DANGER!

1 1.6 Disposal
Please dispose of any trash in an environmental friendly fashion. Please discard properly of any heating system related components.
One is only allowed to work on electrical components, if one is certified for such work. Prior to opening the control: shut down the power supply and pad lock against accidental reactivation. Observe all applicable installation guidelines.
1.4.3 Boiler Room Guidelines DANGER due to poisoning. Insufficient combustion air can result in dangerous operation if all combustion air is taken from indoors. Please observe that combustion air openings are not reduced in size or closed. If this problem has not been corrected, one can not operate the boiler. Make the end-user aware of these guidelines and their potential danger. FIRE DANGER due to flammable or liquid materials
Make sure that flammable and liquid materials are not in the close vicinity of the boiler.
Tools, Materials and Accessories
For the installation and maintenance of the boiler you will need typical tools used in the trade. In addition, the following components are useful: Boiler cart with rope or Buderus boiler cart. Wood blocking. Cleaning brushes and/or chemical cleaning agents for a wet cleaning.

PRODUCT DESCRIPTION

The G115 boiler is a low temperature boiler for oil or gas firing for outdoor reset operation or as a cold start boiler. The boiler consists of: optional Logamatic control boiler jacket boiler block with insulation customized burner The optional Logamatic control manages most control functions in a heating system. As an alternative, a Honeywell aquastat can be used for boiler control. The boiler jacket serves to reduce energy loss and as a noise reducing agent. The boiler block transfers the heat generated by the burner to the boiler water. The insulation reduces the stand-by losses.
Fig. 4 Boiler less burner
Control panel Boiler jacket Boiler block with insulation Burner door cover
Customized burner The boiler must be equipped with a customized burner for operation. Please observe the technical data of the boiler when selecting a burner ( Chapter 3.1, page 7). SYSTEM DAMAGE due to improper burner.
Use only burners recommended by Buderus as is discussed in our technical documents.
Technical Data less Burner
Select your suitable burner based on this information.

23 5/8"

39 5/8" 30 3/8"
L LK 1 3/4" 25 1/4" VK Rp11/4" 8 7/8"

5"

5 7/8" 4 3/8"

10 3/8"

20" 3 1/4" RK 1" NPT 8 7/8" EL Rp 3/4" 2 7/8"

12 1/4"

5/8" 1"

2 7/8"

Fig. 2
Dimensions and connections (measurements in inches)

Connections (Measurements see following tables): VK = Boiler supply RK = Boiler return EL = Boiler drain (Connection for drain valve) Keep plugs in place in remaining 3 top rear tappings. Boiler model Number of sections Heating Capacity (Gross Output) Net IBR Boiler water content Fireside volume Oil firing rate Fireside pressure drop Permissible max. supply temperature 1 Btu/hr Btu/hr Gal cu.ft. GPH psi F psi s 115/74,000 64,000 8.7 1.20.60 115/98,000 85,000 10.8 1.75 115/120,000 104,000 12.9 2.21

0.00058 0.58 40

Allowable operating pressure Maximum Reset High Limit for temperature sensor and overheat thermostat (STB)
Table. 1 Technical data less burner
High limit (overheat thermostat STB) Permissible maximum supply temperature = High limit (STB) 32 F e.g.: High limit (STB) = 212 F, maximum permissble supply temperature = = 180 F Select the your high limit (STB setting) according your local codes and requirements.
Boiler model 115/21 Inch Inch Inch Inch Inch Inch Lbs 10 3/22 7/1/115/7/3/1/5/5/1/20 7/115/5/1/1/4
Total boiler length (L) Boiler block length (LK) Combustion chamber length Firebox diameter Burner door thickness Distance between boiler feet (FL) Dry weight 1
Table. 2 Dimensions, Weight and other Data
Weight incl. packaging material approx. % more.

Operating Conditions

By maintaining the operating requirements listed on the following page, one can expect long and trouble free operation of the boiler. Proper and timely maintenance procedures must be followed. SYSTEM DAMAGE In case one does not follow these operating requirements it can lead to premature failures. Major deviations can cause permanent damage to the boiler. Follow the instructions on the rating label and those in the manual.
3.2.1 General Operating Requirements
Operating conditions Minimum boiler temperature Boiler Shut-down Mixed temperature Heating Circuit w/ mixing valve 1 Minimum return temperature
Systems controlled by R2017 controls for outdoor reset operation No requirements Operating conditions are met with R2107 control 2 Automatic with Logamatic R2107 No requirement, yet beneficial No requirement, except with with low temperature boiler with modulating burner 130/113 F system design Oil firing: 113 F Necessary with: Gas firing: 130 F radiant floor applications Systems with large water content > 115 gal/100,000 Btu/hr)

Component Boiler block Boiler jacket, installed on boiler Burner door and burner door cover installed on boiler block B-Kit-components: Supply manifold (11/4" NPT) 30 psi relief valve (") boiler drain Pressure/temperature gauge (1" NPT R1) conversion nipple (parallel to NPT) 90- elbow (1" NPT) 90- elbow (" NPT) Burner mounting studs and washers Screw in feet Control panel, alternative aquastat2 Technical documents

Packaging 1 Pallet

1 Plastic packaging with boiler1
1 cardboard box (ordered separately) 1 Plastic packaging w/ boiler
Table. 9 Packaging and components
B-Kit packaging is supplied inside the combustion chamber. Honeywell aquastat is supplied with customized burner if so ordered.

Moving the Boiler

SYSTEM DAMAGE due to bumps. Protect the boiler from bumps and rough treatment. NOTICE Protect the boiler connections from damage and dirt, when the boiler is not installed immediately. NOTICE Please dispose of the packaging in an environmental fashion.
This chapter describes how to move the boiler.
Reducing Boiler Weight for Transport
One can reduce boiler weight by removing the front panel and burner door itself. Remove the screws holding the front panel in place. Lift up the front panel slightly and remove.

Fig. 3

Removing the front panel
Open burner door by removing the two burner door bolts. Lift burner door from hinges. NOTICE Protect the burner door and the burner tube from damage and dirt, when burner door is removed from the boiler.

Fig. 4

Removal of burner door
Moving the Boiler Lifting and Carrying the Boiler
NOTICE The boiler is secured to the pallet with two bolts. Remove the bolts from pallet before lifting the boiler.
The boiler can be picked up at the hand grips located along the lower jacket panels. NOTICE BODILY DANGER due to carrying of heavy loads.

Fig. 5

Lifting and carrying the boiler
Lift and carry the boiler with at least two people at the designated hand grip positions.
Moving the Boiler with Boiler Cart
You can order a Buderus kuli cart from your local wholesaler. BODILY DANGER if the product is not properly secured to the cart. Use proper moving equipment such as the Buderus kuli cart or other dolly. Secure the boiler to the cart and move the boiler to the job location. Lift up the boiler from the rear side by using moving equipment (e. g. Buderus kuli cart or other dolly). Secure the boiler to the cart. Move the boiler to the job location. NOTICE By tipping the cart, you can install the boiler feet ( Chapter 6.3, page 17).

Fig. 4 5

Reversing burner door (on burner door)
Hex head bolts for door eyelets Door eylet Burner door Door hinges Flue baffles
Placing the Boiler 6.3 Installation of Boiler Feet (Components of B-Kit)
You can level the boiler using the screw-in boiler feet, so that air can not collect in the boiler. Requirement: remove front panel from boiler ( Chapter 5.1, page 13). NOTICE When installing a G115 boiler on top of a horizontal Buderus DHW indirect tank, do not use the boiler feet on the boiler, but rather use the feet to level the tank. Tip the boiler slightly using the boiler cart ( Chapter 5.3, page 14) or put a piece of wood under one side. Screw in the boiler feet 1/4" to 3/8". Level the boiler.
Fig. 2 Installation of boiler feet Boiler rail Boiler feet

Placement of the Boiler

Bring the boiler to its final location. Put a level on the boiler and adjust boiler feet to level the boiler. NOTICE Protect the boiler connections from dust and debris, if the boiler will not be connected right away.

Fig. 11

Leveling the boiler

Boiler Installation

This chapter describes how the individual components must be installed on the boiler. These components are: Flue connection Water connections Electrical connections Burner installation (field installation) Fuel line connection
Installation of Venting System
7.1.1 For Oil-Fired, Direct Vent Applications Follow instructions in the G115 Direct Vent Manual, supplied with the direct oil burner options. 7.1.2 For Chimney Venting Connect boiler with 5 vent pipe to vertical chimney and use vent material approved by local codes for oil-fired boilers. If codes net present, refer to: NFPA 31, Installation of Oil-Burning Equipment. NFPA 211, Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances. In Canada, refer to CSA B139, Installation Code for Oil-Burning Equipment. NFPA 211 requires chimney to be lined prior to connecting boiler. Instecting and cleaning existing chimney Inspect existing chimney prior to installing new boiler. Clean and remove any blockage from chimney. Repair or replace defect pipes or liner. Repair chimney with mortar and joints if necessary. Down Drafts NOTICE To avoid down drafts, extend chimney at least 3 feet above location of roof penetration and at least 2 feet above any roof portion within 10 feet.
We reserve the right to make any changes due to techincal modification!
Minimum clearances to combustibles for vent pipe
Vent Pipe Typ Minimum clearances

Double-wall Single-wall

6" 18"
Table. 11 Minimum clearances to combustibles for vent pipe
Minimum recommended chimney size Minimum recommended chimney size: 8" x 8" (6 " x 6 " inside liner) or 6" round with 15 ft minimum height. Use 5" chimney liner when relining existing chimney. Vent pipe installation Slide 5" vent pipe on flue connection and secure with 2 screws using pre-drilled holes in boiler breeching.

NOTICE Avoid long horizontal runs, excessive number of elbows and tees. Slope vent pipe at least " per foot up towards chimney. Connect breeching above the bottom of chimney to avoid blockage. Avoid extending breeching too far into chimney. Install thimble or slip joint at connection point to allow removal for cleaning. After burner start-up, set breeching draft to -.01 to -.02 inches WC using draft guage. (Over fire pressure can be slightly positive). When necessary, install barometric control in breeching, to relieve excessive draft or to comply with applicable codes. Always position barometric control blade vertically. Set proper opening using draft gauge. 2
Fig. 2 Securing the flue connection
Flue connector Boiler vent collar
DANGER Do not use barometric control and seal all vent joints if: excessive resistance to flow of combustion gases can be expected. actual chimney diameter and/or height is less than recommended. Installation of a CO detector is recommended in this case. Positive over fire pressure operation of boiler will establish draft in venting system.
Boiler Installation Installation of Water Connections
SYSTEM DAMAGE due to leaking connections. Install the piping connections to the boiler without having undue stress on the near boiler piping.
7.2.1 B-Kit Installation Use the B-kit components located in the boiler fire box to finalize the boiler supply connection. Use the 1-1/4" BSP x NPT conversion nipple at the supply connection. Identify the section with the longer thread length is threaded BSP (straight thread). The threads on this side also have no taper. (NPT side has taper). Using high quality Teflon and/or pipe dope, insert the longer threaded end into the boiler supply connection (VK). VK

1"

R1" (Europe)

1" NPT (USA)

Fig. 13
Measuring thread length on 1-1/4" conversion nipple
Install 90 degree elbow 1" NPT on conversion nipple. Orient in desired direction. Install supply manifold into 90 degree elbow. You can orient this manifold in three different directions (Fig. 14). Install pressure/temperature gauge. NOTICE The pressure relief valve can only be installed after the hydrostatic test ( Chapter 7.3, page 21). Use the supplied " street 90 to ensure that the relief valve discharge is installed horizontally. NOTICE We recommend, specially in older, large volume systems, to install a dirt filter in the return connection to the boiler to reduce waterside debris build-up. 1 2

B-Kit Installation

90 degree 1" NPT elbow Supply manifold Pressure/temperature gauge Relief valve 90 degree " NPT street elbow
7.2.2 Installation of Boiler Drain (B-Kit Component) Install the " boiler drain (B-kit component) into the EL tapping. NOTICE Install a fill connection in the supply piping to the boiler. RK EL

Fig. 15

Boiler drain installation
7.2.3 Installation of System Components Use the adjacent diagram as an aid during the installation of near boiler components. Legend for Fig. 16
Relief valve Pressure/temperature gauge Ball valve Air eliminator System pump Back flow preventer Expansion tank Automatic feet valve Flow check Purge station

Supply

Fill valve

Return

Boiler drain
Additional installation samples are found in Chapter 12, page 43.

Fig. 16

Installation diagram
Filling and Checking for Water Leaks
The boiler must be tested hydrostatically for leaks. Check the entire system for leaks prior to placing the system in operation to prevent leaks during operation. SYSTEM DAMAGE Be careful not to expose the system to excessive test pressures during the hydrostatic test as it can damage pressure, control and safety components. Make sure that all pressure, control and safety components are NOT installed during the hydrostatic test. Perform the hydrostatic at 1.5 times the expected operating pressure and in accordance with local code requirements:

Fig. 17

Pressure and temperature gauge
Maximum operating pressure Maximum test pressure 45 psi 75 psi

30 psi 58 psi

(based on supplied relief valve) (based on 50 psi relief valve)
Plug relief valve connection ( Fig. 14, page 20) and all boiler openings with plugs. (Not supplied). Close the ball valve to the expansion tank. Open automatic feed valve. Fill the boiler slowly with the feed valve. Open the automatic air eliminator to allow air to escape. Slowly fill the heating system. Monitor the pressure gauge. Check all water connections for leaks. Vent the heating system by opening and bleeding radiators. Open purge valve slowly and allow air to escape. When water pressure drops during the fill, open up the fill valve more. When no leaks are found, remove plug, drain water and install relief valve (Fig. 14, page 20).

Remove rear top cover. Remove first rear sheet metal screws. Remove top cover plate. The electrical wiring will run through this race way.

Fig. 20

Removal of top rear cover and top cover plate
7.7.1 Control System Installation Slide plastic front tabs of control panel in the oval shaped openings. Slide the control panel forward. Push forward on plastic snap tabs in rear of control to engage them into the top panels square knock-outs. 2 1
Fig. 4 Installation of control
Plastic snap tabs Plastic front tabs Oval knock-outs Square knock-outs
Remove top cover of control panel. Remove cover screws. Secure control to top cover using small sheet metal screws.

Removal of top cover

Top cover screws Sheet metal screws
7.7.2 Installation of Temperature Sensor and Burner Cable SYSTEM DAMAGE Be careful not to kink or have the capillary tubes come in contact with sharp surfaces. Route the capillary tubing carefully and avoid kinking. Route capillaries and sensor wiring to the immersion well. Route the capillary tubing carefully and avoid kinking. Route capillaries and sensor wiring to the immersion well. Strap excess tubing and wiring together and place on top of insulation. Burner wiring can be routed down towards the front of the boiler. If burner is supplied with a wiring harness, route harnesss between jacket panels and boiler insulation. Install burner wiring per wiring instructions included with Logamatic control or refer to diagrams located on pages 51 to 53. NOTICE Every G115 boiler has a factory installed immersion well for use with a Honeywell aquastat. When installing a Logamatic control, you must replace the installed brass well with the chrome well supplied with the Logamatic control. Bring the sensor bundle to the installed chrome well and slide bundle into the well. The plastic holding clip will slide back. Insert all sensing elements fully into the well and secure tubing with furnished metal holding clip. NOTICE Make sure all sensing elements are all fully inserted into the well and make good contact with well inner surface. Make sure to use the tension clip in the middle of sensing elements. 7.7.3 Electrical Connections Install a power supply point near the boiler in accordance with local and state code. 2 3
Routing and connecting of capillary, sensor and electrical wiring
Cable raceway opening in top front cover Capillary tubing and sensor wiring. Well location. Burner cable/wiring

Testing of the Manual Reset High Limit (STB) of Logamatic controls
The manual reset high limit will permanently interrupt burner operation once its limit (230 F) is exceeded. To restore operation, it is required to reset this control and lower the water temperature well below its fixed setting. Refer to Logamatic Service Manual to check operation of manual reset high limit.
Install Front Jacket Parts
Hang boiler front panel into slots of boiler side panels. Secure front panel with the two screws into the side panels.

Fig. 34

Installation of boiler front panel
Placing the Boiler in Operation 8.10 Detailed Start-up Procedure
Check off performed start-up steps, sign and date.
Start-up Procedure 1. Filling of system and check for leaks Page Value Measured 21 __________ psi 2. Set operating pressure vent heating system check operation of relief valve pre-set expansion tank pressure ( instructions) 28 __________ psi see expansion tank manufacturer' Comments
3. Check combustion air and venting system 4. Check position of flue baffles 5. Turn on control ( 6. Turn on burner ( Refer to control Service Manual) Refer to burner manual) __________ F 8. Check manual reset high limit (STB) 9. Adjust control settings based on requirements ( Manual)) 10. Inform end user and hand over instructions Confirm start-up procedure Refer to control Service 32
7. Measure stack temperature (Adjust if needed)
Company stamp/signature/date
NOTICE Always inform your customer regarding proper fuel source and record in Operating Manual.

Normal Boiler Shut-down

With Buderus Logamatic controls: Turn the main switch to "0" position. This shuts off power to components wired directly to the control panel.

1 ON/OFF switch

Abb. 35 Shutting down heating system (Logamatic 2000)
With Honeywell aquastat control: Shut off main heating system switch. (Position "OFF") This shuts off power to all components wired through this switch. Further shut-down procedure: documentation. refer to aquastat

Fig. 36

Heating system shut-down (with aquastat)
Shut off fuel supply by closing main valve. SYSTEM DAMAGE due to freezing.
When the system is shut off, the system could potentially freeze up. Keep the system operational as long as possible. Protect the system against freeze-up by draining the entire system at its lowest point.

Emergency Shut-down

We reserve the right to make any changes due to technical modifications! Buderus Heiztechnik GmbH http://www.heiztechnik.buderus.de

Fig. 39

Brushing out the combustion chamber
Boiler Installation and Maintenance Manual Logano G115 US Issue03/2004
10.3.2 Wet Cleaning Use for the wet cleaning a suitable cleaning agent designed to dissolve the internal build-up or clean the soot. Following the wet cleaning, proceed with the brushing steps outlined in ( Chapter 10.3.1, page 36). NOTICE Observe and follow recommendations of the cleaning agent' manufacturer. Under certain conditions you may need to deviate from the guidelines below. Cover control with plastic to prevent water damage. Spray heating surfaces evenly with cleaning agent. Close burner door and turn on heating system. Heat the boiler to a minimum temperature of 160 F. Turn the system off. Brush out heating surfaces.
10.4 Testing System Pressure
The system pressure should be 15 to 30 psi for a closed system. Check system pressure. When the pressure gauge shows less than 12 - 15 psi, the pressure is too low. SYSTEM DAMAGE due to frequent make-up water.

CAREFUL!

When you add frequently make-up water to the system, this can lead to corrosion and lime build-up in the system. Make sure that the heating system is equipped with automatic air elimination. Verify that the system has no leaks and check the expansion tank for proper operation.
Fig. 40 Pressure/temperature gauge to display system pressure and supply temperature
SYSTEM DAMAGE due to material stresses as a result of temperature differences. Add only additional make-up water when the system is cold (Temperature gauge reading should not exceed 100 F).
Add make-up water through the automatic feed valve. Vent system. Check system working pressure.
10.5 Testing Relief Valve
Check the functioning of the relief valve every 1 to 3 years as required per local code. Make sure nobody is near the discharge of the relief valve. Lift up on the relief valve. The relief valve must open and discharge water. If the valve does not discharge, replace the valve and recheck. If the defective valve is not replaced, it can lead to damage to certain system components due to excessive high pressures.
Boiler Maintenance 10.6 Inspection and Maintenance Procedure
Sign off and date performed service work.
Service work 1. Check general status of system
This service and maintenance protocol can also be copied for further use.
Page Date: ______ Date: ______ Date: ______
2. Do visual performance test on system
3. Check fuel and water components for: Leaks during operation Hydrostatic water test Visual corrosion Exterior system changes 4. Check flue passages for soot, shut off system 35

" Boiler Bypas

Fig. 44

Zoning with zone valves and built-in bypass for larger water volume systems

KR PH KR PS

Fig. 45 Multiple zones with DHW, high temperature and low temperature circuits with a motorized 3-way valve

Spare Parts

13 Spare Parts
The following parts are available through Buderus Hydronic Systems. Model specific part numbers are listed under the various models. In other cases the table shows the number of components for each model. Boiler block and burner door(Fig. 46)
Item Description G115/section
10 Boiler block G115 05952285
Legend for tables 12 and 13: x = no spare part (x) = component of a set, only furnished with the set 0 = no picture available

Part number G115/section

05952290

G115/section

05952295
Front section components: Plug G1 1/4" right Gasket for plug D41,7x55x1,5mm AFM 34,white Blocking plate with screw M8x16 Screw DIN7991 M8x16 Ms 63015342 (x)
rear section components: Plug DIN1" Threaded stud M10x65 5.6 Distance sleeve R3/8"x39 Hex. head nut ISO4032-M10-8-A3K Washer DIN125-A10,5-A3K Immersion well Pmw-3See (4 1/2")"US" Tie bar - Set M8x310mm Tie bar - Set M8x440mm Tie bar - Set M8x555mm Flue collector Sealing rope 8x1050 GP Glue for securing rope (a 310ml) Return diffuser 1 1/4-NPT1 compl. G115"US" Gasket 55x41,7x1,5mm 05127574 63028061 05555070 (x) (x) (x)
Flue collector components
Spare parts which are not furnished with the spare boiler block: 180 Flue baffle Boiler rail 420mm long Boiler rail 540mm long Boiler rail 660mm long Washer DIN126-9 Hex. head screw ISO4017-M8x25-8.8 Hex. head nut DIN6923-M8-8.8-A3K Door hinge G105/G115 Scheibe DIN125-A10,5-A3K Sechskantschraube ISO4017-M10x25-8.8 Sechskantschraube ISO4014-M10x65-8.8 Washer DIN125-A10,5-A3K Boiler feet M10x51mm complete (x) (x) (x) 05327033 (x) (x) (x) (x) 67900117
Tab. 12 Boiler block and burner door
or: 210 Flue silencer D130 with adapter 100mm long, with condensate drain, lower sound absorption Flue collar DN130 complete Flue collar DN130 complete (step cuff) Sealing rope10x2000 GP Burner door complete Door hinge Washer DIN125 A10,5 A3K Hex. head screw ISO4017 M10x25 8.8 Observation port cover complete G115/G125/G135 Gesket 30x30x3 Sight glass Tempax 30x30x3,3mm Sight glass cover plate Hex. head screw ISO4017 M6x12 8.8 A3K Pressure measuring port M6 SW10 V2 Burner door insulation G115 W607 Insulating plate for burner door 24mm Insulating ring for burner door 10mm Washer DIN9021 A6,4 A3K Sheet metal screw DIN7981 C ST6,3x25 A3T Sealing rope14x1650 GP Glue for securing sealing rope to burner door (a 310ml) Mounting material for boiler block G115 "US" Components: 1 Hex. head screw M8x16 Ms 2 Distance sleeve R3/8"xHex. head nut ISO4032 MA3K 8 Washer DIN125 A10,5 A3K (x) 4 Washer DIN4 Hex. head screw ISO4017 M8x25 8.Hex. head nut DIN6923 M8 8.8 A3K 4 Hex. head screw ISO4017 M10x25 8.Hex. head screw DIN6921 M10x65 8.Hex. head screw ISO4017 M6x12 8.8A3K 2 Washer DIN9021 A6,4 A3K 2 Sheet metal screw DIN7981 C ST6,3x25 A3T B-KIT G115"US" Components: 1 Supply manifold G115"US" degree 1 1/4 NPT elbow degree 3/4 NPT elbow Conversion nipple R11/4-11/4NPTxBoiler drain valve 3/4 1Relief valve 3/4Mx3/4F 30PSI 1 Pressure / Temperature gauge 1/4NPT 1 Screw-Set B-Kit G115"US" 1 Boiler feet set M10xGasket for flue collar DN130 complete Flue silencer DN130 complete, without condensate drain; higher sound absorption 05354010 05074020

SP30D Providing Domestic Priority w/ Buderus Boilers and Tanks
Domestic Tank Pump Heating Pump

Fig. 48 Wiring diagram 1

FOR MULTIPLE ZONES:
JUMPER ON 2 HEATING PUMP H 2 T DELETE T C2 T C1 L1 B2 R COOL Heat W Set to 130

SP30D and Burner Wiring

Aquastat L8148A Oil or L8148E Gas L2

115V AC 240V AC

ADD RELAY-BOARD AND WIRE IT WITH
C1 CONNECTED TO POWER SUPPLY L2
14 SP30D and Burner Wiring

L2 Pump 1

L2 Pump 2

L2 Pump 3

Tank Sensor
Pump-Relay-Board Setpoint 50 to F

Burner Oil or Gas 1 L1

115 VAC

240 VAC

L1 NO 1 NC NO 2 NC On Gas Boilers G124/G234, B 1 and B2 will be connected to the Boiler Control, 24V 24V #18 Wire 120V AC 3 Tank Sensor 6 COOL Heat Set to 130

Setpoint 50 to F

This wiring diagram is generic in scope and does not purport to address all design, installation, or safety considerations. This diagram is for reference use by code officials, designers and licensed installers. It is expected that installers have an adequate knowledge of accepted industry practices for the equipment, procedures and applications involved.

BUDERUS HYDRONIC SYSTEMS

FILE NAME : DRAWN BY:
SP30D Holger Hinse APPROVED BY: Dr. Lou Vorsteveld

Type: FOR:

SP30D AQUASTAT GENERIC WIRING SCHEMATIC GAS / OIL BOILER W/ L8148A OR L8148E HW AQUASTAT

DATE :

3/12/2004

Fig. 49

Wiring diagram 2

Fig. 50 Wiring diagram 3

R7184B

Fig. 51

Wiring diagram 4

Table of Key Words

15 Table of Key Words

Aquastat. 24

Restoring lock-out conditions. 41 Reversing burner door swing. 16. 23. 23. 23. 13. 13. 32. 41. 17 7, 8 5, 9. 10.7 25
Burner assembly. Burner cable installation. Burner cover removal. Burner door reversal. Burner door jacket panel removal Burner door jacket installation. Burner lock-out resolution. Boiler feet installation. Boiler model. Boiler room.
Sealing rope replacement. Stack temperature adjustment Strain relief adjustments. Supply manifold. System operating pressure. 36. 30. 27. 7. 11, 22
Technical data. 7 Temperature sensor installation. 26 Tools. 5 Transport w/ kuli cart/dolly. 14
Clearance. Cleaning of flue passages. Combustion air requirements. Connections. Control panel installation.

Vent connection installation. 18
Water quality considerations. 11 Wet cleaning. 37
Dirt trap system. 21 Disposal. 5 Drain valve installation. 21
Electrical connections. Electricity restoration. Emergency switch. Environmental concerns. 34.29.23
Flue baffle removal. Flue baffle position confirmation Fuel fumes. Fuel requirements. Fuel supply restoration.
Heating system emergency switch. 34 Hydrostatic pressure test. 22

Input ratings. 7

Jacket component installation. 32
Main electrical shut-off switch Main fuel shut-off valve. Maintenance requirements. Make-up water. Manual reset high limit. 32
Operating pressure (allowable). 7 Operating requirements. 8 Original parts. 12
Placing the boiler in operation. Placing the boiler out of operation. Protocol, service and maintenance. Protocol, start-up procedure. 39 33

Heating Contractor:

PRODUCTS MANUFACTURED BY
BBT Thermotechnik GmbH 35573 Wetzlar www.buderus.de
BBT North America Corporation 50 Wentworth Avenue Londonderry, NH 03053 Tel: 603-552-1100 Fax: 603-584-1681 www.buderus.net
BBT North America Corporation reserves the right to make changes without notice due to continuing engineering and technological advances.

All applicable local, state, and national codes and regulations must be observed for the installation of the boiler: The local building code requirements regarding placement, combustion air and venting and chimney system must be followed. Follow applicable electrical code requirements. Follow the local code and standards regarding safe boiler operation. NOTICE Use only original Buderus spare parts. Buderus can not be held liable for damage caused by non-Buderus parts. NOTICE The boiler installation must be performed by a qualified installer in accordance with regulations put forth in NFPA-31 Installation of Oil-Burning Equipment. The installation must comply with all local and national codes, regulations and authorities having jurisdiction regarding the installation of oil fired boilers. For Canada refer to the guidelines of CSA/ CGA-B139 Installation Codes.
This document contains important information regarding safe and proper installation, operation and maintenance of the boiler. The high tech G115 WS boiler is designated as a hot water heating boiler. The Installation and Maintenance Instructions are directed to the installing contractor who has professional knowledge regarding boiler installation and maintenance.

Explanation of symbols

Warnings are indicated by a warning triangle and a grey background.
Signal words are used to indicate the seriousness of the ensuing risk if measures for minimising damage are not taken. Caution indicates that minor damage to property may occur. Warning indicates that minor personal injury or severe damage to property may occur. Danger means that severe personal injury may occur. Very serious cases may result in death. Notes are identified in the text by this symbol. They are bounded by horizontal lines above and below the text. Notes contain important additional information. Notes do not contain any warnings or information about hazards or risks.
Installation Guidelines Caution: DANGER TO LIFE from electric shock. V Do not work on electrical components unless you have the required qualification. V Do not work on electrical components unless you have the required qualification. V Prior to opening the control: shut down the power supply by turning off the emergency shut-off switch or disengaging the heating system circuit breaker, and prevent from accidental reactivation. V Observe all applicable installation guidelines.

The boiler is a low-temperature oil-fired appliance with automatic control panel or aquastat for boiler water temperature. The boiler consists of: Boiler heat exchanger with insulation Boiler jacket Control panel or aquastat The controls monitor and control all electrical boiler components. The boiler can alternatively be fitted with a simple aquastat control. The boiler jacket prevents heat loss and acts as a noise insulator. The boiler heat exchanger transfers the heat generated by the burner to the heating water. The insulation prevents energy loss. Suitable burners Caution: Risk of system damage from use of incorrect burner. V Only the burner provided may be employed with this boiler. Fig. 1

615 225-01.1RS

Boiler without burner
Control panel Boiler jacket Boiler heat exchanger with insulation Burner door Burner door panel

Pack contents

Upon delivery, check that the packaging is complete and undamaged. Component Boiler heat exchanger Boiler casing, factory-fitted to boiler heat exchanger Burner door and burner door panel, factory-fitted to boiler heat exchanger B-kit components: 1 Supply manifold G115"US" elbow 90 1-1/4" elbow 90 3/4" double nipple R1-1/4"1-1/4" NPT x 75 boiler drain 3/4" relief valve 3/4" x 3/4" 30PSI temperature/pressure gauge Bolt set B-Kit G115"US" adjustable boiler feet M10 x 51 packed Controller or, alternatively, Aquastat2) Technical documentation Tab. 1 Package Contents
1) in the combustion chamber in the boiler 2) Aquastat may be supplied with burner

Packaging 1 pallet

1 foil package 1)

1 box 1 foil package

Dimensions Specifications
Logano G115 WS dimensions
23 5/8" 39 5/8" 1 3/4" 30 3/8" 5"

25 1/4"

VK Rp1 1/4" 8 7/8"

5 7/8" 4 3/8"

10 3/8"
20" 3 1/4" RK 1" NPT 8 7/8" EL Rp 3/4" 2 7/8"

12 1/4"

5/8" -

1" 2 7/8"

019 141-02.1RS

Fig. 2

Connections and dimensions (measurements in inches)
VK = Boiler supply RK = Boiler return EL = Boiler drain (connection for drain valve)
Connections and dimensions:

Boiler model Boiler sections Heating capacity (gross output) Thermal output (net IBR output) Boiler water content Gas capacity Oil firing rate Flue gas back-pressure Permissible flow temperatureSafety1) Allowable operating pressure Maximum time constant of thermostat and high limit safety cut-out (STB) MBtu/hr MBtu/hr Gal cu.ft. GPH W.C. F psi s Unit G115/3 WS 74 8.7 1.20 0.7 G115/4 WS 95 10.8 1.75 0.9 0.04" - 0.06" 40 G115/5 WS 119 12.9 2.21 1.0
Tab. 2 Technical data for boilers without burners
1) Limit (safety temperature limiter, STB) Maximum permitted flow temperature = Safety limit (STB) - 32 F Example: Safety limit (STB) = 212 F, maximum permitted flow temperature = 212 - 32 = 180 F The safety limit must meet the national regulations of the country concerned. Boiler model Boiler overall length (L) Boiler block length (LK) Combustion chamber length Combustion chamber length Burner door thickness Distance between boiler feet (FL) Net weight1) Unit Inch Inch Inch Inch Inch Inch Lbs 10-3/8" 330 G115/3 WS 23-5/8" 21-1/8" 16" G115/4 WS 28-5/8" 25-" 20-" 10-5/8" 3-5/8" 16-1/8" 403 20-7/8" 476 G115/5 WS 33-3/8" 30-" 25-"
Tab. 3 Dimensions, weight and other data for boilers without burners
1) Incl. packaging material approx. 6-8 % more

Conditions for operation

Maintaining the specified operating conditions will enable the boiler to provide a high level of reliability and long service life. Some details relate only to operation with Buderus Logamatic control panels. Caution: Risk of system damage if operating conditions are not maintained. Irreversible damage to individual components of the boiler as a whole or the heating system may occur. V The information on the rating plate is binding and must be observed. 2.8.1 General operating conditions
Operating conditions Min. boiler water temperature no requirements operating temperatures are ensured by the Logamatic controls2) Operating interruption (complete boiler shutdown) heating circuit with heating circuit mixing valve1) Min. return temperature
In combination with Logamatic control for variable low-temperature operating modes, such as Logamatic 2107 Automatically by Logamatic controls not required but recommended with low-temperature heating system design 130/113 F Required with: Underfloor heating systems Systems with high water content: > 115 gal/MBH (1 MBH = 100.000 Btu/hr) In conjunction with a Logamatic controls for constant boiler water temperatures, e.g. Logamatic 2109 or with supplementary external programmer and aquastat 150 F3) possible if, after interruption of the operation, there is at least 3 hours heating operation required Required with: Systems with high water content > 115 gal/MBH: 130 F

Operating conditions Air intake flow cross-section for combustion air drawn from outside (divided between max. 2 apertures)
Tab. 6 Observe national regulations for boilers which draw their air supply from the boiler room. If the burner is to be operated with sealed combustion by drawing its combustion air solely from the outdoors, follow burner manufacturer's specification. 2.8.4 Conditions, Fuel
Notes Requirement in greater detail This boiler can be operated with #2 Fuel Oil ASTM D396-05 Type 2. Select a burner that is suitable for this fuel typ. Free of contaminants (for example dust, mist, humidity), i. e. a constant operation will not lead to accumulation of deposits, in valves, strainers and filters and could lead to service calls.
Operating conditions Permissible fuels for boilers without integral burners Contamination

Tab. 7 Fuels

Conditions power supply
Notes Requirement in greater detail 120 V AC nominal 10 A 60 Hz IP 40 (protected against contact by entry of foreign objects > 0.04 inches (> 1 mm ), no water proofing) Observe the voltage range of the burner and controls used. The outer casing/boiler must be grounded for safety reasons and in order to function correctly.
Operating conditions Power supply voltage Circuit breaker Frequency Enclosure rating
Tab. 8 Power supply 2.8.6 Conditions for hydraulic system and water quality
Notes Requirement in greater detail psi psi F F On some controls adjustable on site from 212 to 248 F. The heating system may only be filled and topped up with water of domestic water quality. We recommend a pH value of 8.2 9.5. Maximum 30 psi with the supplied safety valve.
Operating conditions Operating pressure (above atmospheric) Permissible site test pressure Safety temperature limitation by TR temperature control Safety temperature limitation by manual reset high limit (STB) Water quality
Tab. 9 System configuration and water quality

Moving the boiler

Caution: Risk of system damage from impact. Fragile components could be damaged. V Observe the transport instructions on the packaging. Protect boiler connections from damage and dirt if the boiler is not installed immediately.
This chapter details how to move the boiler safely.
Dispose of packaging in an environmentally responsible manner.
Reducing boiler weight for transportation purposes
If required, you can reduce the weight of the boiler by removing the burner hood and door. V Unscrew the burner door-panel screws. V Lift burner door panel slightly and draw forward to remove.

615 225-02.1RS

Fig. 3 Prevent the burner door from falling over and damaging the burner and blast tube.
Removing burner door panel
V Unscrew two hex-head bolts at the sides. V Open burner door. V Lift the burner door off its hinges.

019 141-04.1RS

Reversing boiler door

The burner door is factory-fitted with the hinges on the right the burner door opens to the right.You can change the burner door hinges over to the left-hand side if desired to suit the installation site. Remove the burner hood/burner door panel first ( Chapter 3.1, page 12). V Removing the burner door ( Chapter 3.1, page 12). V Unscrew the hinge bolts and remove the hinges. V Mount the hinges on the left-hand side of the boiler using the hinge bolts.

019 141-08.1RS

Fig. 8
Reversing the burner door (boiler heat exchanger attachments)

Hinge bolts Hinges

V First remove the hinge lobe bolts and then the hinge lobes. Mount the hinge barrels on the left-hand side of the boiler using the hinge-barrel bolts. V Hook the burner door with the hinge lobes onto the hinges. V Check that the heat exchanger baffles are placed horizontally ( Chapter 6.3, page 29). V Close the burner door and secure with the two hexagon-head bolts.Tighten the hexagon-head bolts evenly (approx. 90 Lbs/inch) so that the burner door seals properly. If the burner door hinges have been changed over to the left-hand side, the burner cable must be disconnected from the burner before opening the burner door.

019 141-09.1RS

Fig. 9
Reversing the burner door (door attachments)
Hinge-barrel bolts Hinge lobes Burner door Hinges Heat exchanger baffle plates
Mounting the adjustable feet (included with B-kit)
Level the boiler with the adjustable feet to prevent air pockets forming inside the boiler. Requirement: the burner hood/burner door panel must have been removed first ( Chapter 3.1, page 12). If the boiler is mounted on top of a horizontal hot water tank, the adjustable feet are not needed. V Tilt the boiler with the aid of a hand truck or trolley ( Chapter 3.3, page 13) or place a wooden batten underneath it. V Screw in adjustable feet " 3/8". V Gently set the boiler down.

019 141-10.1RS

Fig. 10 Fitting adjustable feet
Angle bracket Adjustable feet
Positioning and leveling the boiler
V Position the boiler in its final location. V Level the boiler horizontally by turning the adjustable feet and using a level. Protect boiler connections from damage and dirt if the boiler is not installed immediately.

019 141-11.1RS

Fig. 11 Leveling the boiler horizontally
This chapter details how to install your boiler correctly. The individual steps involved are: Connecting the flue Connecting the water pipes Making the electrical connections Fitting the burner Connecting the fuel supply

Flue pipe installation

5.1.1 Chimney venting Connect boiler to vertical chimney with a 5" vent pipe. Use only venting systems that comply with local codes and regulations. If local codes are not existent, refer the the following regulations: NFPA 31, Installation of Oil-Burning Equipment, NFPA 211, Standard for Chimneys, Fire Places and Solid Fuel Burning Appliances, In Canada refer to CSA B139, Installation Code for OilBurning Equipment, NFPA 211 requires chimney to be lined before connecting boiler. Inspecting and cleaning existing flue Before installing the new boiler, check and clean the old flue system. V Remove blockages and dirt from the chimney. V Clean chimney. V Repair or replace faulty sections. V If necessary, repair chimney with mortar and joints. Down drafts To prevent down drafts extend chimney at least 3 feet above the roof opening and at least 2 feet above any part of the roof within a radius of 10 feet.

Fig. 13 Checking thread length on double nipple

Fig. 14 Installing B-Kit

90 1" NPT street elbow Double nipple Supply manifold Pressure/temperature gauge Pressure relief valve 90 " NPT elbow
We recommend installing a dirt filter (optional) in the boiler return connection to reduce build-up of debris on the water side.
5.2.2 Installation of boiler drain (included in B-Kit) V Seal boiler drain to connection EL. Install a fill connection in the supply piping to the boiler.

019 141-15.1RS

Fig. 15 Installation of boiler drain

RK Return EL Drain

5.2.3 Installing system components See the installation diagram for installation of the heating system components. For more installation examples refer to page 43. Chapter 10,

019 141-16.1RS

Fig. 16 Installation diagram
11 VK EL RK Pressure relief valve Pressure/temperature gauge Ball or stop valve Air eliminator (in main supply) System pump Flow check valve Expansion tank Automatic feed valve Flow check valve Purge station Water feed Boiler supply Drain Return
Filling the heating system and checking for leaks
The boiler is tested for leaks at the factory. Before putting the heating system into operation, it must be checked to ensure that no leaks will occur during operation. Caution: Risk of system damage from excess pressure when testing for leaks. Pressure, control and safety equipment may be damaged by excessive pressure. V When you carry out a leakage test, make sure that no pressure, control or safety equipment that cannot be isolated from the boiler water chamber is fitted. Caution: Risk of damage to system due to temperature stresses. If you fill the heating system when it is hot, the resulting temperature stresses can cause stress cracks. The boiler will then leak. V Only fill the heating system when cold (the flow temperature should be no more than 100 F). V Pay attention to the water quality as specified in the operator's log, and record the volume and quality of the water used to fill the system. Carry out the leak test at 1.5 times the standard operating pressure and in accordance with the codes. Maximum operating pressure 30 psi (with safety valve supplied) 58 psi (with 50 psi relief valve) Maximum on-site testing pressure 45 psi 75 psi

019 141-17.1RS

Fig. 17 Pressure/temperature gauge
Tab. 12 Maximum testing pressure V Seal pressure relief valve connection ( Fig. 14 "Installing B-Kit", page 19) and all other open connection with blind plugs. V Isolate the expansion tank from the system by closing the valve. V Open the mixing and shut-off valves on the heating water (primary) side. V Slowly fill the boiler with tap water.
Caution: Health risk from contaminated domestic water. V Always observe the regulations and standards applicable in your jurisdiction for the prevention of contamination of drinking water (e.g. by water from heating systems). V Open the cap of the automatic air vent by one full turn to allow air to escape. V Slowly fill the heating system. Observe the pressure gauge whilst filling. V Check the connections and pipework for leaks. V Bleed the system via the radiator bleed valves if applicable. V Top with water if the pressure drops as a result of bleeding the system. V Installing pressure relief valve ( Fig. 14 "Installing BKit", page 19)

Mounting the burner

Only burners that comply with the boiler specification can be used with this boiler. ( Chapter 2.7, page 8). Caution: Risk of system damage from use of incorrect fuel. V Only use burners which meet the technical boiler requirements. V Screw studs included with the B-Kit to the burner door. Approved burners with accessories (such as aquastat and circulator) are also available as a package from Buderus. V Install burner with the correct nozzle and settings (air, pump pressure, turbulator settings, flange position). V Place the seal on the studs and secure the burner with the included nuts. For details of the correct burner settings flue system documentation and burner documentation. V Follow the manufacturers direction for installation, fine adjustment and regular maintenance procedures.

019 141-18.1RS

Fig. 18 Burner door mounting holes
Connecting the fuel supply
Make the fuel connection in accordance with all applicable local and national codes and regulations. We recommend fitting a fuel filter and de-aerator. V Visually inspect the fuel pipe and clean or replace, if necessary. V Install a shut-off valve into the fuel supply pipe. V Connect the fuel pipe free of stress to the boiler. V Check the fuel line for leaks.

Installing aquastat

An aquastat controls the boiler supply temperature. V Install aquastats in the sensor well as specified by the installation manual. For operating the boiler with aquastat page 28. Chapter 6,

Fig. 27 Pressure/temperature gauge for showing operating pressure and supply temperature
Checking the safety valve
V Make sure that no persons are in the discharge area of the pressure relief valve. V Raise the lever on the pressure relief valve. The pressure relief valve must open and release pressure. If the pressure relief valve does not discharge, it must be replaced, because system components can be damaged by excessive pressure.
Checking position of heat exchanger baffles
Prior to commissioning, check that the heat exchanger baffles are in a horizontal position: V Open burner door by removing the two hexagon-head bolts at the sides. V Slightly withdraw the flue gas baffles from the heat exchanger. V Adjust the heat exchanger baffles to a horizontal position and push them back into the heat exchanger. V Close burner door with the two hexagon bolts (approx. 90 inch-lbs). Tighten the hexagon bolts evenly to properly seal the burner door.

019 141-27.1RS

Fig. 28 Opening the burner door
1 Flue gas baffles in the heat exchanger
Preparing the heating system for operation
V Open the fuel supply at the main shut-off valve. V Switch on the heating system emergency shut-off switch and/or the appropriate circuit-breaker.
Starting up the control and the burner
For further start-up steps, follow the burner start-up sequence.To do so, it is essential that you consult the burner documentation. Use the on/off switch on the controls to switch the heating system on. The burner starts up if the system is calling for heat or if you set the controls to manual mode. service instructions for the controls. V Select "Manual" mode. V Set the boiler water temperature control to the desired temperature. V Switch the on/off switch on (position "I").

019 141-28.1RS

Fig. 29 Switching on the controller (e. g. Logamatic 2000)
Boiler water thermostat On/off switch
Notes on commissioning the burner
Allow burner to operate for 15 to 20 minutes before performing a combustion test. Earlier combustion tests can lead to incorrect readings as a result of burning off the sealing rope. We recommend rechecking the burner after a few weeks of operation. Incorrect burner adjustment can cause contamination of the boiler (e.g. soot), leading to low efficiency, high emissions, and a greater risk of service calls. V Always check combustion with the following instruments. V Never adjust burner visually. Required instruments: CO2 measuring equipment Draft measuring equipment Oil pressure gauge Stack thermometer Smoke tester V Check the combustion chamber pressure at the test port. V Check the breeching draft at a test port drilled in the vent connector (chimney vent models only).

019 141-29.1RS

Fig. 30 Pressure test port on burner door

1 Pressure test port

Raising flue gas temperature
For the set flue gas temperature for the boiler see the technical data ( Chapter 2.7, page 8). You may raise the flue gas temperature if you discover during tests that the flue gas temperature is too low for the type of chimney used (risk of condensation) by one or several of the following measures: Caution: Risk of burning by touching hot boiler parts. V Wear appropriate protective gloves or use pliers.
V Adjusting the position of heat exchanger baffles -orV Removing heat exchanger baffles -orV Removing the heat exchanger barrier plate
6.7.1 Adjusting the position of heat exchanger baffles Only adjust or remove heat the exchanger baffles in pairs. V Open burner door by removing the two hexagon-head bolts at the sides. V Adjusting the position of heat exchanger baffles. V Slightly withdraw the flue gas baffles from the heat exchanger. V Turn the heat exchanger baffles to a slanting position and push them back into the heat exchanger. V Close burner door with the two hexagon bolts (approx. 90 inch-lbs). Tighten the hexagon bolts evenly to properly seal the burner door. V Re-check the flue gas temperature.

019 141-30.1RS

Fig. 31 Adjusting the position of heat exchanger baffles 6.7.2 Removing heat exchanger baffles You can remove the baffle plates in pairs to raise the flue gas temperature. V Open burner door by removing the two hexagon-head bolts at the sides. V Remove the baffle plates towards the front. V Close burner door with the two hexagon bolts (approx. 90 inch-lbs) Tighten the hexagon bolts evenly to properly seal the burner door. V Re-check the flue gas temperature.

019 141-31.1RS

Fig. 32 Removing heat exchanger baffles
6.7.3 Removing the heat exchanger barrier plate You can remove the blocking plate to further raise the flue gas temperature if the flue gas temperature is still too low after removing of the baffles. V Open burner door by removing the two hexagon-head bolts at the sides. V Remove diverter plate by loosening bolt. V Re-check the flue gas temperature.

019 141-32.1RS

Fig. 33 Removing the heat exchanger barrier plate
Manual reset high limit (STB)
The manual reset high limit interrupts the power supply if the maximum permissible flow temperature is exceeded. To enable a boiler reset and re-starting, the fault must be removed and the system temperature must have fallen below the limit. V Check the function of the manual reset high limit ( controls maintenance instructions).

Installing the burner door jacket
V Position the burner door panel on the hooks on the boiler casing. V Secure the burner door panel with the two screws at the sides. Danger: Risk of fatal injury from electric shock. V Only operate the boiler with the burner hood/door panel fitted. V The Logano G115 WS must be fitted with a burner that has an operating range that matches the specifications of the Logano G115 WS. Caution: Risk of system damage from use of incorrect fuel. V Only use burners which meet the technical requirements of the Logano G115 WS ( Chapter 2.7, page 8). V Mount the selected burner to the hole circle in the burner door. V Connect burner cable to burner. ( Installation instructions of burner).

615 225-03.1RS

Fig. 34 Installing the burner door jacket

6.10 Commissioning log

V Initial and date the commissioning steps carried out. Commissioning operations 1. Fill heating system and check for leaks Heating system pressure 2. Bringing the system up to operating pressure V bleeding heating system V Testing relief valve V adjust the expansion tank pressure ( manufacturers documentation) 3. 4. 5. 6. see the expansion tank 28 ____________ psi Page 21 ____________ psi Readings taken Comments
Checking combustion air supply and flue system Checking position of heat exchanger baffles Switching on the controls and burner ( tion) controls' documenta30 ____________ F
Checking flue gas temperature and raising if required

7. 8. 9.

Checking the manual reset high limit (STB) Adjusting the controls settings to suit the customer's requirements ( controls' documentation) Informing the end user and handing over technical documentation Confirmation of properly completed commissioning
Company stamp/signature/date
Inform the customer about the correct fuel and correct operating pressure. Enter the details in the table ( boiler operating instructions).
Shutting down the heating system
Caution: Risk of system damage from freezing. If the heating system has been switched off, it may freeze up in cold weather conditions. V Leave the heating system switched on as long as possible. V Protect a disabled heating system from freezing by draining the heating system and hot water pipes at the lowest point.

Cleaning the boiler

The boiler can be cleaned with brushes and/or by a wet method. Cleaning equipment is available as accessory. Caution: Risk of burning by touching hot boiler parts. V Wear appropriate protective personal safety equipment. V Open burner door by removing the two hexagon bolts on the sides. 8.3.1 Cleaning the boiler with brushes V Note the position of the heat exchanger baffles for later. V Remove the hot gas baffle plates from the hot gas passages. V Clean the hot gas baffle plates with one of the two cleaning brushes.
Fig. 37 After opening the burner door
V Clean the hot gas passages by turning the round cleaning brush.

019 141-37.1RS

Fig. 38 Brushing out the hot gas flues V Clean the combustion chamber with a flat brush. Remove the debris from the combustion chamber, the hot gas flues and the flue connection. V Refit the heat exchanger baffles in their original positions. V Check sealing rope on burner door. Replace damaged or hardened gasket cord. You can obtain suitable gasket cord from your local Buderus sales office.

019 141-38.1RS

V Close burner door with the two hexagon bolts (approx. 90 inch-lbs). Tighten the hexagon bolts evenly.
Fig. 39 Brushing out the combustion chamber
8.3.2 Wet cleaning (chemical cleaning) For wet cleaning use a cleaning agent appropriate for the degree of soiling (soot or scale). Proceed with the wet cleaning in the same order as described for cleaning with brushes ( Chapter 8.3.1, page 36). Follow the instructions for the cleaning product. You may need to proceed differently from the method described here in some circumstances. V Cover the control panel with plastic to prevent spray from entering the control panel. V Spray cleaning agent evenly into the heat exchanger heater passages. V Close burner door and start up the heating system. V Heat the boiler to a temperature of at least 160 F. V Shut down the heating system. V Brush out the heat exchanger heater.
Checking heating system operating pressure
The system pressure for closed systems must be psi (1.0 2.1 bar). V Check system pressure. V If the pressure gauge shows less than 15 psi, the pressure is too low. Top up the system with water. Caution: Risk of system damage due to frequent topping up. If you have to top up the heating water frequently, the heating system may suffer damage from corrosion or scaling, depending on the water quality. V Ensure that your heating system is bled properly. V Check the heating system for leaks and proper operation of the expansion vessel.

Page Date:______ 36

4. 5. 6. 7.
Date:______ 1. 2. 3. 4. 5. 6. 7. Company stamp/signature

Troubleshooting

Two type of fault are distinguished: Burner faults and Control and heating system faults. If there is a burner fault the fault indicator lamp on the burner comes on ( burner documentation). Such faults can generally be reset by pressing the reset button on the burner. Controls and heating system faults are indicated on the controls display if it has one. For further information see controls' documentation. Correcting burner faults Caution: Risk of system damage due to too many resets Too many resets can damage the burner's ignition transformer. V Do not press the reset button more than three times in a row. V If the fault does not reset after the third attempt, try to localize and rectify the fault with the help of the burner documentation. V Notify a service engineer if necessary. V Press reset button on burner. Caution: Risk of system damage from freezing. The heating system can freeze up in cold weather if it has been disabled by a fault shutdown. V Rectify the fault immediately and restart the heating system. V If this is not possible, protect your heating system from freezing by draining the heating system and hot water pipes at the lowest point.

615 225-04.1RS

Fig. 41 Resetting the burner

1 Burner

Installation examples

KR MAG PH PW

Check valve Expansion tank System pump Hot water pump SH SV THV WH Heating circuit adjuster Pressure relief valve Thermostatic radiator valve Water compensation pipe (diversion)

Key to abbreviations

THV SV

G125 G115 WS/NA

019 141-40.1RS
Fig. 42 Multiple circuits with circuit valves

1 Baseboard

KR PH SV

G115 WS/NA G125 WS/NA

019 141-41.1RS
Fig. 43 Multiple circuits with circuit valves

THV SV PH

G115 WS/NA G125

3/4"

019 141-42.1RS
Fig. 44 Multiple circuits of water diversion for systems with a high water volume

Radiator Boiler bypass

KR PH KR PS 120 100