Buderus Logano GE615 Installation And Maintenance Instructions Manual Download Page 54

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Heating system inspection and maintenance

Logano GE615 - We reserve the right to make any changes due to technical modifications.

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Tab. 16 Continuation

Summary of Contents for Logano GE615

Page 1: ...read thoroughly prior to installation and maintenance Installation and maintenance instructions Calorific value forced draft sectional boiler Buderus Logano GE 615 Buderus Logano GE 615 Logano GE615 6 720 617 717 07 2008 GB ...

Page 2: ...ing clean out cover onto rear section 24 4 11 3 Fitting the burner door 25 4 11 4 Inserting the hot gas baffles 25 4 12 Filling the heating system and checking for leaks 27 4 13 Installing the burner 29 4 14 Boiler flue connections 30 4 14 1 Fitting the flue pipe sealing collar accessory 30 4 14 2 Fitting the flue gas temperature sensor accessory 30 4 15 Fitting the boiler casing 31 4 15 1 Fitting...

Page 3: ... page 45 z Open window s z Do not operate electrical switches z Extinguish all naked flames z From outside the building call gas supplier and authorised contractor If you can smell flue gases there is a risk of poisoning V Switch off the heating system Æ page 45 z Open windows and doors z Inform an authorised contractor Risk to life from electric shock z Electrical connections must only be made by...

Page 4: ...1 Logano GE615 forced draft boiler 1 Boiler casing 2 Insulation 3 Boiler block 4 Control device 2 2 Correct use The Logano GE615 forced draft boiler is intended for generating heating water You may use any type tested oil or gas fired burners to EN 267 or EN 676 provided their operating range meets the boiler specification Using the boiler for any other purpose will be considered improper use Bude...

Page 5: ...0 1200 0 1188 0 1297 0 Overall boiler length LG mm 1926 2096 2266 2436 2606 2776 2946 3116 Length of boiler block LK mm 1804 1974 2144 2314 2484 2654 2824 2994 Loose boiler section transport unit mm Width 1096 height 1640 depth 170 Boiler block transport unit mm Width 1096 height 1640 length LK Combustion chamber length LF mm 1525 1695 1865 2035 2205 2375 2545 2715 Diameter of combustion chamber m...

Page 6: ...ll load2 kg s 0 2328 0 2625 0 2602 0 3039 0 3012 0 3408 0 3376 0 3776 0 3741 0 4237 0 4196 0 4694 0 4652 0 5112 0 5061 0 5525 CO2 content oil 13 CO2 content gas 10 Required draught Pa 0 Hot gas resistance mbar 2 4 3 4 4 2 4 2 4 1 4 5 5 4 5 8 Permissible flow temperature3 C 1104 100 1205 Permissible operating pressure bar 6 Maximum time constant T on thermostat s 40 Maximum time constant T on monit...

Page 7: ...s EL heating oil LPG Natural gas Biogas special conditions of use Comments The boiler can only be operated with the specified fuels The output figures shown in the table Specifications and dimensions are nominal output figures In practice some of these values will sometimes not be reached within the specified output range in order to adhere to LRV regulations Country Poland Fuels EL heating oil LP...

Page 8: ...ite z Dispose of packaging in an environmentally responsible manner Observe all standards and guidelines applicable to the installation and operation of this heating system in your country The information on the rating plate has precedence and MUST be observed Caution System damage caused by frost z Set up the heating system in a room safe from the risk of frost Total boiler output Q Ca HCO3 2 con...

Page 9: ...ns Component Piece Packa ging Boiler block 1 Pallet Fittings 1 Case Parts 1 Case Casing Pack A 1 Case Casing Pack B 1 Case Insulation 1 Foil bag Tab 5 Scope of supply pre assembled block Component Piece Packa ging Front rear central sections with upper flow connection and burner door 1 Pallet Central sections depending on boiler size 2 5 Pallet Base unit fittings 9 16 sections 1 Case Supplementary...

Page 10: ...wall clearances Observe the recommended wall clearances for easier boiler installation cleaning and maintenance Adhere to the minimum clearances in brackets in all cases Take into account the space required for opening the burner door The burner door can be hung on the right or left The wall clearance on the hinge side must be at least the same as the amount by which the burner projects AB Recomme...

Page 11: ...ou are not using a boiler plinth accessory angled steel sections 100 x 50 x 8 mm or flat steel sections 100 x 5 mm must be put in place when installing the base Fig 5 Base dimensions A sound absorbing plinth is available as an accessory The boiler plinth prevents the transmission of vibrations to the base Number of sections L1 base L2 steel section 9 1670 1470 10 1840 1640 11 2010 1810 12 2180 198...

Page 12: ...ntre section 6 Anchor rod 7 Installation direction arrow 8 Front section 9 Burner door with burner plate The boiler block is always installed from the back for wards i e the rear section Æ Fig 6 3 is always installed first and the front section Æ Fig 6 8 always installed last When assembling observe the installation direction arrows Æ Fig 6 7 for each boiler section Make sure you position the midd...

Page 13: ...id instructions z File down any burrs on the hubs Fig 8 Deburring the hub z Clean the packing grooves where required using a wire brush and cloth z Clean the hub sealing faces with a rag soaked in white spirit z Evenly coat the hub sealing faces with red lead putty Fig 9 Coating the hub sealing faces 1 Upper hub sealing face 2 Lower hub sealing face 3 Packing groove Caution Risk of burning through...

Page 14: ...ig 11 Coating the packing grooves with adhesive 1 Packing grooves The upper nipple must protrude approx 43 mm and the lower nipple approx 32 mm out of the corresponding hubs The packing grooves must be clean and dry to enable the packing cord to adhere properly Caution Risk to health through noxious vapours and skin contact during the processing of materials such as adhesives adhesive bases or red...

Page 15: ...an and dry Clean if necessary z Clean the hub sealing faces with a rag soaked in white spirit Fig 13 Preparing the central section 1 Hub sealing face 2 Sealing springs z Coat the hub sealing faces with red lead putty z Coat the packing springs with adhesive adhesive base Unroll the required length of packing cord KM cord from the roll supplied Peel the backing paper from the packing cord when inse...

Page 16: ...middle of the hubs and slightly draw together the compression tools using the clamping nut Fig 15 Using the boiler compression tool 1 Boiler compression tool lower hub 2 Boiler compression tool upper hub 3 Flange bearings top 4 Flange bearings bottom To make installation easier place the boiler section to be fitted onto the nipple on the upper hub first The boiler section can then be adjusted acco...

Page 17: ...erial fatigue Improperly used or poorly maintained compression tools may break z Never work directly in front of the compression tool while it is being tensioned z Ensure that no one is standing in front of the compression tool Caution Compression tool damage The compression tool may be damaged or destroyed if you compress pull rods with loose threaded connections z Always check the pull rods befo...

Page 18: ...fitted last z Insert the anchor rods with spring packs fitted into the cast lugs on the top left and right and bottom left and right next to the boiler block hubs z Put a nut onto each of the threaded anchor rods and tighten by hand z Now tighten the nuts on the anchor rods 1 to 1 turns V Level the boiler block vertically and horizontally on the base silencing plinth Æ see section 4 3 1 page 11 Us...

Page 19: ...foot wedges provided for this purpose Once the boiler block is levelled remove the transport stay from the upper and lower hubs Fig 20 Removing transport stay 1 Upper hub 2 Lower hub 3 Transport stay Warning Danger to life from falling loads z Observe the transport information on the data sheet attached to boiler block when lifting the boiler block off the pallet The following pages describe the i...

Page 20: ...n the upper boiler hub Fig 21 Sealing in the feed pipe 1 Flat gasket 2 Dummy flange 3 Lug 4 Feed pipe 5 Recess in upper boiler hub 4 7 Sealing the sensor well fittings case Sensor well R z Seal sensor well R from the front length 110 mm into the upper R tapped hole in the flow connection Sensor well R z Seal sensor well R ffrom the front length 110 mm into the lower R tapped hole in the flow conne...

Page 21: ...b z Hook the other outer steam tube elements L2 onto each other as shown in Fig 25 detail z Hook on the outer steam tube element with the handle L1 last z Close off lower boiler hub with flat gasket and dummy flange Fig 24 Inserting the outer steam tube 1 Outer steam tube element L3 2 Outer steam tube element L1 3 Flat gasket 4 Dummy flange 5 Outer steam tube element L2 The length and number of ou...

Page 22: ... pressure gauge class 1 0 to measure the pressure V Drain water via fill and drain valve Æ Fig 23 1 page 21 prior to connecting the water systems or if a hub joint is leaking 4 9 3 Leaking hub joints If leaking hub joints are detected during the pressure test proceed as follows z Remove feed pipe and outer steam tube Fig 25 Separating the boiler block V Undo nuts on anchor rods and remove anchor r...

Page 23: ...ng the flow at a later stage Fig 26 Fitting a connection flange 1 Flow connection flange 2 Flat gasket 3 Upper boiler hub return connection 4 Flat gasket 5 Weld neck flange Caution System damage through leaking connections z Secure the supply pipes free of stress to the boiler connections z Make sure the customer has a WRAS approved method for filling the system Caution System damage caused by dep...

Page 24: ... Place the flue gas header onto the four threaded studs on the rear section and secure using washers and nuts Fig 27 Positioning the flue gas header 1 Packing cord joint in the upper part of the groove 2 Packing cord 3 Flue gas header 4 Studs 5 Rear section 6 Studs 4 11 2 Screwing clean out cover onto rear section Fig 28 shows the fully equipped rear section with the clean out covers on the flue g...

Page 25: ...inge pins Fig 29 Fitting the burner door 1 Hinge pin top 2 Packing cord joint side 3 Hinge pin bottom 4 Hinge lobe bottom 5 Holes in the burner door 6 Hinge lobe top 4 11 4 Inserting the hot gas baffles V Take hot gas baffles from the fittings case and insert into the hot gas flue according to the inscription on them Æ see Fig 30 Fig 31 page 26 Fig 32 page 26 and Tab 1 page 5 Fig 30 Inserting the ...

Page 26: ...left Top right Bottom left Bottom right 9 2 x sickle profile 2 x sickle profile 2 x sickle profile 2 x sickle profile 10 2 x sickle profile 2 x sickle profile 2 x sickle profile 2 x sickle profile 11 2 x sickle profile 2 x sickle profile 2 x sickle profile 2 x sickle profile 12 1 x corrugated profile 1 x corrugated profile 2 x sickle profile 2 x sickle profile 13 2 x sickle profile 2 x sickle prof...

Page 27: ...r primary side z Fill the system via an approved filling link 4 12 1 Filling the heating system Filling 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 hea ting appliances i e Domestic in house Fluid Category 3 Non Domestic other than in house Fluid Category 4 Depending on the Fluid Category ...

Page 28: ...ressure 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 V z Enquire from your installer whether you can use your public water untreated or whether you need...

Page 29: ...crew burner plate onto the burner door seal with GP packing cord diameter 10 mm z Screw the burner to the burner plate z Cut out insulating rings to match the blast tube diameter z Fill the remaining gap between burner door insulation and blast tube with the modified insulation rings z Connect the sight glass blower connection to the burner to ensure the sight glass remains clear of deposits Fig 3...

Page 30: ...ps must press onto the flue gas header outlet and one onto the flue pipe z Tighten jubilee clips The flue pipe sealing collar must fit smoothly and firmly in place Fig 37 Fitting the flue pipe sealing collar 1 Flue pipe sealing collar 2 Flue gas temperature sensor 3 Coupling 4 Flue pipe 5 Ubilee clips 6 Flue gas header 4 14 2 Fitting the flue gas temperature sensor accessory z Weld the coupling in...

Page 31: ...the boiler size V Arrange the insulation on the boiler block as shown in the diagram in Æ Fig 39 the figures to the left of the boiler blocks represent the number of boiler sections z Push insulation under the boiler block The boiler section feet are placed in the cut outs in the insulation Fig 38 Boiler block with insulation 1 Insulation Fig 39 Insulation for the various boiler sizes dimensions i...

Page 32: ...e rear cross bar must point towards the back z Place lengthways bars from the side onto the cross bars and screw in place with self tapping screws The folded edges of the of the lengthways bars must face towards the back while the slotted holes are positioned towards the centre of the boiler Fig 40 Fitting cross bars and lengthways bars 1 Cast lug 2 Lengthways bar 3 Cross bar top front 4 Cross bar...

Page 33: ...prings z Close the slit below the flue outlet with tension springs Fig 42 Fitting lower lengthways bars and insulation 1 Top rear bar 2 Rear section insulation 3 Tension springs 4 Lower lengthways bar 5 Lower lengthways bar z Push rectangular insulation onto the top front bar z Fasten insulation with 3 tension springs z Feed burner cable over the insulation down the side of the boiler block Fig 43...

Page 34: ...ble strain relief 2 Lower cross bar 3 Front plinth panel z Push the lower folded edge of the first side panel section behind the lower lengthways bar lift slightly and hook the top of the section into the slots on the upper lengthways bar Fig 45 Fitting the side panel section 1 First side panel section 2 Upper lengthways bar 3 Lower lengthways bar z Push the lower folded edge of the remaining side...

Page 35: ...ake any changes due to technical modifications 35 4 15 3 Fitting side panels and hoods z Fit the side panels left and hoods right as shown in the diagram Fig 47 Arrangement of side panels left and hoods right for the various boiler sizes dimensions in mm ...

Page 36: ... front hood A into the slots on the lengthways bar and push forwards z Screw rear of hood A to each lengthways bar using one self tapping screw Fig 48 Fitting the front hood A 1 Haken 2 Slot in lengthways bar z Push folded edge of 400 mm wide hood D under the front hood Fig 49 Fitting hood D 1 Front hood 2 Hood D ...

Page 37: ...r and lower boiler rear panels 1 Upper boiler rear pane 2 Lower boiler rear panel z Screw left right front panel section to the cast lug on the burner door using four hexagon bolts for each z Hook burner door panel into the cut outs in the front panel Fig 51 Fitting the left and right front panel 1 Burner door panel Before the remaining hood sections are put in place the control panel must be fitt...

Page 38: ...panel forwards and then tip back The flexible hooks must latch into the rectangular openings at the rear of the front boiler cover z Screw the base of the control panel on the left and right of the cable duct on the front boiler hood using two self tapping screws Fig 52 Fitting the control panel 1 Terminal cover 2 Flexible hook 3 Rectangular openings in the front boiler cover 4 Push in hooks 5 Ova...

Page 39: ...ake care to ensure correct cable and capillary tube routing z Insert cable clips with cable inside into the clip frame and secure by clamping it with the tab Fitting the rear panel section and terminal cover z If necessary push cut the knock out section out of the rear panel section z Hook the lower hook on the rear panel section into the clip frame and apply pressure at the top until the side hoo...

Page 40: ... as follows z Push controller sensor TRK out of the sensor holder by pressing it gently Fig 55 Temperature sensor set z Feed controller sensor into sensor well R and secure with a screw z Feed both sensors STB high limit safety cut out and Logamatic FK and the two sensor blanking pieces into sensor well R and fix in place Fig 56 Installing the temperature sensor set The STB sensor differs from the...

Page 41: ... that the hot gas baffles have been inserted correctly Fig 57 Checking that hot gas baffles are seated correctly Caution Boiler damage Through contaminated combustion air z Ensure adequate ventilation z Do not use or store chlorinated cleaning agents or halogenated hydrocarbons as contained in spray cans solvents or cleaning agents paints and adhesives for example in the boiler room z Do not opera...

Page 42: ...5 1 2 Setting the capacity open vented heating systems In open systems the hydrometer needle must lie within the red field z Set the green needle on the hydrometer to the required capacity z Top up the heating water or drain via the boiler fill and drain valve until the required capacity has been reached Fig 59 Hydrometer for open systems 1 Hydrometer needle 2 Green needle 3 Red field 5 2 Start up...

Page 43: ...27 4 Check the position of the hot gas baffles the 16 section boiler has no hot gas baffles page 41 5 Start up the control panel See control panel documentation 6 Check the flue pipe for leaks 7 Commission the burner See burner documentation 8 Check the flue gas temperature 9 Check the flue pipe for leaks 10 Check the soundness of the hot gas side of the boiler 11 Enter the fuel used in the corres...

Page 44: ...ow rate through the boiler until the required temperature is reached This is then maintained by continuing to control flow based on the boiler temperature The controls can reduce the flow rate by closing the valves on the mixed heating circuits or by modulating the boiler primary pumps or by closing the motorised butterfly valves or by having a motorised valve in the boiler return on a single boil...

Page 45: ...measures In the event of an emergency e g a fire proceed as follows z Never risk your own life Your own safety is paramount z Close the main fuel shut off valve z Isolate the heating system from the mains power supply using the heating system emergency stop switch or the corresponding domestic fuse Caution System damage caused by frost The heating system can freeze up in cold weather if it has bee...

Page 46: ...e heating system Æ see section 6 1 page 45 Opening the burner door Fig 61 Opening the burner door 1 Front side panel section left 2 Front side panel section right 3 Front panel section burner door casing z Using the hand hole lift the side panel sections slightly and remove Do not remove the front panel sections burner door casing z Using a spanner loosen the burner door fixing screws from the sid...

Page 47: ...he hot gas flues Fig 62 Removing the hot gas baffles z Remove lower boiler rear panel V Loosen tension springs below the flue outlet Æ see Fig 42 page 33 z Fold both ends of the insulation upwards and fasten with the tension springs z Remove the clean out covers from the flue gas header Fig 63 Removing the clean out covers 1 Insulation folded upwards 2 Insulation folded upwards 3 Clean out cover o...

Page 48: ...gs on the rear section and the flue gas header Æ Fig 63 page 47 z Check packing cords on the clean out openings and burner door Replace damaged or hardened packing cords Fig 65 Cleaning the hot gas flues 1 Lower hot gas flues 2 Combustion chamber 3 Upper hot gas flues No of sections Brush ID Brush dimensions diameter in mm Used in Shaft designation K adapter Längen der Stangen in mm 9 11 4 5 8 75x...

Page 49: ...boiler water temperature to at least 70 C z Shut down the boiler z Allow boiler to cool open burner door z Brush out the hot gas flues 7 4 Checking the operating pressure A distinction is generally made between open and sealed systems In practice open heating systems are seldom installed Follow the cleaning agent and cleaning equipment instructions In some circumstances you may need to proceed dif...

Page 50: ...tes below the green field The system needs to be topped up with water z Top up with water until the desired operating pressure is reached z Vent the heating system during filling Fig 66 Pressure gauge for sealed systems 1 Red needle 2 Pressure gauge needle 3 Green field 7 4 2 Checking the fill level open systems In open systems the hydrometer needle must lie within the red field z Check that the h...

Page 51: ...he heating circuit must been carried out by a method that has been approved by the Water Regulation Advisory Scheme WRAS for the type of hea ting 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 69 see right z Control va...

Page 52: ...d 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 untreated or whether you need to treat it before filling your system z Notify your installer if you need to regularly add top...

Page 53: ...see burner documentation 6 Check the flue gas pipe for proper functioning and safety see burner documentation 7 Check water pressure and inlet pressure of the diaphragm expansion vessel on sealed heating systems 49ff 8 Check water pressure and inlet pressure on open heating systems 49ff 9 Check the DHW cylinder and corrosion protection anode for proper functioning see DHW cylinder documentation 10...

Page 54: ...nical modifications 54 Date _____ Date _____ Date _____ Date _____ Date _____ Date _____ Date _____ 1 2 3 4 5 6 7 8 9 10 11 Company stamp signature Company stamp signature Company stamp signature Company stamp signature Company stamp signature Company stamp signature Company stamp signature Tab 16 Continuation ...

Page 55: ...ing cords on the burner and burner door and replace if required 48 8 Start up the heating system 41 9 Record the final checks of the maintenance work incl measurements and test results 10 Check functioning and safety in operation Confirm the professional inspection Company stamp signature Company stamp signature Company stamp signature Tab 17 Maintenance report Date _____ Date _____ Date _____ Dat...

Page 56: ...ormation on burner faults please refer to the burner technical documentation To reset burner faults z Press burner reset button Caution System damage caused by frost The heating system can freeze up in cold weather if it has been switched OFF through a fault shutdown z Rectify the fault immediately and restart the heating system z If this is not possible Drain the heating system and DHW pipework a...

Page 57: ...8 Faults Logano GE615 We reserve the right to make any changes due to technical modifications 57 ...

Page 58: ...8 Faults Logano GE615 We reserve the right to make any changes due to technical modifications 58 ...

Page 59: ...8 Faults Logano GE615 We reserve the right to make any changes due to technical modifications 59 ...

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