requirements are defined in the USA the l...

Page 10: ...minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no le...

Page 11: ...eturn connection on the boiler2 VK Supply connection on the boiler3 1390 mm 54 23 32 EL RK 6 720 642 625 02 1o LG VK LK 125 mm 4 59 64 LF T 750 mm 29 17 32 14 11 64 360 mm AA 1826 mm 71 57 64 1596 mm...

Page 12: ...04 77 23 32 1974 84 13 32 2144 91 7 64 2314 97 51 64 2484 104 31 64 2654 111 3 16 2824 117 7 8 2994 Single boiler section size B H T inches mm 43 9 64 64 9 16 6 45 64 1096 1640 170 Boiler block transp...

Page 13: ...37 0 9251 1 0348 0 4196 0 4694 1 0256 1 127 0 4652 0 5112 1 1158 1 2181 0 5061 0 5525 CO2 content oil 13 CO2 content gas 10 Required flue pressure draft requirement PSI Pa 0 0 Fireside pressure drop i...

Page 14: ...1 Crate Additional fittings content depends on boiler size 1 Crate Assembly parts 1 Crate Jacket pack A 1 Crate Jacket pack B 1 Crate Thermal insulation 1 Foil pouch Tie rods set with spring packages...

Page 15: ...loth Fine emery cloth Wire brush 3 in 1 oil Solvent gasoline mineral spirits Level tape measure chalk straight edge Boiler assembly tool size 2 3 Fig 4 Boiler assembly tool size 2 3 dimensions in mm 1...

Page 16: ...ill not be able to use the cleaning kit Alternatively shorter cleaning devices or wet cleaning may be used Observe the recommended wall clearances for complete opening of the burner door for boiler in...

Page 17: ...s 100 50 8 mm or sheet metal with the dimensions 3 15 16 13 64 inches 100 5 mm A silencing boiler base is available as an accessory from Buderus 6 720 642 621 01 1o L 2 820 mm 100 mm 100 mm 1160 mm 50...

Page 18: ...ge 23 7 1 Assembly of a boiler block from sections Fig 8 Rear section The assembly of the boiler block is always done from the rear to the front that is the rear section Fig 7 3 is always mounted firs...

Page 19: ...nipple with a rag soaked in solvents or gasoline and coat evenly with sealant B Insert nipple directly into the top size 4 181 70 and bottom size 2 119 50 hub on the rear section B Strike the nipple w...

Page 20: ...of the butt joints Fig 13 3 Fig 13 Inserting sealant rope 1 Packing grooves 2 Sealant rope 3 Butt joints Prepare the first intermediate section with top supply connection B File down any burrs on the...

Page 21: ...on tools using the clamping nut Fig 16 Using the boiler assembly tool 1 Boiler assembly tool bottom hub 2 Boiler assembly tool top hub 3 Pressure flange top 4 Pressure flange bottom B Place ratchet wr...

Page 22: ...t and right and bottom left and right next to the boiler block hubs B Turn and tighten each nut on the tie rods by hand B Now tighten the nuts on the tie rods 1 to 1 turns B Level the boiler block ver...

Page 23: ...he boiler section foot wedges provided for this purpose B After leveling the boiler block remove the transport safety brace from the top and bottom hub The following pages describe the installation of...

Page 24: ...Seal and install sensor well R from the front length 4 21 64 110 mm into the top R tapped hole of the supply connection Sensor well R B Seal and install sensor well R from the front length 4 21 64 11...

Page 25: ...ribution tube element hook in the one with the handle L1 B Close off bottom boiler hub with flat gasket and flange cover Fig 25 Inserting the lower distribution tube 1 Lower distribution tube element...

Page 26: ...via the fill and drain connection Purge the air from the boiler block via the boiler supply connection with purger 7 7 2 Seal leaks If leaky hub connections are discovered during the pressure test pro...

Page 27: ...boiler hub return connection 4 Flat gasket 5 Weld neck flange NOTICE Risk of system damage from leaking connections B All pipe connections to the boiler must be free of stress and tension NOTICE Syst...

Page 28: ...onto the four threaded studs on the rear section and secure using washers and nuts Fig 28 Positioning the draft diverter 1 Sealant rope joint at the top of the groove 2 Sealant rope 3 Draft diverter...

Page 29: ...bottom 5 Holes in the burner door 6 Hinge lobe top 7 9 4 Inserting the flue gas baffles B Remove the flue gas baffles from the crate and insert into the flue gas passages as indicated by their inscri...

Page 30: ...represent the number of boiler sections B Push thermal insulation under the boiler block The boiler feet are placed in the cut outs in the thermal insulation Fig 34 Boiler block with thermal insulatio...

Page 31: ...M L 15 H L V L 11 H L V L 10 H L V L M L 14 H L V L M L 16 H L V L 12 H 1 2 3 4 5 6 7 8 V H V H V H V H V H V H V H V H Item Fig 35 Number of boiler sections LV in inch mm LM in inch mm Ln H in inch...

Page 32: ...wards the center of the boiler Fig 36 Fitting front rear and side profile rails 1 Cast lugs 2 Side profile rail 3 Front profile rail top front 4 Rear profile rail top rear 5 Side profile rail 6 Cast l...

Page 33: ...uld be the time to route it on the outside of the insulation Fig 39 Fitting the rectangular thermal insulation and burner cable installation optional 1 Thermal insulation 2 Spring hooks 3 Burner cable...

Page 34: ...t slightly and slide the hook into the slots in the top side profile rail Fig 41 Mounting the side panel 1 First side panel 2 Top side profile rail 3 Bottom side profile rail B Push the remaining side...

Page 35: ...9 boiler sections 2 10 boiler sections 3 11 boiler sections 4 12 boiler sections 5 13 boiler sections 6 14 boiler sections 7 15 boiler sections 8 16 boiler sections LA 11 1 32 280 mm LB 26 49 64 680...

Page 36: ...oiler sections 6 14 boiler sections 7 15 boiler sections 8 16 boiler sections LA 11 1 32 280 mm LB 13 25 64 340 mm LC 15 3 4 400 mm LD 15 3 4 400 mm LE 19 15 16 485 mm LF 20 5 64 510 mm LG 22 7 16 570...

Page 37: ...st top cover and side panels B Screw the bottom rear boiler with the cut out for the fill and drain connection down onto the side panels Fig 47 Fitting the top and bottom boiler rear panels 1 Top rear...

Page 38: ...g 49 5 must press onto the draft diverter outlet Fig 49 6 and and one onto the vent pipe Fig 49 4 B Tighten hose clamps Fig 49 5 The vent pipe sealing collar Fig 49 1 must fit smoothly and firmly in p...

Page 39: ...lt the control panel forward and then tip back The flexible hooks must engage with the rectangular openings at the rear of the front boiler cover B Attach the base of the control panel to the top cove...

Page 40: ...secure by closing the lever Mounting rear panel and terminal cover B If necessary break away section from the rear panel B Engage the lower hook of the rear panel section with the frame at an angle a...

Page 41: ...ensor TRK manual reset high limit and Logamatic sensor FK or thermostat sensor are installed in the sensor wells The sensors must be arranged as follows B Push the control panel sensor TRK out of the...

Page 42: ...oor seal with GP sealant rope diameter 25 64 inches 10 mm B Screw the burner to the burner plate B Cut insulating rings to match the burner tube diameter Fig 56 2 B Fill the remaining gap between the...

Page 43: ...CE Boiler damage from contaminated combustion air supply B Ensure there is sufficient air supply B Do not use or store any chlorine containing cleaning agents or halogenated hydrocarbons e g in spray...

Page 44: ...t it up 11 4 Initial burner start up B When commissioning the burner follow the instructions in the technical documentation enclosed with the burner B Complete the commissioning log for the burner Det...

Page 45: ...t if the boiler was assembled on site page 26 5 Record the filling water quantity and composition in the operator s log included with the technical documentation 6 Check position of the flue gas baffl...

Page 46: ...he main fuel shut off valve B Shut off the fuel supply to the burner NOTICE Risk of system damage from freezing B The heating system can freeze up if it is disabled e g shut down due to a fault B Prot...

Page 47: ...ler door 1 Front side panel left 2 Front side panel right 3 Front panel sections burner door jacket B Loosen the fastening screws of the burner door with a flat wrench from the side B Swing out burner...

Page 48: ...48 B Check sealant ropes on the cleanout openings and burner door Replace damaged or hardened sealant ropes Fig 62 Heat exchanger flue gas passages cleaning 1 Bottom flue gas passages 2 Combustion ch...

Page 49: ...8 Number of sections Brush designation Brush size inch mm Application Rod designation Length of the rods inch mm 9 11 4 5 8 2 61 64 4 21 64 75 110 2 23 64 2 7 8 60 73 7 7 8 3 5 32 200 80 Flue gas pas...

Page 50: ...nel with plastic to prevent spray from entering the control panel B Spray cleaning agent evenly into the heat exchanger flue gas passages B Close burner door and start up the heating system B Heat the...

Page 51: ...ing pressure is reached stop the procedure B Purge the heating system via the purge valves on the system B Fill with water again if the operating pressure drops as a result of purging the system 7 747...

Page 52: ...amination Shut down the heating system first 48 5 Check the burner burner documentation 6 Check the flue gas and venting system for proper operation and safety see burner documentation 7 Check the ope...

Page 53: ...Subject to technical modifications 53 Date ____________ Date ____________ Date ____________ Date ____________ 1 2 3 4 5 6 7 8 9 10 Company stamp signature Company stamp signature Company stamp signat...

Page 54: ...surfaces and flue gas baffles 48 4 Clean the combustion chamber 48 5 Clean the draft diverter 48 6 Insert the flue gas baffles 29 7 Check gaskets sealant ropes on the burner and burner door and replac...

Page 55: ...Subject to technical modifications 55 Date ____________ Date ____________ Date ____________ Date ____________ 1 2 3 4 5 6 7 8 9 10 Company stamp signature Company stamp signature Company stamp signat...

Page 56: ...r 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 The heating system can freeze up in cold weather i...

Page 57: ...covered under the manufacturer s warranty Item Fig 65 Designation Spare parts list 1 Group 1 boiler block front page 58 2 Group 2 boiler block rear page 60 3 Group 3 boiler block accessories page 62 4...

Page 58: ...technical modifications 58 Fig 66 Group 1 boiler block front Logano G615 6720906689 aa RS Kesselblock GE615 20 2 22 21 23 17 18 20 1 14 4 12 12 12 16 16 16 14 11 11 11 14 10 5 7 9 8 6 19 3 20 25 27 26...

Page 59: ...8028 Tie rod M16x2360 cpl 5128030 Tie rod M16x2530 cpl 5128032 Tie rod M16x2700 cpl 5128060 18 Spring package for tie rod 5526300 19 Hexagon nuts ISO4032 M16 8 A3K 82585200 20 Washer DIN125 A17 A3K 38...

Page 60: ...cations 60 Fig 67 Group 2 boiler block rear Logano G615 Ansicht A Ansicht A 90 gedreht M10x50 M8x12 6720906690 aa RS Kesselblock GE615 R ckansicht 5 16 19 30 18 24 25 15 17 10 14 11 12 12 5 6 6 6 6 6...

Page 61: ...r G615 cpl 70003785 5321806 11 Rear panel G615 70003786 5932680 12 Sealant rope GP14x1650mm long 63020965 14 Cleanout cover compl for the draft diverter 5371906 15 Sealant rope GP10x1070mm long 630209...

Page 62: ...om left bottom right 2x sickle profile 2x sickle profile 2x sickle profile 2x sickle profile 2x sickle profile 2x sickle profile 2x sickle profile 2x sickle profile 2x sickle profile 2x sickle profile...

Page 63: ...kle profile T1 67902701 4 Flue gas baffle bottom sickle profile T2 67902702 5 Flue gas baffle with wave profile 5265250 6 Vent pipe G615 wt70S2 5384862 7 Thermal insulation vent pipe part 1 2 67902965...

Page 64: ...are parts Logano G615 Subject to technical modifications 64 Fig 69 Group 4 burner door Logano G615 M5x16 M10x25 M12x40 St6 3x25 6720906692 aa RS Brennert r GE615 20 3 14 1 17 18 16 15 11 10 2 9 8 7 5...

Page 65: ...A3K 3869840 7 Washer 6 4x20x1 25 A3K 10x 7 747 030 742 8 Burner plate 10x430x430 V1 ungeb verp 8 718 575 172 9 Sealant rope 10x2000 GP 63020963 10 Inspection hole cover plate cpl 63037570 11 Gasket D4...

Page 66: ...ject to technical modifications 66 Fig 70 Group 5 jacket fastening Logano G615 M8x12 M8x12 M8x12 M8x12 M8x12 M8x12 M8x12 M8x12 M8x12 6720906693 aa RS Verkleidung GE615 Grundbegestigung 6 7 15 14 1 10...

Page 67: ...ver left G615 67902658 7 Thermal insulation front cover right G615 63014989 8 Rear panel insulation G615 67902649 9 Profile rail compl 1720mm long G615 67902652 Profile rail compl 1890mm long G615 679...

Page 68: ...are parts Logano G615 Subject to technical modifications 68 Fig 71 Group 6 sheetmetal parts front rear Logano G615 M8x12 M8x12 St3 5x22 6720906694 aa RS Verkleidung GE615 12 14 13 7 9 3 15 1 2 4 9 17...

Page 69: ...902851 7 Rear panel bottom G615 5932732 8 Flat head screw ST3 9x9 5 A3T 10x 5932734 9 Burner connection cable 170 4300 mm long compl 7 747 026 999 12 Connection terminal 7 pin green BR 1 burner 707933...

Page 70: ...sheet metal parts Logano G615 6720906695 aa RS Verkleidung GE615 Anordnung 1 3 5 1 4 5 1 2 2 5 1 2 3 5 1 3 3 5 1 3 4 5 9 7 8 11 10 6 9 7 12 11 10 6 9 7 7 7 12 10 6 9 7 12 7 11 6 1 4 4 5 1 2 4 5 2 9 12...

Page 71: ...4 Side panel G615 775br left cpl parts E I 67902632 5 Top cover front G615 cpl part A 67902630 Top cover cpl 340br G615 part B 67902645 6 Top cover cpl 400br G615 part C 67902633 7 Top cover G615 400b...

Page 72: ...re parts Logano G615 Subject to technical modifications 72 Fig 73 Group 8 sheetmetal parts carriers Logano G615 St4 8x19 St4 8x19 6720906696 aa RS Verkleidung Tr ger f r Regelger t 4 4 4 4 2 10 8 3 1...

Page 73: ...Cover for control panel carrier 63045232 4 Flat head screw ST3 9x9 5 A3T 10x 7 747 026 999 5 Cover plate for control panel carrier 63045231 8 Conduit shield blue 63045229 9 Conduit slotted blue 1x 630...

Page 74: ...sembly tool 15 B Boiler conditions of use 7 F Fill water 43 Fuels 7 I Inspection contract 47 M Maintenance contract as required basis 47 Make up water 43 O Operating pressure maximum 8 S Safety instru...

Page 75: ...ions of the buil dings 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 ma...

Page 76: ...Tel 603 552 1100 Fax 603 584 1681 www buderus us U S A Products manufactured by Bosch Thermotechnik GmbH Sophienstrasse 30 32 D 35576 Wetzlar www buderus com Bosch Thermotechnology Corp reserves the...

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