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Introduction

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

Boiler Installation and Maintenance Manual SB735 • Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

Technical Changes!

Buderus Hydronic Systems, Inc. reserves the right to
this make changes due to continued technological and
engineering improvments.

Updating Technical Informations

Please contact us if you have suggestions for improving
this manual or when you have noticed incorrect
information.

Manufacturers Address:

Buderus Hydronic Systems, Inc.
50 Wentworth Ave

Londonderry, New Hampshire 03053

www.buderus.net

Document number: 6302 2320

Issue: 10/2003

This equipment conforms to the following
European and US requirements:

– 90/396/EWG European gas fired

guidelines
Standards: EN 677, EN 303-1,

EN 303-3, DIN 4702-6

– 92/42/EWG

European efficiency
guidelines

– 73/23/EWG

European low voltage
guidelines

– 89/336/EWG EMV- European

electromechanical code
guidelines

– 97/23/EG

European pressure

vessel guidelines

Standard:

TRD 702

– ASME Boiler and Vessel Pressure

Code

Confirmation regarding confirmity with
respect to these guidelines can be obtained
upon request from Buderus Hydronic
Systems, Inc.

Содержание SB735 Series

Страница 1: ...6302 2320 10 2003 US CA For installers Please read these instructions carefully Boiler Installation and Maintenance Manual Condensing Gas Boiler SB735 Series ...

Страница 2: ...ormation Manufacturers Address Buderus Hydronic Systems Inc 50 Wentworth Ave Londonderry New Hampshire 03053 www buderus net Document number 6302 2320 Issue 10 2003 F This equipment conforms to the following European and US requirements 90 396 EWG European gas fired guidelines Standards EN 677 EN 303 1 EN 303 3 DIN 4702 6 92 42 EWG European efficiency guidelines 73 23 EWG European low voltage guid...

Страница 3: ...onnections 6 4 Boiler Installation 7 5 Anti Vibration Supports 8 6 Boiler Assembly 9 6 1 Installation of the Thermal Insulation and Jacket Panels 9 6 2 Boiler Jacket Pack A 11 6 3 Boiler Jacket Pack B 15 6 4 Installation of the Control Panel and Sensor Well 16 6 5 Burner Door and Burner 18 6 6 Boiler Jacket Top Covers 19 6 7 Rating Tag Plate 19 6 8 Boiler Jacket Pack C 20 6 9 Venting System 21 6 1...

Страница 4: ...venting system to the atmosphere Use only approved venting materials Have the system inspected by an authorized person prior to start up Only start up the system after approval Check system for leaks The Buderus SB735 boiler is a condensing boiler suitable for firing with natural gas or propane only The installation of a low water cut off and pressure relief valve must be based on local code requi...

Страница 5: ...he boiler Boiler jacket panels and installation components packaged in a wooden crate and cardboard The assembly components are located in Pack A The insulation blankets are packaged in 2 plastic bags A sound attenuating boiler base is supplied standard with the SB735 1200 model Electronic control panel in cardboard box optional A condensate neutralization package can be ordered separately Hydroni...

Страница 6: ...EL Boiler Drain M Sensing Port for Temperature Sensor Ø AA Vent Pipe Diameter L LK H B HAA Ø AA M VK RK2 AKO RK1 EK EL Boiler Model 790 970 1200 Max Input MBH 2751 3378 4179 Max Output MBH 2605 3251 4079 IBR Net MBH 2265 2827 3547 Thermal Efficiency 96 9 96 3 97 6 Combustion Efficiency 94 7 95 6 96 5 Length L Inch 91 108 108 Length LK Inch 75 92 92 Hight H Inch 81 81 81 Width B Inch 54 54 54 Boile...

Страница 7: ...ndation The supporting floor must be level and of sufficient strength Observe the indicated side clearances when placing the boiler Fig 2 Dimensions shown indicate minimum clearances to combustibles or space needed to swing open burner door Place the boiler horizontally on the supporting foundation J NOTICE Make sure to install the base supplied with the SB735 1200 Fig 2 Clearance dimensions for S...

Страница 8: ...n Table 4 on the floor where the boiler is to be installed J NOTICE Prepare the foundation where the anti vibration supports are to be located with a smooth trowel of 1 8 per linear foot and with a slight rise to the back This ensures an even load distribution over the longitudinal anti vibration brackets and adequate boiler ventilation z Position align and place the boiler on the supports The boi...

Страница 9: ...ide when fitting the insulation blankets z Position the insulation blankets for the boiler body so that the cut outs are located over the cross brackets plates Fig 5 Item 1 J NOTICE Position the narrow insulation blanket for boiler model 790 at the rear and note the drain cut outs J NOTICE Note the cut outs for the low water indicator and the cross bracket holder Fig 7 Item 1 5 z Position the fron...

Страница 10: ...e insulation blanket with round cut out Fig 7 Item 2 with its wide edge facing upwards on the left front of the boiler body wide edge up and secure with four clips 2 left 2 right on the surrounding thermal insulation A CAUTION Ensure that the wide edge is at the top at the hinge bolts z Close the burner door and re secure with eight hexagon bolts z Position the thermal insulation strip Fig 7 Item ...

Страница 11: ...al cross bracket Fig 10 Item 1 z Secure the central gross bracket Fig 10 Item 1 at the top to the fixing bracket using two bolts washers and nuts Fig 10 Item 2 J NOTICE Ensure that the edge of the central cross bracket Fig 10 Item 1 points forward z Lightly secure the central cross bracket front Fig 9 Item 1 on the left and the right side using two bolts and washers J NOTICE Initially secure the c...

Страница 12: ...into the respective recess of the front center and rear cross brackets z The bracket is secured at the front hole and the rear slot using one self tapping screw each Fig 12 z Hook the second bracket Fig 12 Item 3 with the U shaped edge into the respective recess of the front centre and rear cross brackets z The bracket is secured at the front hole and the rear slot using one self tapping screw eac...

Страница 13: ...l 790 and Item d screw position for models 970 and 1200 Hook in both covers centrally behind the bracket and align horizontally then join both pieces with two bolts z Secure the left and right side of the cover Fig 13 Item 2 to the front and rear using one bolt each z Secure the blue cover Fig 13 Item 4 at the left and right front of the cover Fig 13 Item 2 using two bolts respectively Item 1 Rear...

Страница 14: ...ig 15 z Push the side walls back z Push the ends of the insulation blankets behind the side wall edge z Insert the small side sections Fig 15 Item 3 into the side and at the bottom z Secure the side wall nearest the front to the central cross brackets using one self tapping screw Fig 15 Item 2 and secure the central cross bracket z Secure the small side sections Fig 15 Item 3 at the front using tw...

Страница 15: ...us de 6 3 Boiler Jacket Pack B z Position the front boiler cover Fig 16 Item 1 on top of the side wall edge and pull forward until the left and right hooks lock into the slots z Secure the front boiler cover by means of two self tapping screws Fig 16 Item 2 which should be inserted through the boiler cover brackets and the side wall edge into the horizontal bracket Fig 16 Install the boiler front ...

Страница 16: ...g 17 z Secure the control panel to the front top cover on left and right inside in the cable raceway using two self tapping screws J NOTICE If necessary break or cut out the knock out from the rear wall of the control panel Fig 18 Make all electrical connections in accordance with the wiring diagram and local code requirements z Insert cable clips into the clip frame and secure by pivoting the lev...

Страница 17: ...ut sensor well M see page 6 in Fig 1 Fig 19 z During the insertion the plastic spiral Fig 20 Item 2 holding the sensor together slides back automatically To ensure a perfect contact between the sensor well Fig 20 Item 3 and the sensor surfaces thereby guaranteeing the safe temperature transfer push the compensating spring Fig 20 Item 1 z Push the sensor holder Fig 20 Item 4 from the side or from a...

Страница 18: ...st for example for the complete removal of the door z Push the hinge bolts Fig 21 Item 1 out from the bottom through the top z Insert both hinge bolts with washers on the opposite side Fig 21 Do not forget to use the washers Observe the burner manufacturer s installation instructions Use or modify drilled burner plate accessory the appropriate burner plate subject to burner make and type J NOTIVCE...

Страница 19: ...ower front wall Fig 24 Item 1 z Hook the lower front wall with four offset hooks onto the slots of the side wall edge Fig 24 z Hook the offset brackets of the top front wall Fig 24 Item 2 into the slots of the lower front wall edge and at the top into edge of the front top cover J NOTICE If the front wall can only be located with some difficulties re align the central cross bracket z Hook the uppe...

Страница 20: ...d secure on the left and right side with two self tapping screws each z Insert the upper rear wall section Fig 26 Item 3 with Z profile behind the central rear wall section on the edge of the side wall and secure on the left and right side with two self tapping screws each z Hook the upper small rear wall section Fig 26 Item 4 with the bracket into the upper rear wall section and secure with a sel...

Страница 21: ...reas corners or directly behind vegetation Vertical Terminations z Roof penetrations should follow all applicable codes and the vent manufacturer s instructions The vent should never be installed at less than the required clearances to combustible materials per UL NFPA and local codes Double wall or thimble assemblies are required when penetrating combustible walls and roofs z Vertical discharges ...

Страница 22: ... excessive weight on the horizontal runs A WARNING Use only an approved vent starter coupling and approved vent pipe from the same manufacturer for Buderus SB boilers Do not mix components from different systems The vent system could fail causing flue gas spillage resulting in severe personal injury or death Permissible Equivalent Venting Length Configurations for SB735 Boilers A NOTICE Above leng...

Страница 23: ...pipe Where this is impracticable use only stainless steel or plastic tee pieces in the separate feed hose pipe z Secure furnished supply manifold and gasket to upper water connection VK connection in Fig 1 page 6 z Install furnished relief valve in supply manifold and pipe discharge full port to nearby floor drain z Install low water cut off and aquastat s in available manifold tappings z Install ...

Страница 24: ...and debris build up Flush the entire heating system prior to firing the boiler To avoid corrosion and debris build up on the water side of the boiler It is required to test the fill and make up water per Instructions for Water Preparation for Boiler D NOTICE Observe the installation instructions for the neutralization system Follow the instructions supplied with boiler burner controls and low wate...

Страница 25: ...m is required J NOTICE We recommend an annual service contract for the maintenance The factory required maintenance steps are outlined in the check list see section 9 Check List Follow the burner manufacturer s instructions regarding burner maintenance 8 2 Cleaning of the Boiler A DANGER due to incorrect boiler brushers Use only brushes made available through Buderus Hydronic System Inc H DANGER d...

Страница 26: ... reversing door aside z Remove the hexagon bolts from the boiler door Fig 29 Item 2 and open the door z Clean the combustion chamber and the heating surfaces z Brush out the secondary and third firetubes Fig 30 J NOTICE When cleaning the secondary and third firetubes the entire brush head should protrude from the firetube before the cleaning brush is withdrawn again z Remove any cleaning residues ...

Страница 27: ...r 6 Remove condensate drain hose from neutralization system 7 Check and clean combustion chamber 8 Check and clean out fire tube passages 9 Flush condensate drain connection at boiler 10 Check and clean flue collector 11 Check burner gasket replace if necessary 12 Check gasket on reversing door replace if necessary 13 Reattach condensate drain hose 14 Close off the reversing cover bolt down and as...

Страница 28: ...can be filled by 180 clean out the container 5 Fill with fresh granulate in accordance with instructions 6 Replace and if necessary bolt down the container lid of the neutralization system 7 Plug in the mains cable of the neutralization system into a main socket 8 Reconnect all hose connections and check for leaks 9 Start up the neutralization system 10 Specialist contractor __________ 01 Date Spe...

Страница 29: ...ck List 9 29 We reserve the right to make any changes due to technical modifications Boiler Installation and Maintenance Manual SB735 Issue 10 2003 Buderus Heiztechnik GmbH http www heiztechnik buderus de ...

Страница 30: ...Notes We reserve the right to make any changes due to techical modifications Buderus Heiztechnik GmbH http www heiztechnik buderus de Boiler Installation and Maintenance Manual SB735 Issue 10 2003 30 ...

Страница 31: ...31 Notes We reserve the right to make any changes due to techical modifications Buderus Heiztechnik GmbH http www heiztechnik buderus de Boiler Installation and Maintenance Manual SB735 Issue 10 2003 ...

Страница 32: ...053 Tel 603 552 1100 Fax 603 584 1681 www buderus net Products manufactured by BBT Thermotechnik GmbH D 35573 Wetzlar www buderus de BBT North America Corporation reserves the right to make changes without notice due to continuing engineering and technological advances ...

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