Buderus Logano GE315 Installation And Maintenance Instructions Manual Download Page 38 | Manualshive

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2

Burner installation

38

Installation and maintenance instructions Logano GE315 • Issue 02/2006

We reserve the right to make any changes due to technical modifications.

4

System shutdown

You can connect control devices series 4000 to
Logano GE515 boilers. These control devices are shut
down through identical steps.

4.1

Shutting down the system via the
control device

Shut down your boiler via the control device. The burner
is automatically shut down when the system is shut down
via the control device.

z

Isolate the main fuel valve.

4.2

Shutting down the system in an
emergency

In other dangerous circumstances, isolate the main fuel
shut-off valve and the electrical power supply of the
system via the boiler room main fuse or the emergency
stop switch for the boiler room.

z

Isolate the main fuel valve.

CAUTION!

SYSTEM DAMAGE

through frost.

The heating system can freeze up if it is
not in use, e.g. through a shut-down
because of fault(s).

z

Protect your heating system against
frost damage, where temperatures
below zero are expected. Drain the
heating water at the drain cock at the
lowest point in the system. To do this,
open the air vent valve at the highest
point in the system.

USER NOTE

z

Only in an emergency, switch off the
system via the boiler room fuse or
heating system emergency stop switch.

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Summary of Contents for Logano GE315

Page 1: ...1 02 2006 GB For the installer Please read thoroughly prior to installation and maintenance Installation and maintenance instructions Logano GE315 Cast iron sectional boiler for oil or gas pressure jet burners ...

Page 2: ... any damage resulting as a consequence of such use Your warranty could be invalidated if you do not comply with the installation and operating instructions We reserve the right to make any technical modifications Constant development may lead to minor deviations of illustrations functional steps and specifications from those described shown EU DECLARATION OF CONFORMITY The design and operation of ...

Page 3: ...ractice BS 6880 Code of practice for low temperature hot water heating systems for output greater than 45 kW BS 6644 Specification for Installation of gas fired hot water boilers of rated inputs between 70 kW net and 1 8 MW net 2nd and 3rd family gases CP 342 2 centralised hot water supply BS 5449 Forced circulation hot water systems BS 5546 Installation of gas hot water supplies for domestic purp...

Page 4: ...8 2 5 Leak test 19 2 5 1 Leak test preparation 19 2 5 2 Test pressure 20 2 6 Installation of fittings and burner door only for unassembled boilers 21 2 6 1 Positioning the flue gas collector 21 2 6 2 Cleaning cover at the rear section 21 2 6 3 Install the burner door 22 2 6 4 Insert the hot gas baffle plates 22 2 6 5 Burner installation 23 2 6 6 Fit the flue gas pipe sealing collar optional access...

Page 5: ...tenance instructions Logano GE315 Issue 02 2006 6 4 Checking the water level 43 6 5 Filling and operational water 43 6 6 Checking the system water pressure 44 6 7 Inspection and maintenance reports 46 7 Correcting burner faults 48 Appendix 49 Dimensions and Specification 49 Ratings and system handover 50 ...

Page 6: ...wer supply as well as maintenance and repair work Only registered gas fitters may carry out work on gas components Carry out maintenance and cleaning procedures annually As part of these steps check the proper function of the entire system Immediately correct all discovered faults 1 2 Boiler application Observe the details on the boiler data plate which are crucial max flow temperature 100 C max o...

Page 7: ...er segments 2 1 1 Pre assembled delivery 1 Pallet Boiler block with burner door and feed pipe 1 Cartons Casing depending on boiler size 1 Foil packaging Thermal insulation 2 1 2 Supplied in sections 1 Pallet Front and rear segment 3 central segments and burner door 1 Pallet Central segments depending on boiler size 1 Carton Mounting components and flue gas collector 1 Bundle Tie bars and return he...

Page 8: ...sh 3 in 1 Oil Solvent petrol or solution Spirit level ruler chalk straight edge Blanking flange with vent facility for pressure test 2 2 1 Boiler compression tool size 2 2 2 2 2 Boiler compression tool 2 3 complete in toolbox Segments Compression tool per boiler hub Extension pieces per boiler hub Length total mm 5 7 1 0 1560 8 9 1 1 1 0 2160 2160 Segments Compression tool per boiler hub Extension...

Page 9: ...rfectly flat and level The front edge of the boiler should be flush with the edge of the plinth You can cast a concrete plinth if the optional boiler plinth is not used When casting the plinth you must incorporate a steel angle with the dimensions 100 x 50 x 8 mm or a steel strip with the dimensions 100 x 5 mm see Fig 3 and the following table Fig 1 Dimensions of plinth and length of angular or fl...

Page 10: ...hen installing your boiler please maintain the recommended minimum dimensions shown in brackets Select the recommended clearances between wall and boiler to enable easy access during installation maintenance and service work The distance from the wall on the hinge side must at least permit the burner withdrawal AB We recommend a distance between wall and boiler of AB 100 mm Length LK depends on th...

Page 11: ...section Fig 5 Item 10 last During assembly note the arrows denoting the direction of installation Fig 5 Item 9 and proceed according to the following instructions and illustrations ATTENTION Risk of injury through inadequately secured boiler sections For your own safety use only suitable means of transportation when handling the boiler sections e g a sack truck with strap or a stair truck etc When...

Page 12: ... brush and cloth z Clean the hub sealing faces Fig 8 Item 1 2 with a cloth soaked in white spirit z Coat the hub sealing faces evenly with the orange sealing compound Marked as LEINOMENNIGE During the next step the nipples are prepared for the closing up of the boiler sections z Clean nipples with a cloth soaked in white spirit and coat half the surface with the orange sealing compound z Fit the n...

Page 13: ... required length of packing cord KM string from the roll supplied Separate the backing paper from the cord but do not stretch as you insert the cord into the packing groove Preparation of the first middle section z Remove any burrs from the hub using a file see Fig 7 z Ensure the sealing grooves are clean and dry clean where necessary z Clean the hub sealing faces with a cloth soaked in white spir...

Page 14: ...g 14 Item 3 4 onto the pull rods Fig 1 or Fig 2 Item 4 z Insert one pull rod through the upper and one through the lower boiler hub z Push additional pull flanges onto both pull rods Fig 15 Item 3 at the back of the boiler Fig 15 Item 1 and secure each with a wedge Fig 15 Item 2 or cylindrical pin for compression tool 2 2 z Hold the pulling rod at the centre of the boiler hubs and with the clampin...

Page 15: ...ly Assemble all other boiler sections as described The front section is assembled last ATTENTION Do not continue to tighten the assembly by force once the hubs are in contact Further tightening could damage the boiler sections ATTENTION Loosening the boiler compression tool size 2 3 can lead to a slackening of the pull rod screw connections Fig 16 Item 1 Therefore check and if necessary re tighten...

Page 16: ... in the cast profiles Fig 17 Item 1 2 3 Note when inserting the tie bars that the spring sets are fitted at the back of the boiler z By hand screw one nut onto each of the tie bars threads z Now tighten the nuts on each tie bar by 1 to 1 turns z Align the boiler on the plinth or vibration absorbing plinth in the horizontal and vertical plane see chapter 2 3 Positioning page 9 z Remove the boiler c...

Page 17: ...plinth in the horizontal and vertical plane see chapter 2 3 Positioning page 9 To do this use the boiler section base wedges supplied The return header and sensor well installation described on the following pages applies to boilers delivered as pre assembled in sections CAUTION DANGER TO LIFE Hazard from falling material Hazard through falling from unsuitable means of transportation Observe Healt...

Page 18: ...ert the return header from the front into the upper boiler hub z Close the pipe with a blanking flange Fig 19 Item 2 2 4 5 Sealing the sensor well Sensor well z Seal the sensor well Length 110 mm Fig 20 Item 1 from above into the threaded hole of the flow connection Fig 20 Item 2 NOTE The profile Fig 19 Item 3 on the end plate of the feed pipe must engage into the recess of the upper boiler hub Fi...

Page 19: ...ffle plates page 20 2 5 1 Leak test preparation z Close the lower boiler hub at the front and rear Fig 21 Item 3 To do this set the corresponding gasket Fig 21 Item 1 onto the respective boiler hub and seal the corresponding drain plug into the appropriate port Fit the plug with internal thread for the drain cock Fig 21 Item 2 to the rear of the boiler z Fit the drain cock not supplied as standard...

Page 20: ...ions You must use new nipples and gaskets for the re assembly Draw the boiler sections together and re test for leaks 2 5 2 Test pressure The test pressure during the leak test depends on the design pressure for each individual heating system and should be 1 5 times nominal pressure normally 7 8 bar for 30 minutes Use a pressure gauge class 1 0 for measuring the pressure z The weld neck flange is ...

Page 21: ...t before packing the sealing cords as a gasket between the boiler and flue gas collector z Coat the packing groove with adhesive primer 181 z Firmly press the sealing cord into the groove You must insert the packing cord so that it lies in the lateral area of the groove Fig 24 Item 3 z Position the flue gas collector onto both bolts at the rear section Fig 24 Item 4 5 and secure with washers and n...

Page 22: ...on the butt ends of the gasket string on the side of the section Fig 26 Item 2 z Hook the burner door with the hinge rings onto the hinge pins 2 6 4 Insert the hot gas baffle plates z Remove the hot gas baffle from the fitting crate and insert it into the hot gas ways according to the instructions cast into the baffle body see Fig 27 and the following table NOTE The hot gas baffles are already fit...

Page 23: ...n of the burner connection flange z Secure the burner plate on the burner door with screws provided seal with sealing cords of 10 mm diameter z Screw the burner to the burner plate z Cut out insulating rings according to the burner pipe diameter Fig 28 Item 2 z Fill the remaining gap between the thermal insulation on the burner door and the burner blast tube Fig 28 Item 4 with suitably adapted ins...

Page 24: ...er onto the flue gas pipe z Tighten the jubilee clips After the jubilee clips have been tightened the flue gas pipe sealing collar must fit evenly and closely 2 6 7 Fit the flue gas temperature sensor Option z Weld the coupling Fig 29 Item 3 at a distance of 2 x flue gas pipe diameter A min 720 mm from the flue gas collector into the flue gas pipe z Install the flue gas temperature sensor Fig 29 I...

Page 25: ...onto each tie bars Fig 30 Item 2 z Insert the cross support bracket at the front on top of the boiler Fig 30 Item 1 between the first and the second nut of the tie bars and secure on the cast lugs z Tighten the outer nuts z Secure the cross support bracket at the lower front Fig 30 Item 3 with two screws on the boiler section feet of the front section z Secure the upper rear support bracket Fig 31...

Page 26: ...are set into the cut outs of the thermal insulation Tab 1 Thermal insulation dimensions z Slide the thermal insulation for the rear section Fig 33 Item 2 onto the flue gas coupling Ensure that the cut out for the boiler flow and return points upwards z Hook the thermal insulation for the rear section into the upper cross support bracket using two spring hooks Fig 33 Item 1 z Close the gap below th...

Page 27: ...of the thermal insulation down over the side of the boiler block z With two screws secure the burner cable and strain relief on the lower cross tie rod Fig 34 Item 4 2 7 3 Side and top casing z Hook the side casing Fig 35 Item 1 with cut outs into the slots of the upper cross support bracket Fig 35 Item 2 and push forward against the end stop see arrow in Fig 35 z With two self tapping screws each...

Page 28: ...trol unit position the capillary tubes and the sensor well and insert the sensors into the wells before any other hood components are positioned see chapter 2 8 Control unit page 30 z Position the rear hood Fig 37 Item 1 between the side walls so that the cut out engages Fig 37 Item 2 above the cross support bracket Push the plinth rails front and back Fig 38 Item 2 on the lower side wall edge and...

Page 29: ...g 41 Front wall installation 2 1 2 1 3 2 1 3 z Secure the rear upper boiler wall Fig 39 Item 2 on the back of the rear hood Fig 39 Item 1 and on the side walls z Secure the lower rear boiler wall Fig 40 Item 2 with the cut out for the fill drain cock at the bottom on the side walls Fig 40 Item 1 3 z Hook the front wall Fig 41 Item 3 at the bottom centre into the plinth front Fig 41 Item 2 z Hook t...

Page 30: ...t the front of the boiler with the locating tabs Fig 43 Item 4 into the oval apertures of the front boiler hood Fig 43 Item 5 Pull the control unit forward and then pivot it back Ensure that the resilient hooks Fig 43 Item 2 engage at the rear into the rectangular apertures of the front boiler hood Fig 43 Item 3 z Secure the control unit base on the r h and l h side of the cable way Fig 43 Item 6 ...

Page 31: ...een sealed into the flow connection coupling see chapter 2 4 5 Sealing the sensor page 16 The sensor bundle three sensors one sensor blank Fig 45 Item 1 connected to the control unit is fitted into the sensor well z Lead the capillary sensor to the measuring point on the boiler and insert it into the sensor well Fig 45 Item 2 then secure the assembly with a sensor securing device Fig 45 Item 3 z S...

Page 32: ...nto the clip frame and secure by pivoting the lever Fig 47 Item 1 z Hook the rear wall Logamatic 43 with the lower hooks into the clip frame and push the top part home until the hooks engage Fig 44 Item 2 z Fit the terminal cover Fig 43 Item 1 with two self tapping screws and secure on the control unit base Fig 48 Fig 47 Securing the electrical connection cables Fig 48 Boiler with control unit ins...

Page 33: ...es after the system has been filled Check after the first three to six months during the first maintenance whether the ph value of the heating water has settled down CAUTION BOILER DAMAGE through heavy dust deposits z Do not operate the boiler where heavy dust contamination persists e g through building work inside the boiler room CAUTION SYSTEM DAMAGE through temperature stresses z Fill the heati...

Page 34: ...ing and refilling of the heating circuit must been carried out by a method that has been approved by the Water Regulation Advisory Scheme WRAS for the type of heating appliances i e Domestic in house Fluid Category 3 Non Domestic other than in house Fluid Category 4 Depending on the Fluid Category the approved method should comprise of the following 1 Requirements Fluid Category 3 systems fig see ...

Page 35: ...eating system Observe the pressure gauge whilst filling z Close the water tap and the boiler drain valve once the required operating pressure has been reached z Bleed the system via the radiator bleed valves z Top up with water if the pressure drops as a result of bleeding the system z Take the hose off the boiler drain valve z Enquire from your installer whether you can use your public water untr...

Page 36: ... device Please check in the documentation of the series 4000 control device which you are using how to commission the control device 3 4 Start up the burner z Proceed with the commissioning of the burner in accordance with the installation and maintenance instructions included with the burner z Complete the commissioning report included in the burner documentation You may raise the flue gas temper...

Page 37: ...age individual steps Comments signature 1 Fill the heating system with water Page 33 2 Vent the heating system via radiators and air vents 3 Leak test carried out only for boilers supplied in sections Page 19 4 Check the location of the hot gas baffle plates Page 36 Page 33 5 Commission the control device Page 36 6 Start up the burner See burner documentation 7 Check the flue gas temperature Page ...

Page 38: ...wn the system in an emergency In other dangerous circumstances isolate the main fuel shut off valve and the electrical power supply of the system via the boiler room main fuse or the emergency stop switch for the boiler room z Isolate the main fuel valve CAUTION SYSTEM DAMAGE through frost The heating system can freeze up if it is not in use e g through a shut down because of fault s z Protect you...

Page 39: ...rner is checked and maintained annually by a heating engineer We recommend that you take a service contract to ensure this is done regularly Failure to maintain the boiler will lead to higher fuel cost possible breakdown reduces Service life WARNING DANGER TO LIFE through the explosion of volatile gases z Work on gas components must only be carried out by qualified and authorised personnel USER NO...

Page 40: ...dealer 6 2 Cleaning with cleaning brushes z Disconnect your heating system from the mains electricity supply z Switch the On Off switch Fig 49 Item 1 on the control unit to 0 OFF z Isolate the main fuel valve z Slightly raise the front wall and remove forward Fig 50 z Loosen the four screws securing the burner door on the front sections see chapter 2 6 3 Burner door installation page 20 z Open the...

Page 41: ...he boiler back z Loosen the hook springs below the flue gas coupling see Fig 33 page 24 z Pivot both ends of the thermal insulation upwards Fig 52 Item 1 and fix with the hook spring z Remove the cleaning cover on the rear section Fig 52 Item 2 and the flue gas collector Fig 52 Item 3 z Use the cleaning brushes You will find an illustration of the various types of brushes offered by Buderus option...

Page 42: ...n the burner door Replace all damaged or hardened seals z Clean the hot gas baffle plates with the cleaning brushes z Insert the hot gas baffles into the hot gas flues see chapter 2 6 4 Insert the hot gas baffle plates page 20 z Close the cleaning cover and the burner door Tighten all screws equally z Pivot the thermal insulation on the rear section and draw together below the flue gas coupling us...

Page 43: ...t 70 C z Brush out the hot gas flues 6 4 Checking the water level z For systems with a header tank set the red marker on the pressure gauge to the required system pressure On sealed systems the pressure gauge marker must be within the green range z Check the system water level where required replenish with water and vent the entire system If water is lost during operation replenish it slowly and v...

Page 44: ...ystems On sealed systems the pressure gauge needle Fig 51 item 2 must be within the green range Fig 51 item 3 Set the red needle Fig 51 item 1 on the pressure gauge to the required system pressure z Set the pressure gauge needle accordingly z Check the system water pressure USER NOTE z Create the operating pressure required for the system CAUTION SYSTEM DAMAGE through frequent re filling The syste...

Page 45: ...low Fig 51 item 2 the green range Fig 51 item 3 You then need to re fill the heating system with make up water see chapter 3 System start up page 33 z Top up with water as required z Vent the heating system z Check the water pressure once more CAUTION SYSTEM DAMAGE through temperature stresses z The boiler must only be filled via a filling tap installed in the return pipe In the UK the boiler must...

Page 46: ...leaks visible signs of corrosion signs of ageing 4 Check the combustion chamber and the heating surface for contamination shut down the system for this step page 38 5 Check the burner function See burner documentation 6 Check the flue gas routing for function and safety See burner documentation 7 Check the water pressure and inlet pressure of the diaphragm expansion vessel in sealed systems page 4...

Page 47: ... heating surfaces page 42 4 Clean the combustion chamber page 42 5 Clean the flue gas collector page 42 6 Install the hot gas baffle plates page 22 7 Check and if required replace gaskets packing cord on burner and burner door See burner documentation 8 System start up page 33 9 Final check of the maintenance work document the measurement and test results See burner documentation 10 Check the func...

Page 48: ...addition any burner fault is indicated by a fault lamp on the burner z Press the burner reset button see burner operating instructions See the technical burner documentation for information regarding the resetting of the burner if the burner will not start after three attempts CAUTION SYSTEM DAMAGE through frequent activation of the reset button The burner ignition transformer may be damaged if yo...

Page 49: ...2 185 138 154 182 136 162 180 132 158 176 141 168 190 Flue gas mass flow rate oil Part load 60 Full load3 kg sec kg sec 0 0283 0 0391 0 0482 0 0377 0 0482 0 0643 0 0458 0 0641 0 0779 0 0539 0 0777 0 0913 0 0620 0 0913 0 1052 CO2content oil 13 0 Flue gas mass flow rate gas Part load 60 Full load3 kg sec kg sec 0 0284 0 0392 0 0484 0 0379 0 0484 0 0645 0 0460 0 0643 0 0781 0 0541 0 0780 0 0916 0 062...

Page 50: ...nd legal regulations and requirement and has been commissioned Date signature system builder The technical documentation has been handed to the user The user was advised of all safety requirements and was instructed in the use and maintenance of the above system Date signature user For the system builder Type ________________________ User _________________________ Manufacturer s no _______________...

Page 51: ...Notes 51 We reserve the right to make any changes due to technical modifications Installation and maintenance instructions Oil and gas fired special boilers Logano GE515 Issue 02 2006 ...

Page 52: ...don Worcester WR4 9SW Tel 01905 752794 Fax 01905 753130 www buderus commercial co uk In the UK Buderus is a trading name of BBT Thermotechnology Ltd BBT Thermotechnik GmbH D 35573 Wetzlar www heiztechnik buderus de info heiztechnik buderus de ...

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