Buderus GA124 Installation Manual

6304 0309 – 04/2005 US For heating engineersInstallation and maintenanceinstructionsSealed combustion gas boilerLogano GA124CAUTION!Observe the safety instructions of thisinstallation and maintenance manualbefore placing the boiler in operation.WARNING!If installation, adjustment, modification,operation or maintenance of theheating system is carried out by anunqualified person, this may result indanger to life and limb or propertydamage. The directions of thisinstallation and maintenance manualmust be followed precisely. Contact aqualified service company, serviceprovider or the gas company if supportor additional information is required.CAUTION!The operating manual is a componentof the technical documentation handedover to the operator of the heatingsystem. Discuss the instruction in thismanual with the owner or operator ofthe heating system to ensure that theyare familiar with all information requiredfor operation of the heating system.Note: Keep this installation and maintenance manual available for futurereference.Please read carefully prior to installation and maintenance.

Contents11.3 Inspection of the boiler and burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4811.4 Preparing boiler for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4911.5 Cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5011.6 Cleaning the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5411.7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5511.8 Maintenance protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5912 Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6113 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8014 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/20053

1Safety1 SafetyObserve these instructions for your safety.The burner and control must be correctly installed andadjusted to ensure safe and economical operation of thegas-fired boiler.Read this installation and maintenance manual carefullyand note the details on the boiler nameplate beforeplacing the boiler in operation.1.1 Correct useThe Logano GA124 gas-fired boiler is designed to heatwater for a hot water heating system for heating singleor multiple occupancy buildings.1.2 Observe the following symbolsTwo levels of danger are identified and signified by thefollowing terms:WARNING!CAUTION!RISK TO LIFEIdentifies possible dangers emanatingfrom a product, which might lead to seriousinjury or death if appropriate care is nottaken.RISK OF INJURY/SYSTEM DAMAGEIdentifies potentially dangerous situations,which might lead to medium or slightinjuries or to material losses.Additional symbols for identification of dangers and userinstructions:.RISK TO LIFEfrom electric shock.1.3 Please observe these notes1.3.1 National regulationsThe heating system must comply with the relevantregulations issued by national authorities, or theregulations issued by the National Fuel Gas Code, ANSIZ 223.1. In Canada the regulations of CAN/CGA B 149.1or 2, Installation Code for Gas Burning Appliances andEquipment, must be observed.If specified by the local regulatory authorities the heatingsystem must comply with the regulations of the"Standard for Controls and Safety Devices forAutomatically Fired Boilers", ANSI/ASME CSD-1.Carbon monoxide detectors must be installed asspecified by the local regulations. The boiler must beserviced annually; see Chapter 11 "Boiler inspectionand maintenance", page 48.Boiler operating conditionsMaximum boiler temperature 220 °FMaximum operating pressure58 psiThe hot water pipe system must comply with the currentlegislation and regulations. If an existing boiler isreplaced, the complete hot water pipe system must beinspected to ensure that it is in perfect condition toensure safe operation.WARNING!RISK TO LIFEdue to neglecting your own safety in caseof emergency, such as with a fire.• Never put yourself at risk. Your ownsafety must always take priority.WARNING!USER NOTETip for the optimum utilization and settingof the control(s) plus other usefulinformation.We reserve the right to make any changes due to technical modifications.4 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Safety 1WARNING!CAUTION!RISK TO LIFEfrom explosion of flammable gases.If you smell gas there is a danger ofexplosion..• Never work on gas lines unless you arelicensed for this type of work..• Make sure that a qualified companyinstalls the boiler, connects gas andventing, places the boiler in operation,connects the electrical power, andmaintains and repairs the boiler.• No open flame. No smoking. Do notuse lighters.• Prevent spark formation.Do not operate electrical switches,including telephones, plugs or doorbells.• Shut off main gas supply valve.• Open doors and windows.• Warn other occupants of the building,but do not use door bells.• Call gas company from outside thebuilding.• If gas can be heard escaping, leave thebuilding immediately, prevent otherpeople from entering, notify police andfire from outside the building.SYSTEM DAMAGEdue to incorrect installation.• Observe all current standards andguidelines applicable to the installationand operation of the heating system asapplicable in your country.CAUTION!SYSTEM DAMAGEdue to unsatisfactory cleaning andmaintenance.• Clean and service the system once ayear. Check that the complete heatingsystem operates correctly.• Immediately correct all faults to preventsystem damage.USER NOTEOnly use original Buderus spare parts.Losses caused by the use of parts notsupplied by Buderus are excluded from theBuderus warranty.1.3.2 Installation notesWARNING!WARNING!RISK TO LIFEfrom explosion of flammable gases.• Never work on gas lines unless you arelicensed for this type of work.RISK TO LIFEfrom electric shock.• Do not carry out electrical work unlessyou are qualified for this type of work.• Before opening a unit: disconnectelectrical power completely and lock toprevent accidental reconnection.• Observe the installation regulations.WARNING!RISK TO LIFEfrom electric shock.• Disconnect the power supply to theheating system before conducting anywork on it, e.g. switch off the heatingemergency switch outside the boilerroom.• It is not sufficient just to switch off thecontrol.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/20055

1Safety1.3.3 Information on the boiler room 1.4 Tools, materials and accessoriesWARNING!WARNING!RISK TO LIFEby poisoning.Insufficient ventilation during operationrequiring room ventilation may causedangerous flue gas leaks.• Make sure that inlets and outlets are notreduced in size or closed.• If faults are not corrected immediately,the boiler must not be operated.• Inform the system operator of the faultand the danger in writing.RISK TO LIFEby poisoning.When working on the flue gas monitoringequipment leaking flue gas may endangerthe lives of people.• Do not attempt to repair the flue gastemperature sensor.• Use only original parts when replacingparts.• When replacing the flue gastemperature sensor install the new onein the specified position.You need standard tools for the installation andmaintenance of the boiler as used in heating systeminstallation and oil, gas and water installations.The following additional items will also be useful.– Boiler cart with rope or Buderus boiler cart– Cleaning brushes and/or chemical cleaning agentsfor wet cleaning1.5 Disposal• Dispose of the packaging material in anenvironmentally compatible fashion.• Dispose of any components of the heating systemthat require replacement in an environmentallycompatible fashion.WARNING!RISK TO LIFEby poisoning by leaking flue gas.If the flue gas monitor trips frequently,there may be a problem with the chimneyor the flue gas venting.• If the flue gas monitor trips frequentlythe fault must be corrected and afunction test must be conducted.WARNING!RISK TO LIFEby poisoning by leaking flue gas.• Make sure that the boiler is not fittedwith a thermally controlled flue gasbaffle after the back flow check.WARNING!FIRE DANGERdue to flammable materials or liquids.• Make sure that there are no flammablematerials or liquids in the immediatevicinity of the boiler.We reserve the right to make any changes due to technical modifications.6 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Product description 22 Product descriptionThe boiler is a low temperature gas-fired boiler.USER NOTEThe boiler is fully functional with thefactory-installed aquastat. TheLogamatic 2107 control can also beinstalled in addition to the factory-installedaquastat.3245The boiler consists of:– Aquastat (control unit)– Logamatic 2107 control (optional control)– Boiler jacket and front panel– Boiler block with insulation– BurnerThe control monitors and controls all electricalcomponents of the boiler.The boiler jacket prevents energy loss and acts assoundproofing.The boiler block transfers the heat generated by theburner to the heater water. The insulation preventsenergy loss.1Fig. 1 Logano GA124 boiler1 Burner2 Boiler jacket3 Boiler block with insulation4 Logamatic 2107 control (optional)5 Aquastat (control unit)6 Boiler front panel6We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/20057

Scope of delivery 44 Scope of delivery• Check packaging on delivery for damage.• Check delivery for completeness.Component Qty PackagingBoiler, complete 1 1 palletB-kit components:- supply manifold1 1 foil package 1- 30 psi relief valve- temperature/pressure gauge- 90° elbow (1" NPT)- 90° elbow (3/4" NPT)- boiler drain (3/4")- screw-in feet (4) (M10x51)- wall penetration forhorizontal flue system1 separatepackaging unit- technical documents 1 1 foil packageTab. 2 Scope of delivery1 On palletOptional Accessories 1UnitLogamatic 2107 control 1Heat circulation pump 1Cleaning brush 1Vertical flue system 1Tab. 3Accessories1 Accessories available by separate orderWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/20059

5Moving the boiler5 Moving the boilerThis chapter describes how to move the boiler safely,CAUTION!SYSTEM DAMAGEdue to bumps.• Check the transport diagrams on thepackaging to protect the sensitivecomponents from damage by bumping.USER NOTE• Protect the boiler connections from dirtif the boiler is not installed immediately.USER NOTEDispose of the packaging material in anenvironmentally compatible fashion.5.1 Moving the boiler with boiler cartMove the boiler with packaging and on pallet as much aspossible.CAUTION!RISK OF INJURYif the boiler is not properly secured to theboiler cart.• Use suitable transport equipment, suchas a boiler cart with a belt.• Secure the boiler to prevent it fromfalling.• Position transport equipment (e.g. boiler cart) at theback of the boiler.• Secure boiler to cart.• Move the boiler to the installation location.Fig. 4Moving boiler with trolleyWe reserve the right to make any changes due to technical modifications.10 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Moving the boiler 5• Remove the straps and the cardboard packaging.• Remove the bolts from the pallet.• Lift the boiler at the sides and slide to the edge of thepallet. Place a pipe under the boiler and roll it onadditional pipes to the installation location.• Place the boiler in its final position.Fig. 5Moving the boiler5.2 Lifting and carrying the boilerThe boiler can be picked up at the hand grips shown.CAUTION!RISK OF INJURYdue to carrying heavy loads.• Lift and carry the boiler with at least fourpeople at the designated hand grippositions.Fig. 6Lifting and carrying the boilerWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200511

6Placing the boiler6 Placing the boilerThis chapter explains how to place the boiler andposition it in the boiler room.CAUTION!SYSTEM DAMAGEthrough frost.• Place the boiler in a frost-free room.This boiler is approved for installation in enclosedrooms, such as storage rooms.The boiler is very heavy when full. Check that the floorcan bear the weight before installation.6.1 ClearancesA space of at least 33 inches is required in front of theboiler with the door open to allow sufficient accessspace for operation and maintenance. When the door isclosed, a minimum clearance of 2 inches is required atthe front and sides, 2 inches clearance is also requiredfor the flue pipe and 30 inches clearance to the ceiling.The installation location and the base must be smoothand horizontal. The boiler may be installed on aflammable base, but not on carpet.2"2"31min. 2"min. 2"2"33"min. 2"Fig. 7 Required clearances in the boiler room1 Door closed2 Door open3 Flue pipe2We reserve the right to make any changes due to technical modifications.12 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Placing the boiler 66.2 Leveling the boiler• Screw the four rubber feet 0.25 to 1.0 inches into thebottom rails.• Place boiler on the feet.• Level boiler horizontally and vertically by screwingthe feet in and out.Fig. 8Unscrewing screw-in feetWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200513

7Boiler installation7 Boiler installationThis chapter describes how to install the boiler. Thisincludes the following tasks:– Connecting the heating system– Electrical connection– Fuel supply connection– Installation of flue system7.1 Preparing for installation• Unpack all boxes and containers and check all partsagainst the packing lists to make sure that everythinghas been supplied.USER NOTEEvery boiler is carefully inspected andtested before it leaves the factory.However, if you discover any damage ormissing parts, please inform the supplierimmediately. Before disposing of packingmaterial, make sure that no parts are stillin it.We reserve the right to make any changes due to technical modifications.14 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 77.2 Heating circuit connectionCAUTION!BOILER DAMAGEthrough moisture.• Protect the components of the gasignition system from moisture (dripping,spray, rain) during installation of theboiler, during operation and duringmaintenance work (such as replacingthe pump, replacing the control, etc.).3SYSTEM DAMAGEdue to overheating as a result of low water.12CAUTION!• Note that a boiler installed above thelevel of the heating system must befitted with a low-water alarm. The lowwateralarm must be installed duringinstallation of the boiler ( Fig. 9).22CAUTION!SYSTEM DAMAGEdue to high temperature variations in theheating system.• If the boiler is operated in connectionwith a refrigeration system, make surethat the pipes for the refrigerated liquidare connected in parallel to the boilersystem with suitable valves to preventthe refrigerated liquid from entering theboiler.• The pipe system of a boiler connectedto the heating coils of hot-air heatingsystems that may be exposed to thecirculation of cooled air must be fittedwith a flow-control valve or some otherautomatic system for preventing theboiler water from circulating by gravityduring the cooling cycle.21Fig. 9 Low-water alarm1 Boiler2 Radiator3 Heating system with low-water alarm4 Heating system without low-water alarm422We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200515

7Boiler installationInstallation of B-kitThe relief valve and the pressure/temperature gauge aremounted on the boiler supply VK over the supplymanifold (included in B-kit).• Seal 90° 1" NPT elbow on VK.• Seal supply manifold on 90° 1" NPT elbow. Thesupply manifold can be mounted vertically or rotated90° to the right.• Seal temperature/pressure gauge on supplymanifold.12 34USER NOTEInstall the relief valve after the leak test( Chapter 7.7, page 32).The relief valve must be installed in avertical position.The relief valve must also be installed inaccordance with the requirements of theANSI/ASME Boiler and Pressure VesselCode, Section IV.USER NOTEWe recommend installing a dirt filter(optional) in the heater return connectionto reduce build-up of debris on the waterside.Fig. 10 Installation of B-kit1 Pressure/temperature gauge2 Supply manifold3 Relief valve 3/4"4 90° 3/4" elbow5 90° 1" NPT elbow6 Boiler supply VK7 B-kit rotated 90° right56 7USER NOTEObserve the local regulations forconnection of boiler systems.CAUTION!FIRE DANGERdue to heat.• Note that a minimum clearance of twoinches is required between pipescarrying hot water and flammable wallsin the boiler room.We reserve the right to make any changes due to technical modifications.16 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 77.3 Electrical connectionThe electrical connections of the boiler must bemanufactured as specified by the local codes and thecurrent regulations of the National Electrical Code,ANSI/NFPA–70.In Canada the regulations of CSA C 22.1 CanadianElectrical Code, Part 1, must be observed.The boiler must be grounded as specified by theregulations of the relevant local authorities; otherwisefollow the regulations of the National Electrical Code,ANSI/NFPA–70.USER NOTEWhen making the electrical connectionsfollow the circuit diagrams on page 81to page 83.Install an ON/OFF switch near the boiler.WARNING!RISK TO LIFEfrom electric shock.• When conducting maintenance worklabel all cables before disconnectingthem.• If cables are connected incorrectly thesystem may not operate correctly withpossibly dangerous consequences.• Check that the heating system functions correctlyafter any maintenance work.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200517

7Boiler installation7.4 Installation of Logamatic 2107 control (optional accessory)The boiler is fully functional with the factory-installedaquastat. The Logamatic 2107 control can also beinstalled in addition to the factory-installed aquastat.All Logomatic capillaries and sensors are to be installedto the boiler immersion well together with the existingHoneywell aquastat sensor (see page 20 for details)USER NOTENote the following when making electricalconnections:• Lay out cables and capillaries carefully.• Do not bend the capillaries duringinstallation.• Never carry out any electrical work onthe heating system unless you arelicensed for this type of work. If you arenot a licensed electrician, have aspecialist electrical company make theelectrical connections.• Observe the local regulations.1. Unscrew left and right screws in the side panels, liftfront panel up, pull outward and remove to the front.Fig. 11Removing front panel of boilerWe reserve the right to make any changes due to technical modifications.18 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 72. Lift the back boiler jacket and remove to the back.3. Slide the insertion tabs of the control into the ovalopenings.4. Slide control toward the boiler front panel.5. Push to snap plastic tabs of the control into theknock-outs.Fig. 12Removing boiler jacket6. Remove top cover of control Remove screws fromthe top cover.7. Fasten control with sheet-metal screws.8. Route boiler water sensor cable through the cableopening and unroll to the required length.Fig. 13Removing terminal cover1Fig. 14Installation of Logamatic 2107 controlWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200519

7Boiler installationInstallation of Logomatic boiler water sensor9. Trace boiler water sensor wiring under the frontboiler cover to the measuring point (immersion well).10. Pull sensor clip from the head of the immersion well.11. Pull existing sensor packet from the immersion well.12. Replace a quadrant segment (blank) with the boilerwater sensor of Logamatic 2107.13. Insert entire sensor packet fully into the immersionwell to the stop.14. Press sensor clip from the side or from above on tothe immersion well.15. Carefully roll up unnecessary wiring and capillariesand stow in the Logamatic 2107 control.14235Power connection and connections of additionalcomponentsConnect to the power supply as specified by the localcode.WARNING!FIRE DANGERHot boiler components may damageelectrical wiring.• Make sure that all wiring is routed in theducts or on the boiler insulation.Fig. 15 Front of boiler1 Measuring point (immersion well)2 Sensor holder3 Quadrant (blanking piece)4 Sensor (aquastat)5 Boiler water sensor (Logamatic 2107 control)6 Sensor packet616. Route all wiring to the control through the wiringopening and connect as specified by the circuitdiagram.Install strain reliefSecure all wiring with wiring clips (included with control):– Insert wiring clip with wiring from above into the slotof the clip frame; the lever bar must point upwards(step 1).– Slide wiring clip down (step 2).– Press (step 3).– Move lever up (step 4).1Fig. 16Secure wiring with wiring clipWe reserve the right to make any changes due to technical modifications.20 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 7Installing panel components17. Swivel display unit to the desired position.USER NOTEWe recommend positioning the displayunit straight on combinations with anL-tank.Fig. 17Swivel display unit18. Position terminal cover and screw to control.19. Slide tabs of rear boiler cover under the front boilercover and press down at back.20. Screw rear boiler cover to rear panel of boiler.Fig. 18Positioning terminal coverCAUTION!SYSTEM DAMAGEdue to dirt.If the boiler is assembled and not in use,note the following:• Protect the boiler connections from dirtby closing the connections.Fig. 19Installing rear boiler coverWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200521

7Boiler installation7.5 Fuel supply connection7.5.1 Gas connectionsFor the gas pipe diameter required for the installationplease see Tab. 4 and Tab. 5. Make sure that the pipefitting has the correct thread size.Make sure that a sediment trap is installed at the inlet forthe gas supply pipe to the boiler. A gas shut-off must beinstalled outside the boiler jacket if required by the localcode. We recommend installing a gas shut-off in themain gas pipe to the boiler. The gas pipes must befastened outside the boiler.The local codes must be observed during installation ofthe gas connection, otherwise the regulations of theNational Fuel Gas Code, ANSI Z 223.1.WARNING!Lengthof pipein feetTab. 4DANGER OF EXPLOSIONLeakage from the gas pipes and gasconnections may cause an explosion.• Use soap solution to find leaks.Gas pipe supply volume in cubic feet of gasper hour 11/2 3/4 1 1 1/4 1 1/210 132 278 520 1060 160020 92 190 350 730 110030 73 152 285 590 89040 63 130 245 500 76050 56 115 215 440 67075 45 93 175 360 545100 38 79 160 305 480150 31 64 120 250 380Gas pipe supply volume1 Maximum gas supply volume in cubic feet per hour, based on aspecific gas weight of 0.60 and a gas pressure of 0.5 psi or lessand a pressure gradient corresponding to a water column of0.3 inches.Nominaldiameter ofiron pipe(inches)Equivalent lengths for pipe fittings infeetPipe fitting type90° angle T-piece Stop valveGasvalveEquivalent lengths in feet1/2 1.4 2.7 0.3 0.803/4 2.1 4.1 0.5 1.251 2.6 5.2 0.6 1.61 1/4 3.5 6.9 0.8 2.151 1/2 4.0 8.0 0.9 2.50Tab. 5 Equivalent lengths for pipe fittingsDisconnect the boiler with the gas shut-off from the gassupply pipe system the system is pressure tested with atest pressure greater than 1/2 psi.Fig. 20 Pipe connection to gas fittings – back view1 Gas feed2 Hand stop valve3 Sediment trap123We reserve the right to make any changes due to technical modifications.22 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 7If the gas supply pipe system is pressure tested at a testpressure of 1/2 psi or less, it is sufficient to disconnectthe boiler from the pipe system by closing the stop valve.• The boiler and its gas connections must be tested forleaks before placing it into operation, ( Chapter 9,page 36).Use only sealant that is resistant to corrosion by LPG forpipe connection. Only a small amount of sealant must beapplied to the external thread of the pipe connections.If you wish to convert the boiler to propane, pleasecontact Buderus for the required conversioncomponents. Do not attempt to convert the boiler withoutthe approved Buderus parts and the relevant technicaldocumentation. The technical documentation isincluded with the conversion parts.7.5.2 Installation at high altitudesThe boiler is designed for installation at altitudes below8500 feet above sea level. The boiler must be restrictedappropriately for installation above altitudes of8500 feet. The conversion consists of replacing the maingas orifices.USER NOTEIf the installation location is over 8500 feetabove sea level, please contact Buderusfor the required conversion components.Do not attempt to convert the boilerwithout the approved Buderus parts andthe relevant technical documentation.The technical documentation is included with theconversion parts (accessories).We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200523

7Boiler installation7.6 Installation of flue systemThe boiler system as delivered includes the wallconnection for horizontal flue systems.Flue systems from the following manufacturers can beinstalled for the flue and combustion air lines:Manufacturer Flue pipe 3"horizontalTypevertical*Typeheat fab SAF-T vent SAF-T ventO-flex-L Star 34 -Pro Tech FasNSeal -Z-FlexZ-Flex, modelSVE-Tab. 6 Manufacturer of flue pipe* The roof penetration is not included with the boilerUSER NOTENote that pipes of different maximumlengths are allowable depending on thesize of the boiler and the flue system. Themaximum possible lengths are listed in Tab. 7 - Tab. 11 on page 31 and page 32.USER NOTEYou must follow all directions forinstallation of the flue venting in all partsof the flue system, particularly theassembly instructions of the flue systemmanufacturer. Use only pipes with adiameter of 3" for the flue pipes andaccessories from the manufacturernamed in Tab. 6.Use rigid or flexible metallic pipes with adiameter of 3" for the combustion line.The flue system components can beordered as accessories from yourwholesaler or from other suppliers ofaccessories.CAUTION!OPERATING FAULTSdue to strong winds.If a t-piece is not installed at the end of theflue line, the boiler may stop operating in astorm.• Note that a termination tee must alwaysbe installed at the end of the flue line.• The termination tee can be purchasedfrom the selected flue linemanufacturer.USER NOTEConsult the local building and fireinspection authority for any restrictionsand inspections of heating systems.Comply with the national regulations.Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de24 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 77.6.1 Installation of the wall penetration of a horizontal flue systemsPlease read the following instructions and informationon the installation of the wall penetration carefully andnote the safety instructions.The wall penetration must be installed in the wall asdirected by the regulations and/or local building codes.• Make an opening in the wall with a diameter of six (6)inches at the required position of the wallpenetration.• Insert the wall penetration into the wall from theoutside and attach to the outside wall with the fourscrews.• Insert flue pipe into wall penetration from the outside.Attach the termination tee horizontally to the flue pipeand install as directed by the installation instructionsof the flue system manufacturer.Fig. 21Wall penetration1 2 3Fig. 22 Installing flue pipe1 Wall penetration2 Flue pipe3 End piece of flue pipe (t-piece)We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200525

7Boiler installation• Install flue pipe in the wall penetration so thetermination tee on the flue pipe extends 10 inchesbeyond the front edge of the wall penetration..• Attach the flue pipe to the wall penetration with thetwo securing clips. Rotate the securing clips downand attach with the screws ( Fig. 24).11"3"1• Seal gap ( Fig. 24) with silicone.Make sure that the flue system termination tee throughthe side wall of a building is at least 12 inches above theground.1The flue system termination tee must be installed on allheating systems to ensure proper operation and toprevent foreign bodies from entering the flue system.2The termination tee must be at least 12 inches above theexpected snow level in areas with heavy snowfall.No changes are permitted to the wall penetration or anyother parts of the flue system. All parts must be installedin original condition.The flue system must end no less than seven (7) feetabove a sidewalk or pedestrian passage.Make sure that the termination tee is at least six (6) feetaway from the combustion air intake of another unit.The flue system must be installed more than three (3)feet away from any other opening in the building.Terminating gas meters, controls etc.The flue system must terminate at least four (4) feetbelow, four (4) feet horizontally or one (1) foot aboveevery door, every window or every air vent of a building.Fig. 23 Position of termination tee on the flue pipe1 Securing clips2 3" connection for combustion air pipeFig. 24 Securing clips1 Seal gap with silicone.2 Screws21Clearance to combustibles for stainless steel vent pipeclearance enclosedclearance unenclosedhorizontal8"vertical4"horizontal1"vertical1"We reserve the right to make any changes due to technical modifications.26 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 77.6.2 Installation of the wall penetration of a vertical flue systemsUSER NOTEThe vertical flue system requires the fluepipe and concentric pipe with roofpenetration from Heat-fab, SAF-T vent.Please contact Buderus to select therequired flue system components.You must follow the directions for installation of the flueventing in all parts of the flue system, particularly theassembly instructions of the flue system manufacturer.The combustion air is supplied through a concentric 5"pipe in the vertical flue system. The typical installation ofa vertical system is shown in Fig. 25.12334USER NOTEA condensation trap must always beinstalled at the flue vent.Note the clearances of the roof penetration above theroof as shown in Fig. 25.The maximum length of the concentric combustion airpipe is 10 feet (cf. Fig. 25).Note the maximum length of the complete flue systemincluding the concentric pipe as shown in Tab. 10and Tab. 11, ( page 32).Clearance from flammable building components is notrequired near the concentric pipe penetration. Aclearance of two (2) inches from flammable buildingcomponents is required in the area of flue pipe to theconcentric pipe.When calculating the extended pipe length foradjustment of the combustion air baffle( Chapter 7.6.4, page 30) the length of the concentricpipe must also be taken into account. The condensationtrap need not be considered in the calculation.Fire protection collars ( Fig. 25) may need to beinstalled in existing ceiling penetrations.Fig. 25 Vertical flue system1 Roof penetration2 Fire protection ring3 Fastening the flue pipe4 Condensation trapWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200527

7Boiler installation7.6.3 Installation of the flue and combustion air pipeInstallation of the flue pipe ( Fig. 27) at the boiler• Install condensation trap.USER NOTEA condensation trap must always beinstalled at the flue vent.• Position silicone strip approx. 1/4" wide on the boilerintake (500 ° F-resistant silicone, use G. E. 106 orsimilar).• Attach condensation trap to boiler connection (seearrow) and secure with the included hose clamp.• Place a strip of silicone around the connection pointand smooth it to form a gas-tight connection.2134Installation of the combustion air pipe at the boilerProceed as described above for the flue pipe to installthe combustion air pipe. A condensation trap is notinstalled on the combustion air line.Fig. 26 Condensation trap1 Silicone strip2 Silicone strip3 Hose clamp4 Condensation trap1 2Fig. 27 Back view1 Combustion air line connection2 Flue gas lineWe reserve the right to make any changes due to technical modifications.28 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 7RISK TO LIFEby poisoning by leaking flue gas.• Connect the flue system to one boileronly.• Connection of another boiler maycause serious injury or death.• The flue pipes must not be routed intoanother vent. In addition, the pipes ofthe flue system must not be routedthrough another vent or inside anothervent, such as with an existing brick orfactory-manufactured chimney lining.WARNING!4 4123WARNING!FIRE DANGERdue to insufficient clearance between fluepipe and flammable building components.• Make sure that there is a minimumclearance of two (2) inches toflammable building components.• No minimum clearance is requiredbetween the wall penetration andflammable building components.Fig. 28 Horizontal flue system1 Wall penetration2 End piece of flue pipe (termination tee)3 Condensation trap4 Fastening the flue pipeThe vent pipe must be securely fastened. Verticalventing pipes must be fixed with a fire protection collarat every ceiling penetration and fixed with at least oneretainer at the base of vertical pipe.The flue system pipes must be fixed with retainer bandsalong their length in the vicinity of all elbows andconnections and at intervals of at least 48 inches.When installing fastening components do not drill holesinto any of the components of the flue system whenjoining pipes or fittings or when installing retainer bands.If pipe lengths are cut to size, the cut edges must be filedor ground smooth before joining them. The coupling endof the pipe must not be cut.Make sure that all horizontal venting pipes have a slopeof at least 1/4 inch per foot. All horizontal venting pipesmust have a downward slope to the boiler to prevent anyaccumulations of moisture in the flue system.The flue system is under overpressure. Silicone sealantmust be left to dry for 24 hours before putting the boilerinto operation.Fig. 29 Vertical flue system1 Roof penetration2 Fire protection collar3 Fastening the flue pipe4 Condensation drain12334WARNING!RISK TO LIFEby poisoning by leaking flue gas.• After carrying out one of the aboveinstallation instructions always checkthat all connections in the complete fluesystem are correctly joined and sealed.• Check the seams and joints for leaks.• Have the complete flue systemchecked by a technician once a year.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200529

7Boiler installation7.6.4 Adjusting the combustion air baffleNote the following when calculating the total fluepipe length or combustion air pipe length.– 1 x 90° elbow corresponds to 10 ft of pipe.– 2 x 45° elbows correspond to 10 ft of pipe.– If the combustion air pipe is longer than the flue pipe,the combustion air baffle is adjusted depending onthe total length of the combustion air pipe.USER NOTEIt is not necessary to consider thecondensation trap, the wall penetrationand the termination tee when calculatingthe total pipe length.Determining the combustion air baffle position• Unscrew cover of blower enclosure.• Calculate the extended length of the flue pipe or thecombustion air pipe by adding the individualsections.• Calculate the adjustment dimension X of thecombustion air baffle with the extended pipe length inTable 7-12.• Compare the setting of the combustion air baffle andcorrect if necessary.1 2Fig. 30 Adjusting the combustion air baffle1 Combustion air baffle2 Adjustment dimension XWe reserve the right to make any changes due to technical modifications.30 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 7Adjustment for horizontal flue system independentof room airCombustion air supply through combustion air pipe orflexible combustion air hose from outside.BoilersizeAdjustment dimension X of the combustionair baffle depending on the length (feet) of thehorizontal flue pipe/combustion air pipeupto 12feetupto 20feetupto 30cmupto 40feetup to max. feet30 5.0 4.5 3.5 0 0 (up to 42 feet)23 5.0 5.0 4.5 4.0 4.0 (up to50 feet)17 5.0 5.0 4.5 4.5 4.0 (up to50 feet)Tab. 7 Rigid combustion air pipe 3" as per Fig. 31.12BoilersizeAdjustment dimension X of the combustion airbaffle depending on the length (feet) of thehorizontal flue pipe/combustion air hose30 0 (up to 20 feet maximum)23 4.0 (up to 20 feet maximum)17 4.0 (up to 30 feet maximum)Fig. 31 Horizontal flue system independent of room air1 Flue pipe 3"2 Combustion air pipe 3" or combustion air hose 3"Tab. 8 Flexible combustion air hose 3" as per Fig. 317.6.5 Adjustment for horizontal flue system using room airCombustion air supply from the boiler room.BoilersizeAdjustment dimension X of the combustion airbaffle depending on the length (feet) of thehorizontal flue pipeupto 12feetupto 12feetupto 30feetupto 40feetup to max. feet30 5.5 5.0 5.0 5.0 5.0 (up to42 feet)23 5.5 5.5 5.0 5.0 5.0 (up to50 feet)17 5.5 5.5 5.0 5.0 5.0 (up to50 feet)21Tab. 9Horizontal flue system using room air as perFig. 32Fig. 32 Horizontal flue system using room air1 Flue pipe 3"2 Combustion air inlet from the roomWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200531

7Boiler installationAdjustment for vertical flue system independent ofroom airCombustion air supply through combustion air pipe orflexible combustion air hose from outside.BoilersizeAdjustment dimension X of the combustionair baffle depending on the length (feet) ofthe vertical flue pipe/combustion air pipeup to5 feetup to30 feetup to45 feetup tomax.50 feet30 4.5 3.5 0 -23 4.5 4.0 2.5 2.517 4.5 4.0 3.0 3.01Tab. 10 Rigid combustion air pipe 3" as per Fig. 33BoilersizeAdjustment dimension X of the combustionair baffle depending on the length (feet) ofthe vertical flue pipe/combustion air hose30 0 (up to 30 feet maximum)23 2.0 (up to 30 feet maximum)17 3.0 (up to 30 feet maximum)Fig. 33 Vertical flue system independent of room air1 Flue pipe 3"2 Combustion air pipe 3" or combustion air hose 3"2Tab. 11 Flexible combustion air hose 3" as per Fig. 337.7 Filling heating system and checking for leaksThe boiler is tested for leaks at the factory. Beforeplacing the heating system into use, check it forsoundness to avoid leaks occurring during operation.Water treatmentUSER NOTEHave the water analyzed before filling theheating system. The water may requiretreatment as a result of the analysis.Please consult the local water supplycompany if the water is extremely hard orhas a pH level below 7.0.Fig. 34 Temperature/pressure gaugeCAUTION!SYSTEM DAMAGEdue to overpressure during the leak test.Pressure, control or safety componentsmay be damaged by high pressure.• Before conducting the leak test makesure that no pressure, control or safetycomponents that cannot bedisconnected from the watercompartment of the boiler are installed.We reserve the right to make any changes due to technical modifications.32 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler installation 7Carry out the leak test at 1.5 times the normal operatingpressure and as specified by the local codes as follows:Maximumoperating pressure30 psi (with the included reliefvalve)58 psi (with a different reliefvalve)Tab. 12 Test pressuresMaximumconstruction site testpressure45 psi75 psi• Close connection for relief valve ( Fig. 10,page 16) and all other open connections with plugs.• Disconnect the expansion tank from the system byclosing the cap valve.• Open mixing and stop valves on hot water side.• Fill boiler slowly with water from the buildingconnection.• Turn cap of automatic vent one revolution to allow theair to escape.• Slowly fill heating system. Observe pressure displayon pressure gauge during this process.• Check connections and pipes for leaks.• Bleed heating system through the bleed valves onthe radiators.• If the pressure falls while bleeding, water must beadded.• Install relief valve ( Fig. 10, page 16).We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200533

8Openings for combustion air supply and venting8 Openings for combustion air supply and ventingCAUTION!BOILER DAMAGE AND OPERATINGFAULTSdue to missing or inadequate openings forcombustion air and venting of the boilerroom.The openings for combustion air supplyand venting are always requiredregardless of whether the combustion airis supplied from the room (operation fromroom air) or directly to the boiler throughducts (operation independent of room air).Inadequate venting of the boiler room mayresult in excessive ambient temperatures.This can damage the boiler.Inadequate combustion air supply maycause operating faults.• Make sure that inlets and outlets arenot reduced or closed and that they areadequately sized.• If faults are not corrected immediately,the boiler must not be operated.• Inform the system operator of the faultand the danger.WARNING!FIRE DANGERdue to flammable materials or liquids.• Do not store flammable materials orliquids in the immediate vicinity of theheat generator.Total air supply from inside the buildingMake sure that the boiler room has two permanentopenings that are connected with one or more otherrooms. When calculating the cross-section areas of theopenings, the total combustion output of all gas-firedappliances in the connected rooms must be taken intoaccount. Each opening must have a minimum crosssectionof one square inch per 1000 Btu/h of the totalcombustion output of all gas-fired appliances inside theconnected rooms. Note that the minimum cross-sectionof every opening must not be less than 100 squareinches. One opening must not be more than 12 inchesfrom the ceiling and the other must not be more than12 inches from the floor of the boiler room, calculatedfrom the outer edge of the opening. The shortestdimension of all inlet and outlet openings must not beless than three inches.To ensure an adequate combustion air supply andventing of the heating system suitable measures mustbe taken in accordance with the National Fuel GasCode, Section 5.3, Air for Combustion and Ventilation,or the local codes.In Canada the regulations in accordance with theCSA/CGA–B 149.1 or 2 Installation Codes apply.CAUTION!BOILER DAMAGEdue to contaminated combustion air.• Never use cleaning agents that containchlorine and halogenatedhydrocarbons (e.g. spray bottles,solvents and cleaning agents, paints,glues).• Do not store or use these substances inthe boiler room.• Prevent excessive dust levels.USER NOTEIf contamination of combustion air ispossible (e.g. installation near swimmingpools, dry cleaners or hair saloons),operation with air outside the room isrecommended.We reserve the right to make any changes due to technical modifications.34 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Openings for combustion air supply and venting 8Total air supply from outside the buildingMake sure that the boiler room has two permanentopenings, one of which must not be more than 12 inchesfrom the ceiling and the other must not be more than12 inches from the floor of the boiler room, calculatedfrom the outer edge of the opening. The openings havea direct connection or a connection through ventilationducts to the outside or to rooms that have anunobstructed connection to the outside (crawl space orattic). The shortest dimension of all inlet and outletopenings must not be less than three inches.1. If there is a direct connection to the outside, eachopening must have a minimum cross-section of onesquare inch per 4000 Btu/h of the total combustionoutput of all gas-fired appliances inside the closedroom.2. If there is a connection to the outside throughvertical ventilation ducts, each opening must have aminimum cross-section of one square inch per4000 Btu/h of the total combustion output of all gasfiredappliances inside the closed room.3. If there is a connection to the outside throughhorizontal ventilation ducts, each opening must havea minimum cross-section of one square inch per2000 Btu/h of the total combustion output of all gasfiredappliances inside the closed room.4. If the openings are connected to ventilation ducts,the ducts must have the same cross-section area asthe openings.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200535

9Placing the heating system in operation9 Placing the heating system in operationThe gas burner and gas fittings unit integrated in theboiler have been tested in the factory as described indetail in ANSI Z 21.13 and CGA 4.9 to ensure safeoperation of the heating system and to test specificperformance indicators.WARNING!RISK TO LIFEdue to electrical current when the unit isopen.• Before opening the unit:To prevent electrical shock, isolate theheating system with the heating systememergency stop switch or by shuttingoff the main fuse.• Lock the heating system to preventaccidental reactivation.1. Set the room thermostats to the lowest setting.2. Inspect flue and combustion air piping and theopenings for combustion air supply and ventilation.3. Fill heating system with water and bleed thecomplete system including the radiators.4. Unscrew left and right screws in the side panels, liftfront panel up, pull down and remove to the front.Fig. 35Removing front panel of boilerWe reserve the right to make any changes due to technical modifications.36 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Placing the heating system in operation 9Carrying out leak test5. Open gas valve in the gas line.6. Check the gas connection line to the gas fitting( Fig. 36) for leaks with soap solution. If no leaksare found, continue with step 8. If any leaks arefound, close gas valve.7. Seal leaks and repeat step 6.8. Close main gas shut-off. Remove the screw plug forthe gas pressure measuring port on the gas valve.Install pressure measuring nipple and attach apressure gauge to measure the gas pressure.29. Remove the screw plug for the orifice pressuremeasuring port on the gas valve. Install pressuremeasuring nipple and attach a pressure gauge tomeasure the manifold pressure.10. Open gas valve and measure the gas supplypressure of the boiler. The supply pressure must bebetween 4.7" and 10.5" W.C. for natural gas andbetween 11" and 13" W.C. for propane gas. If thesupply pressure for natural gas is not between 4.7"and 10.5" W.C. and not between 11" and 13" W.C.for propane gas, contact the customer servicetechnician or the gas company.11. Always follow the start-up instructions on the nextpage.143Fig. 36 Gas valve1 ON/OFF button (at ON position)2 Screw plug for gas supply measuring port3 Screw plug for manifold measuring port4 Pilot gas line connectionWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200537

9Placing the heating system in operation9.1 Start-up instructionsRead the instructions before start-up for yoursafety.WARNING!RISK TO LIFEdue to not observing the start-upinstructions and resulting incorrectoperation.• If these instructions are not followedexactly, a fire or explosion may becaused with serious property damageor loss of life or serious injury.• Observe the start-up instructions.WARNING!DANGER OF EXPLOSIONIf you smell gas there is a danger ofexplosion..• No open flame. No smoking.• Prevent spark formation.Do not operate electrical switches,including telephones, plugs or doorbells.• Shut off main gas supply valve.• Open doors and windows.• Warn other occupants of the building.• Evacuate the building.• Call gas company, heating servicecompany or fire department fromoutside the building.ABCDThis unit is fitted with an igniter that automatically starts theburner. Do not attempt to ignite it manually.Check for an odor of gas around the heating system. Thistest must also be conducted at floor level, because sometypes of gas are heavier than air and may accumulate atfloor level.Switch on the ON/OFF switch on the gas fitting by handonly. Never use a tool as assistance. If you cannot actuatethe ON/OFF switch on the gas fitting by hand, do notattempt to repair it. Contact a qualified technician. Anyattempt to use force or to repair the switch may cause a fireor explosion.Do not operate the unit if any part is under water. Contacta qualified customer service technician immediately tohave the unit checked and to replace the parts of thecontrol and gas fittings that were under water.We reserve the right to make any changes due to technical modifications.38 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Placing the heating system in operation 99.2 Making boiler ready for operationSTOP! First read the safety instructions on page 36of this manual.1. Carry out leak test ( page 7). Wait five (5) minutesuntil all gas residues have dissipated. Finally checkwhether there is any smell of gas, including at floorlevel. If there is a gas odor: STOP! Followinstructions in section "B" of the safety instructionson page 36 of this manual. If there is no sign of agas odor, continue with the next step.2. Open main gas valve.9.2.1 Placing heating system with aquastat control in operationThe boiler is fully functional with the factory-installedaquastat.3. Turn on ON/OFF switch (contractor installed) (ONposition). This turns on the boiler with all itscomponents. Then continue with step 7.4. Make sure that the room thermostat signals a heatrequirement (set thermostat at least 10 °F aboveroom temperature).1Fig. 37 Switching on heating system (with aquastat)1 ON/OFF switch (main switch)We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200539

9Placing the heating system in operation9.2.2 Placing heating system with Logamatic 2107 (accessory) in operationThe boiler is fully functional with the factory-installedaquastat. The Logamatic 2107 control can also beinstalled in addition to the factory-installed aquastat.Turn on the heating system with the ON/OFF switch onthe control. The burner starts operating if heat isrequired ( observe control service manual).5. Make sure that heat is required at the control. Select"Manual operation" (hand symbol) with the modeselector switch.6. Turn on ON/OFF switch ("I" position). Then continuewith step 7.USER NOTEAfter carrying out the instructions forstarting described below, the control mustbe set to "AUT" mode (automaticoperation) with the mode selector.12Fig. 38 Turning on heating system (with Logamatic 2107control)1 Mode selection switch2 ON/OFF switch9.3 Then carry out start-up procedures.The following start-up procedures must be carried outregardless of the control type.7. Look at the igniter through the sight glass in theburner housing.1Fig. 39 Front view1 Sight glassWe reserve the right to make any changes due to technical modifications.40 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Placing the heating system in operation 98. Turn gas valve ON/OFF switch counterclockwise toON position.9. The automatic igniter must generate sparks towardsthe pilot burner. The pilot flame must appear andthen ignite the main burner. If the main burner doesnot ignite, close the gas valve. Disconnect heatingsystem from the power supply and inform yourcustomer service technician or LP gas company.10. If the main burner has ignited, the gas valve must bechecked for leaks with soap solution. If no leaks arefound, continue with step 12. If leaks have beenfound, switch ON/OFF switch on gas valveclockwise to the OFF position. Disconnect heatingsystem from the power supply and set thethermostat to the lowest setting.11. Seal leaks. Repeat steps 1 and 2 (regardless of thecontrol in use).Caution:With aquastat control continue with steps 3 and 4,with the Logamatic 2107 continue with steps 5and 6.Then repeat steps 7 to 10 regardless of the controlin use.12. Check the supply gas pressure while the boiler isoperating. The supply pressure must be between4.7" and 10.5" W.C. for natural gas and between11" and 13" W.C. for propane gas. Record themeasured values in the commissioning protocol inthe installation and maintenance instructions.GA124Natural gas Propane[inch W.C.] [inch W.C.]17 3.6 8.923 3.6 9.930 3.5 9.5Tab. 13 Manifold pressure154Fig. 40 Gas valve1 ON/OFF button (at ON position)2 Screw plug for gas supply pressure measuring port3 Safety screw for manifold pressure setting4 Screw plug for manifold measuring port5 Safety screw for pilot ignition pressure setting2313. Check manifold pressure. The manifold pressuremust be set in accordance with the values in Tab. 13. To set the manifold pressure the cover( Fig. 40) on the gas valve must be removed. Turnthe adjustment screw clockwise to increase thepressure and counterclockwise to reduce thepressure. This setting must be adjusted while theboiler is operating.14. Record the set value in the commissioning protocolof the installation and maintenance instructions andscrew the safety screw ( Fig. 40, page 41) into thegas valve again.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200541

9Placing the heating system in operation15. Observe ignition flame through the sight glass( Fig. 39, page 40) in the burner housing.16. The flame must envelope the flame guard 1/2 to1 1/2 inches. If this is the case continue with step 20.17. If the ignition flame is too small or too large, thepressure for the pilot burner must be adjusted withthe corresponding adjustment screw.1USER NOTEThe adjustment screw is behind theignition gas pressure adjustment safetyscrew ( Fig. 40, page 41).218. Remove safety screw for pilot ignition pressuresetting ( Fig. 40, page 41). Turn the inneradjustment screw clockwise to reduce the ignitionflame and counterclockwise to enlarge the ignitionflame.19. After adjustment tighten the ignition gas pressureadjustment safety screw ( Fig. 40, page 41) again.20. Observe main burner flame through the sight glass( Fig. 39, page 40) in the burner housing. Theflame must have a steady and fixed contour andgenerally has a bluish color. If the main burner flamemeets the requirements, proceed with step 21. If themain burner flame is too weak or is yellow or goesout, turn the ON/OFF switch ( Fig. 40, page 41) onthe gas valve clockwise to OFF. Close the gas valveand disconnect the heating system from the powersupply and contact the customer service technicianor the gas company.Checking flame sensor21. Test the safety switch by closing the gas valve. Themain burner flame ( Fig. 42) and the ignition flame( Fig. 41) are extinguished. After six (6) secondsat the most the main gas solenoid valve on the gasvalve must close with an audible noise.22. After 90 seconds the automatic igniter must switchto lock status and stop generating sparks.23. Disconnect the heating system from the powersupply. Open main gas valve. Switch on unit powersupply. A normal operating cycle must follow.24. If the gas valve operates correctly, proceed to step25. If the gas valve does not operate correctly,switch ON/OFF switch ( Fig. 43) on the gas valveclockwise to the OFF position immediately. Closemain gas valve. Disconnect heating system from thepower supply and inform the customer servicetechnician or LP gas company.Fig. 41 Correct pilot flame setting1 1/2 to 1 1/2 inches2 Pilot flame1Fig. 42 Main burner1 Main burner flameWe reserve the right to make any changes due to technical modifications.42 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Placing the heating system in operation 925. Turn gas valve ON/OFF button clockwise to OFFposition.26. Close main gas shut-off.27. Disconnect heating system from the power supplyand set the thermostat to the lowest setting.28. Remove pressure measuring nipple and pressuregauge for measuring gas supply pressure andmanifold pressure from the gas valve and close theopenings with the screw plugs.29. Repeat steps 1 to 10 (depending on the control) and20 to restart the heating system. Check the screwplugs for leaks with soap solution. If no leaks arefound, continue with step 31. If leaks are found,close gas shut-off and switch ON/OFF button on gasvalve clockwise to the OFF position. Disconnect theheating system from the power supply.30. Seal leaks. Open gas shut-off and repeat step 24.31. Carefully wipe away the soap solution to preventcorrosion caused by the alkali content of the soap.32. Check the function of the maximum aquastat tomake sure that it switches off the boiler as soon asthe boiler water temperature set at the aquastat orthe Logamatic 2107 control is reached. Record theresult in the commissioning protocol of theinstallation and maintenance instructions.33. Replace front panel of boiler.1Fig. 43 Gas valve1 ON/OFF button (at ON position)With the Logamatic 2107 control only34. Select AUT (automatic mode) with the modeselection switch.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200543

9Placing the heating system in operation9.4 Shutting off gas supply to boiler1. Set thermostat to the lowest value.2. Disconnect heating system from the power supplybefore carrying out maintenance work.3. Remove front panel of boiler4. Turn gas valve ON/OFF button clockwise to OFFposition. Do not use force.5. Replace front panel of boiler.Fig. 44Remove front panel of boiler1Fig. 45 Gas valve1 ON/OFF button (at ON position)We reserve the right to make any changes due to technical modifications.44 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Placing the heating system in operation 99.5 Instruct owner/operator and hand over technical documentationInform the owner/operator of the operation of thecomplete heating system and the operating instructionsfor the boiler. Together with the owner sign the protocolon page 46 and hand over the technical documentation.CAUTION!SYSTEM DAMAGEdue to frost.The heating system may freeze in frostyconditions if the control is not switched on.• Protect the heating system fromfreezing when there is a danger of frost.• When the main switch or control isswitched off, drain the water from theboiler, the tank and the pipes of theheating system.Änderungen aufgrund technischer Verbesserungen vorbehalten!Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.deInstallation and maintenance instructions Logano GA124 special gas-fired boiler • Ausgabe 04/200545

9Placing the heating system in operation9.6 Start-up protocolPlease check off the start-up work as it is completed andrecord the measured values in the table.Start-up workRemarks or measured values1. Type of gas Natural gas Propane2. Check combustion air, inlet and outlet openings andflue gas connection3. Check the unit fittings (correct orifices?, Tab. 14below) and convert gas type if necessary4. Fill boiler with water and bleed complete heating system5. Measure gas pressure (supply pressure) ––––––––––––––––––– inches W. C.6. Measure manifold pressure and adjust if necessary ––––––––––––––––––– inches W. C.7. Leak check in operating status, check pilot and main burner flame andcorrect functioning of the venting system8. Check maximum aquastat9. Install front boiler panel10. Inform operator, hand over technical documentation11. InstallerOperator:Signature:__________________Signature:__________________Main gas orifice identificationBoiler size 17 23 30Natural gas 265 250 250Propane gas 175 160 160Tab. 14 Main gas orifice identificationUSER NOTE• Inform the customer of the correct fueland enter it in the table ( operatingmanual of boiler).We reserve the right to make any changes due to technical modifications.46 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Taking the boiler out of operation 1010 Taking the boiler out of operation10.1 Normal boiler shut-down1. With the aquastats:Switch off main switch ("OFF" position). This shutsdown the boiler with all components (e.g. burner).2. Additional shut-down procedure follow thedirections for the aquastats.13. Logamatic 2107 control (accessory):Switch off ON/OFF switch on control ("0" position).This shuts down the boiler with all components(e.g. burner).Fig. 46 Shutting down heating system (with aquastat)1 ON/OFF switch1I 04. Shut off main fuel supply valve.CAUTION!SYSTEM DAMAGEthrough frost.The heating system can freeze up in coldweather if it is shut down.• Leave the heating system switched ONconstantly as much as possible.• Protect the heating system from freezingby draining the heater and water pipesat the lowest point.Fig. 47 Shutting down heating system (with Logamatic 2107control)1 ON/OFF switch10.2 Emergency shut-downInform your customer of the procedure in case ofemergency, such as a fire.1. Never put yourself at risk. Your own safety mustalways take priority.2. Shut off main fuel supply valve.3. Shut down the heating system with the heateremergency switch or the corresponding circuitbreaker.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200547

11Boiler inspection and maintenance11 Boiler inspection and maintenance11.1 Why is regular maintenance important?Heating systems require regular maintenance for thefollowing reasons:– To maintain high efficiency operation and to operatethe heating system economically (low fuelconsumption).– To sustain safe operation.– To maintain combustion at an environmentallyfriendly level.All maintenance work must be carried out by a qualifiedcustomer service technician only. When replacingcomponents use only parts approved by Buderus.Maintenance is required once a year. Record the resultsof the inspection in the protocol at page 59.USER NOTESpare parts can be ordered from yourlocal distributor.11.2 Testing the flue system, including combustion air, air inlets and Ventilation openingsCheck the venting system, including the combustion air,inlet and outlet openings. All faults must be repairedimmediately.Make sure that the combustion air feed and the inletsand outlets are not blocked at any point.11.3 Inspection of the boiler and burner1. Visually check the boiler and burner for external dirt.2. Check burner box, supply air hose and burner rodsfor dirt.3. Check air supply hose for damage and replace ifnecessary.4. If dirt is found, clean boiler and burner.We reserve the right to make any changes due to technical modifications.48 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler inspection and maintenance 1111.4 Preparing boiler for cleaning1. Take the boiler out of operation ( Chapter 10.1,page 47).WARNING!RISK TO LIFEfrom electric shock.• Before opening a unit: disconnectelectrical power completely and lock toprevent accidental reconnection.2. Remove front panel of boiler ( Fig. 35, page 36).WARNING!RISK TO LIFEfrom explosion of flammable gases.• Never work on gas lines unless you arelicensed for this type of work..3. Turn gas valve ON/OFF button clockwise to OFFposition. Do not use force.WARNING!RISK TO LIFEfrom explosion of flammable gases.• Wait five (5) minutes until all gasresidues have dissipated. Checkwhether there is any smell of gas,including at floor level. If there is a gasodor: STOP! Follow instructions insection "B" of the safety instructions on page 38 If there is no sign of a gasodor, continue with the next step.1Fig. 48 Gas valve1 ON/OFF button (at ON position)We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200549

11Boiler inspection and maintenance11.5 Cleaning the boilerThe boiler can be cleaned with brushes and/or by wetcleaning. Cleaning tools are available as accessories.11.5.1 Cleaning the boiler with brushesRemove burner:WARNING!RISK TO LIFEfrom electric shock.• Label all electrical wiring beforedisconnecting it for cleaning the boiler.If cables are connected incorrectly thesystem may not operate correctly withpossibly dangerous consequences.• After maintenance test the heatingsystem for proper function.WARNING!RISK TO LIFEfrom electric shock.• Before opening a unit: disconnectelectrical power completely and lock toprevent accidental reconnection.1. Disconnect your heating system from the mainselectricity supply.2. Shut off main gas supply valve.We reserve the right to make any changes due to technical modifications.50 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler inspection and maintenance 113. Disconnect pilot gas line from gas valve.4. Disconnect ignition cable from ignition module.5. Attach gas supply line to burner control holder withwire or string.6. Remove screws ( Fig. 50) between gas valve andburner box. Place the gas connection pipe gasket ina safe place.7. Label connection lines of flame roll-out switch anddisconnect from the switch.65104321789Fig. 49 Front view1 Flame roll-out switch (boiler size 17)2 Gas supply pipe3 Gas valve4 Ignition cable5 Ignition module6 Wire holder for gas supply line7 Burner control8 Ignition gas line9 Air supply hose10 Gas supply line8. Remove screws in burner box cover and removecover.9. Unscrew nuts and remove gas burner with burnerbox.10. Release air supply hose ( Fig. 49) and pull offburner box.21311. If there is dirt in the burner compartment, removeventing fan, otherwise continue with( Chapter 11.6, page 54).41Fig. 50 Removing gas burner1 Fixing nuts2 Screws3 Flame roll-out switch (boiler size 23 and 30)4 Burner box coverWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200551

11Boiler inspection and maintenanceRemoving venting fan12. Remove rear boiler jacket.13. Slide fan manifold into the venting adapter in thedirection of the arrow to the stop.14. Pull off connecting hose for differential pressureconnection on measuring points on fan.15. Disconnect electrical wiring.16. Unscrew the four screws of the fan retainer panel.17. Lift fan with retainer panel slightly and remove.18. Check fan blades for dirt and clean if necessary.19. If the hot gas ducts are dirty clean boiler.Fig. 512Removing rear boiler jacket320. Cover control with foil to prevent entry of metal dustinto the control.21. Use boiler brush to clean out flue gas passages.22. Clean combustion chamber and bottom insulation.1Fig. 52 Removing venting fan1 Pressure measurement point on fan2 Fan manifold3 Fan retainer panel11.5.2 Wet cleaning (chemical cleaning)For the wet cleaning use a suitable cleaning agent forthe degree of build-up of dirt (soot or scale).Use the same procedure as described for cleaning withbrushes ( Chapter 11.5.1, page 50).USER NOTEObserve the directions for use of thecleaning agent. In some case you mayneed use a different procedure from thatdescribed here.Fig. 53Cleaning with brushesWe reserve the right to make any changes due to technical modifications.52 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler inspection and maintenance 1123. Cover control with foil to prevent entry of spray intothe control.24. Ventilate boiler room well.25. Place cloths on the floor insulation to catch excessspray.26. Spray flue gas vents evenly with the cleaning agent.27. Assemble and install the burner in reverse order ofremoval and disassembly ( page 50). Tighten thefixing nuts well. Make sure that the front edge of theburner box cover is properly engaged in the sealinggrommets.28. Install venting fan in reverse order of removal; see page 52.29. The blue connector sleeves on the differentialmeasuring case must be connected to the blueconnecting sleeves of the measuring points.30. Make sure that the fan manifold is completelypushed on to the fan during reassembly.31. Place the heating system in operation.32. Heat the boiler water to a temperature of at least50 °F.33. Take the boiler out of operation.34. Allow boiler to cool.35. Remove burner and venting fan ( page 50).36. Brush out flue gas passages.37. Clean combustion chamber and bottom insulation.38. Remove cloths.39. Ventilate boiler room well again.40. Assemble and install the burner in reverse order ofremoval and disassembly ( page 50). Tighten thefixing nuts well. Make sure that the front edge of theburner box cover is properly engaged in the sealinggrommets.41. Install venting fan in reverse order of removal; see page 52.42. The blue connector sleeves on the differentialmeasuring case must be connected to the blueconnecting sleeves of the measuring points.43. Make sure that the fan manifold is completelypushed on to the fan during reassembly.Fig. 54Spray cleaningWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200553

11Boiler inspection and maintenance11.6 Cleaning the burner1. Remove burner ( page 50).2. Check burner rods for dirt. If necessary, cleanburner as described below.3. Unscrew pilot burner unit from burner.4. Disconnect pilot gas line from ignition burner unit.5. Remove pilot gas orifice and blow out.6. Immerse burner rods in water with cleaning agentand brush off.1 23USER NOTEMake sure that the insulation on the burnershield does not get wet.7. Rinse out burner rods with a water jet; hold burner sowater enters all slots if the burner rods and drainsout again.8. Remove remaining water by swinging the burner.9. Check that the slots of the burner rods are free.Remove water and dirt residue in the slots. If anyslots are damaged the burner must be replaced.10. Assemble and install the burner in reverse order ofremoval and disassembly ( page 50). Tighten thefixing nuts well. Make sure that the front edge of theburner box cover is properly engaged in the sealinggrommets.11. Place boiler in operation as directed in( Chapter 9, page 36).12. Check operation of aquastat.13. Test low water cut-off if installed.14. Check area around boiler for hazards.The area around the boiler must be free fromflammable substances, gasoline or any otherflammable or corrosive vapors and liquids.Fig. 55 Pilot burner unit1 Pilot burner unit2 Pilot gas orifice3 Pilot gas lineWARNING!RISK TO LIFEfrom explosion of flammable gases.After maintenance work leaks may occur inpipes and threaded fastenings.• Make a thorough check for leaks.• Use only approved leak testing agentsto search for leaks.Complete the maintenance protocol to confirm that allmaintenace work has been conducted. Sign themaintenance protocol and discuss it with the owner ofthe heating system.We reserve the right to make any changes due to technical modifications.54 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler inspection and maintenance 1111.7 TroubleshootingEquipment required: Wiring diagram page 81 andvoltage detectors for 120 VAC and 24 VAC.StartClose main gas valve.Switch on power.LED on aquastat oncontinuously.No• 120 V input voltage at N and L at connector X1?If not: check power supply.• 120 V input voltage at L1/L2 and L1X/L2X on aquastat?If not: check wiring.If the wiring is OK: replace aquastat.• 24 V voltage at plugs C and R on aquastat?If not: check wiring.If the wiring is OK: replace transformer.Adjust thermostat to heatrequirement (10 °F above roomtemperature).Adjust temperature control onaquastat to heat requirement(min. 10 °F above boilertemperature).Fan starts?No• Bridge thermostat contacts R and W.If the boiler starts, check thermostat and thermostat wiring.• Check LED on aquastat.It flashes twice: check sensor contacts S2/S1 and sensor wiring.If OK: replace sensor.It flashes three or four times: internal fault, replace aquastat.LED off: Aquastat in reset code, wait 5 minutes for automatic reset.• 24 V voltage at plugs B2/B1 on aquastat.If not: replace aquastat.• Check 24 V voltage at terminals 1 and 4 of the terminal on boiler block.If not: check wiring between aquastat (plug B2 and B1) and terminal onboiler block.If there is voltage at terminals 1 and 4, check 120 V voltage at terminalsL3 and N on plug X3 for the fan.If not: check wiring between relay and terminal on boiler block and relayand plug X1 (input voltage).If the wiring is OK: replace relay.If there is voltage at L3 and N on plug X3, check wiring to fan motor.If OK: replace fan.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200555

11Boiler inspection and maintenanceIgnition sparks visible betweenignition electrode and flameguide.NoCheck S 8600 H automatic igniter.• Check 24 V voltage at terminals 3 and 4 (power supply to S 8600 Hautomatic igniter) of the terminal on boiler block.If not:• Check wiring between terminal on boiler block and S 8600 H automaticigniter.• Check ignition wiring, ceramic insulator of ignition electrode and ignitiongap, adjust if necessary.• Check the ignition cable contact for signs of scorching or kinking.• If OK: replace S 8600 H.Check flame guard.• 24 V voltage at terminals 2 and 3 of the terminal on boiler block?If not: check wiring between flame guard and terminal on boiler block.If OK: replace flame guard.Check air pressure switch.• Check 24 V voltage at terminals 1 and 2 of the terminal on boiler block.If not:• check wiring between air pressure switch and terminal on boiler block.• Check correct adjustment of baffle in fan enclosure (see page 30).• Check venting and combustion air line for correct cross-section.• Check combustion air hose between fan housing and burner for correctcross-section.• Check heat exchanger for blockages.• If the length of the venting pipe or the combustion air pipe exceeds themaximum approved length as specified in Tab. 10 to Tab. 11 onpage32?If OK: replace air pressure switch.Open main gas valve.Ignition burner ignites.NoCheck gas fitting and S 8600 H automatic igniter.• Check that all manually operated baffles are open; check that gasconnections and pressures are correct and that ignition gas nozzles are notblocked.• Check electrical connections between automatic ignition and ignition timeron the gas fitting.• Use MV-MV/PV terminals to check 24 V alternating current at theautomatic ignition. If the voltage is correct replace gas fitting, otherwisereplace automatic ignition.We reserve the right to make any changes due to technical modifications.56 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler inspection and maintenance 11Ignition spark stops as soon asignition flame burns.NoCheck S 8600 H automatic igniter.• Check ignition wiring and ground for continuity.• Check ignition electrode.• Check electrical connections between ignition electrode and automaticignition.• Check whether the ceramic insulator in the ignition electrode is broken.• Check that the ignition flame surrounds the electrode and burns steadilywith a bluish flame.Adjust ignition flame.• If this does not correct the fault, replace the automatic ignition unit.Ignite main burner.NoCheck gas fitting and S 8600 H automatic igniter.• Use MV-MV/PV terminals to check 24 V alternating current and closedcircuit at automatic igniter. If there is no voltage, replace automatic ignition.• Check electrical connections between automatic ignition and ignition timeron the gas fitting.If OK replace gas fitting.System operates until the heatrequirement ends.NoCheck S 8600 H automatic igniter.• Check ignition wiring and ground for continuity. Note: If the ground isweak or faulty, the system may switch off at random evenif the heating system operates properly when tested.• Check that the ignition flame surrounds the electrode and burns steadilywith a bluish flame.• If everything is OK replace automatic ignition.Heat requirement ends,system switches off.NoCheck gas fitting and S 8600 H automatic igniter.• Check operation of thermostat (control).• Disconnect MV wire on automatic igniter.• If the valve closes, check temperature regulator and wiring again, replaceautomatic igniter.• If the valve does not close, replace gas fitting.End of troubleshootingRepeat procedure until heating system operates correctly.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200557

11Boiler inspection and maintenanceSTARTRoom thermostat (control) signals heat requirementFan starts.PHASE 1Ignition attemptIgnition spark generator operates• ignition gas valve opens.Ignition flame burns, S 8600 Hsignals steady ignition flameIgnition burner operationorignition flame does not burn, S8600 H starts ignition attempt,switches off after 90 seconds.PHASE 2Main burneroperatingWith steady ignition flame• ignition spark generator stops.• main gas solenoid valve opens.Main burner operation• S 8600 H monitors ignition flame.Specified thermostat value (control) reachedMain and ignition gas valves close, gas burners goout. Venting fan stops.Power interruptionsystem switches off. Doessystem switch on againwhen power is restored?Ignition flame faultMain gas valve closes,S 8600 H starts ignitionattempt.ENDWe reserve the right to make any changes due to technical modifications.58 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Boiler inspection and maintenance 1111.8 Maintenance protocolPlease check off the maintenance work as it is completed and record the measured values.Follow the instructions on the following pages.Maintenance work Page Date: Date:1. Inspection of the flue system includingcombustion air, inlet and outlet openingspage 482. Inspection of boiler page 483. Inspection of burner page 484. Cleaning boiler page 505. Cleaning burner page 546. Measuring gas supply pressure page 37 –––––––inches W. C. –––––––inches W. C.7 Measuring manifold pressure page 41 –––––––inches W. C. –––––––inches W. C.8. Checking for leaks in operating condition page 379. Checking pilot and main burner flame page 4210: Check operation of venting fan.11. Check maximum aquastat page 5412. Check the area around the boiler for flammablematerials, gasoline or other corrosive liquids.page 5413. Confirm maintenanceConfirmation of correct maintenance(company stamp, signature)We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200559

11Boiler inspection and maintenanceDatum: Datum: Datum: Datum: Datum:–––––––inches W. C –––––––inches W. C –––––––inches W. C –––––––inches W. C –––––––inches W. C–––––––inches W. C –––––––inches W. C –––––––inches W. C –––––––inches W. C –––––––inches W. CWe reserve the right to make any changes due to technical modifications.60 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 1212 Parts listsThe following spare parts are available for Buderusheating systems. If there are more than one Buderusarticle numbers at one item number, these numbers arelisted in the columns corresponding to the variousmodels. In other cases the number of components isshown.Boiler block ( Fig. 56)Itemno.DescriptionBuderusarticle numberModel 17Quantity/modelModel 23Quantity/modelModel 30Quantity/model10 Boiler block complete 6301- 1252 1253 125420 Threaded stud M8x30 5.6 3719 064 4 4 430 Hex nut M8 with locking teeth 5834 410 4 4 440 Immersion well R¾"x100 compl. 5446 065 1 1 150 Gasket D41.7x55x1.5 AFM 34 86159 710 2 2 260 Plug G1¼" left 6073 304 2 2 270 Floor panel 6301- 6439 6438 643780 Shield rear 6301- 6436 6435 643490 Snap nut 4.8100 Washer A8.4110 Sheet metal screw 4.8x22see Mountingmaterial forboiler blocksee Mountingmaterial forboiler blocksee Mountingmaterial forboiler block2 2 22 2 22 2 2120 Gasket kit PK-W11 310 ml cartridge 2037 038 - - -Mounting material for boiler block 63011750 - - -Tab. 15 Boiler blockAt item no. 10: Only complete boiler blocks are replaced, not individual parts.At item no. 50: Between end part and supply connection or return connection or plug.At item no. 120: For sealing between floor panel, shield and boiler block.We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200561

12Parts lists1060506050401001109080201203070Fig. 56Boiler blockWe reserve the right to make any changes due to technical modifications.62 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 12Boiler jacket ( Fig. 57)Itemno.DescriptionBuderusarticle numberModel 17Quantity/modelModel 23Quantity/model5 Logano GA124 nameplate 63013607 1 1 110 GA124 front panel 63016428 1 1 1Model 30Quantity/model15 Stop boltMountingmaterial for 4 4 4boiler jacket17 Stop socketMountingmaterial for 4 4 4boiler jacket20 Plug-in fuseMountingmaterial for 2 2 2boiler jacket22 Sheet metal screw ST3.9x13 A3TMountingmaterial for 2 2 2boiler jacket30 Side panel left/right GA124 63016425 2 2 235 Panhead screw ST3.9x9.5Mountingmaterial for 12 12 12boiler jacket40 Hood front GA124 63016426 1 1 145 Cover – hood front 63016429 1 1 150 Hood rear GA124 63016427 1 1 160 Holder 9105 285 1 1 170 Angle 3x30/20x463 complete 63012813 1 1 180 Rear panel GA124 63029221 1 1 190 Hex head nut M8 5834 410 2 2 2100 Hex head nut M10 5834 422 2 2 2110 Boiler block insulation 6301- 1721 1722 1723120 Clip - insulation 476378 5 5 5Mounting material for boiler jacket 63013095 - - -Tab. 16 Boiler jacketWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200563

12Parts lists4550401201580903060701001101753515172035221030Fig. 57Boiler jacketWe reserve the right to make any changes due to technical modifications.64 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 12Boiler block – attachment parts ( Fig. 58)Itemno.DescriptionBuderusarticle numberModel 17Quantity/modelModel 23Quantity/modelModel 30Quantity/model10 Boiler rail front 9038 156 1 1 115 Boiler rail rear 63015479 1 1 150 Hex screw M8x12see Mountingmaterial Boilerblock4 4 460 Foot M10x51 5871596 4 4 470 Spacer DN 8x8 5176 794 4 4 480 Distance pin M8x63.5 475485 2 2 2110 Snap nut 4.8see Mountingmaterial Boiler 4 4 4block120 Sheet metal screw ST4.8x22see Mountingmaterial Boiler 4 4 4block130 Venting fan housing 6301- 6446 6445 6444135 Fan base plate 6301- 6449 6448 6447140 Adjustment baffle 63016443 1 1 1141 Hex screw M6x12see Mountingmaterial Boiler 1 1 1block142 Washer Ø 6.4see Mountingmaterial Boiler 1 1 1block143 Serrated lock washer Ø 6.4see Mountingmaterial Boiler 1 1 1block144 Hex nut M6see Mountingmaterial Boilerblock1 1 1150 Cover - venting fan housing 6301- 6442 6441 6440151 Hose set DN 4x2x880 silicone 63016451 1 1 1152 Pressure monitor 6301- 6020 6019 6019153 Fan connection wiring 63016491 1 1 1160 Panhead screw ST3.9x9.5see Mountingmaterial Boiler 22 24 24block180 Hose DN 80x1050 63014249 1 1 1185 Hose clip 70–90 195069 4 4 4210 Venting fan pressure reducer 63011683 1 1 1215 Venting fan RLH 108 63016433 1 1 1231 Annular baffle D58x37 6301- 1799 6893 -232 Gasket set 58.5x66x7.5 63016582 1 1 1233 Connector Ø 77/75x48 63016450 1 1 1240 Flue pipe D60x73 with gasket 63011684 1 1 1We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200565

12Parts listsBoiler block – attachment parts ( Fig. 58)ItemDescriptionno.260 Sealing ring D41.7x55x1.5 AFM 34 86159710 2 2 2270 Supply elbow R1xNPT1 L = 357 5407 352 1 1 1280 Return elbow R1xNPT1 L = 92 5407 350 1 1 1290 B-kit G/GA 124 US/CAContents:Buderusarticle numberModel 17Quantity/modelModel 23Quantity/modelModel 30Quantity/model1 supply manifold G/GA1241 elbow 11 elbow 3/4 I/A1 boiler drain 3/41 relief valve 3/4Mx3/4F 30PSI1 temperature/pressure gauge 1/4 NPT4 feet M10x5163037069 1 1 1Mounting material for boilerContents:4 snap nuts 4.8 SNU22124 sheet metal screws DIN7981 C ST4.8x221 hex screw ISO4017 M6x12 8.81 washer DIN125 A6.41 hex nut ISO4032 M6 81 lock washer DIN6797 A6,424 panhead screws ST3.9x9.52 lock washers DIN 6797 A5.31 cable clip 2.5x92 - Ty - 23M63016501 - - -Tab. 17 Boiler blockWe reserve the right to make any changes due to technical modifications.66 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 12150160215232233185160(232)135240141142231160210 185180185153140151130 12014314427026029015211015180290290110505070706060155060506010260280Fig. 58Boiler block – attachment partsWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200567

12Parts listsSwitch box ( Fig. 59)Itemno.DescriptionBuderusarticle numberModel 17Quantity/modelModel 23Quantity/modelModel 30Quantity/model10 Switch box GAW 027 00 "US" 63015739 1 1 120 Terminal bar 4 mm2 4-pinsee Mounting materialGAW 027 US1 1 130 Sheet metal screw F ST3.5x16 A3Ksee Mounting materialGAW 027 US5 5 540 Relay 24V AC 1xS 120V AC/15A 63015750 1 1 150 Sheet metal screw F ST3.5x6.5 A3Ksee Mounting materialGAW 027 US10 10 1060 Holder GA124 (mounting plate) - 1 1 170 Aquastat relay L7148F 63015742 1 1 180 Sheet metal screw C ST3.5x22 A3Ksee Mounting materialGAW 027 US5 5 590 Burner unit cover plate "US" compl. 63015747 1 1 1100 Lock washer A4.3 A3Ksee Mounting materialGAW 027 US5 5 5110 Hose line AWG 2x18 063/076 63015745 1 1 1120 Wiring harness GAW 022/024/026/027 63015746 1 1 1130 Temperature sensor 209659B 63015749 1 1 1140 Blank for 1/4 annular sensor 7060 110 1 1 1150 Compensator spring 5446 800 1 1 1160 Sensor holder 7060 986 1 1 1170 Transformer 120V/24V "US" compl. 63015748 1 1 1180 Automatic igniter S 8600H1006 63015743 1 1 1190 Panhead screw ST3.9x9.5 A3Esee Mounting materialGAW 027 US5 5 5200 Connection line 63015744 1 1 1210 Sheet metal screw C ST2.9x16 A3Ksee Mounting materialGAW 027 US5 5 5220 Plug 3-pin black 93.923.4354 5493 464 1 1 1230 Socket 3-pin black 93.031.3253.0 7060 911 1 1 1240 Plug 3-pin green/black 5493 465 1 1 1250 Socket 3-pin green 7060 912 1 1 1260 Sheet metal screw C ST2.9x22 A3Ksee Mounting materialGAW 027 US4 4 4270 Socket 5-pin black 7060 913 1 1 1280 Sheet metal screw F ST3.5x9.5 A3Ksee Mounting materialGAW 027 US2 2 2Mounting material for GAW027 US63015810- - -Tab. 18 Switch boxWe reserve the right to make any changes due to technical modifications.68 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 12Fig. 59Switch boxWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200569

12Parts listsHousing for burner ( Fig. 60)ItemDescriptionno.Tab. 19 Housing for burnerBuderusarticle numberModel 17Quantity/modelModel 23Quantity/model10 Flame guard 128 °C compl. (with screws) 63015665 1 1 120 Screw C M4x16 ST A3K30Housing cover CE124 compl. "US" with gasket,view glass and screwsSee burnermounting setModel 30Quantity/model1 1 16301- 5561 5562 556340 Panhead screw ST3.9x9.5 A3T 5947 754 14 16 1650 Housing cover gasket60View glass compl. with retainer, gasket andscrewsSee housinggasket set1 1 17100 256 1 1 170 Bush diameter 44 mm slit 63011272 1 1 180Housing frame CE124 compl. "US" with gasketand screws6301- 5564 5565 556690 Housing frame gasketSee housinggasket set1 1 1100 Gasket 125x20x2 mmSee housinggasket set2 2 2110 Housing cover bottom - 1 1 1120Screw CE M5x12 CombiTorxSet with 15 pieces63010217 - - -130 See housing gasket set 6301- 0821 0845 0846140 Glue Elastosil E 41 in 90 ml tube 63011270 1 1 1We reserve the right to make any changes due to technical modifications.70 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 12Fig. 60Housing for burnerWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200571

12Parts listsGas fitting group VR 8204 H ( Fig. 61)ItemDescriptionno.Tab. 20 Fitting group VR 8204 HBuderusarticle numberModel 17Quantity/modelModel 23Quantity/model10Pipe section compl. 151 lg AE124X/CE124X"US" for 3 and 4 sections5176 736 1 1 –10Pipe section compl. 241 lg AE124X/CE124X"US" for 5 sections5176 737 – – 120 Screw 8x32x1¼See burnermounting set2 2 230 Screw 8x32x½See burnermounting set6 6 640 Fittings VR8204H 1006 ½" NPT compl. "US" 63015667 1 1 150 O-ring D22.22x2.62 5483 082 1 1 160Pipe unit with flange G1 44 mm compl. with O-ring, screws and gasketModel 30Quantity/model63015557 1 1 170 Gasket D21x30x3 5959 282 1 1 1We reserve the right to make any changes due to technical modifications.72 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 12Fig. 61Fitting group VR 8204 HWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200573

12Parts listsIgnition burner ( Fig. 62)ItemDescriptionno.10Ignition burner Q3451 E compl. "US"(with screws, ignition burner holder, ignitiongas nozzle EG and ignition cable)20 Screws 8x32x3/1630 Ignition burner holderTab. 21 Ignition burnerBuderusarticle numberModel 17Quantity/modelModel 23Quantity/modelModel 30Quantity/model63015767 1 1 1See burnermounting setSee burnermounting set1 1 11 1 140 Ignition gas nozzle EG BCR 20 5181 648 1 1 140 LPG nozzle - BBR 12 5176 998 1 1 150 Ignition gas screws D4 5181 672 1 1 160Ignition gas line DA4 CE124 compl. "US"(with screws and bush)70 Screw CE M4x12 A3K CombiTorx80 Screw CE M5x12 A3K CombiTorx6301- 5548 5549 5550See burnermounting setSee burnermounting set1 1 11 1 1We reserve the right to make any changes due to technical modifications.74 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 12Fig. 62Ignition burnerWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200575

12Parts listsBurner grate ( Fig. 63)ItemDescriptionno.10Burner grate CE124 compl. with main gasnozzle "US"Buderusarticle numberModel 17Quantity/modelModel 23Quantity/modelModel 30Quantity/model6301- 5516 5517 551820 Sealing ring 13x18x1.5 mm 5883 094 2 3 4The main gas nozzles are suitable for operationat altitudes between 0 and 8500 feet.The appropriate gas conversion parts arerequired for operation at altitudes above 8500feet.30Main gas nozzle 2,65 mm hole SW16 48 mm formodel EG G20 0–8500 feet5484 392 2 - -30Main gas nozzle 2.50 mm hole SW16 48 mm formodel EG G20 0–8500 feet5484 380 - 3 440 Insulation "US" 6301- 5528 5529 553050 Ceramic glue Thermofix tube 115 g 2037 312 1 1 160 Air baffle CE124 5 sections top/bottom 63011005 - - 170 Screw CE M5x12 CombiTorxSee burnermounting set- - 280 Screw CE M4x12 CombiTorxSee burnermounting set- - 290 Glass pane Tempax 30x30.3.3 mm 5447 620 1 1 1Burner mounting set GA124 63015551 - - -Tab. 22 Burner grateWe reserve the right to make any changes due to technical modifications.76 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 12Fig. 63Burner grateWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200577

12Parts listsUSER NOTEThe complete burner is supplied only inthe model for natural gas G20 for 0-8500 feet. If a different model of burner iswanted, the corresponding gasconversion parts must be included in theorder. The replaced parts must remainwith the heating system for a possiblefuture reconversion.SpecificationsGas burner CE124 ( Fig. 64)ItemDescriptionno.Buderusarticle numberModel 17Quantity/modelModel 23Quantity/modelModel 30Quantity/model10 Gas burner CE124 G20 "US" 6301- 5513 5514 5515LP kit. GA124 (G31) 0-8500 "US/CA" 6303- 7804 7805 7805LP kit. GA124 (G31) 8501-12000 "US/CA" 6303- 7807 7808 7808NG kit. GA124 (G20) 0-8500 "US/CA" 6303- 7806 7812 7812NG kit. GA124 (G20) 8501-12000 "US/CA" 6303 7810 7811 7811Tab. 23 Burner types, gas conversion partsWe reserve the right to make any changes due to technical modifications.78 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Parts lists 12Fig. 64Gas burner CE124We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200579

13Specifications13 SpecificationsMain gas orifice identification and rated orifice pressure for natural gasBoiler size Number of nozzles Main gas orifice identificationfor altitudes [feet]0–8500 ft 1) 8501–12000 ft 2)Rated manifoldpressure[in. W.C.]17 2 265 260 3.623 3 250 245 3.630 4 250 245 3.5Tab. 24 Main gas orifice identification and rated manifold pressure for natural gasMain gas orifice identification and rated orifice pressure for LP gasBoiler size Number of orifices Main gas orifice identificationfor altitudes [feet]0–8500 ft 2) 8501–12000 ft 2)Rated manifoldpressure[in. W.C.]17 2 175 170 8.923 3 160 155 9.930 4 160 155 9.5Tab. 25 Main gas orifice identification and rated manifold pressure for LP gas1) factory setting2) use conversion parts only as directed by the technicaldocumentationUSER NOTEIf the installation location is over 8500 feetabove sea level, please contact Buderusfor the required conversion components.Do not attempt to convert the boilerwithout the approved Buderus parts andthe relevant technical documentation.The technical documentation is included with theconversion parts (accessories).We reserve the right to make any changes due to technical modifications.80 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Wiring diagrams 1414 Wiring diagramsFig. 65Wiring diagram – Model GA124We reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200581

14Wiring diagramsFig. 66Wiring diagram – Model GA124We reserve the right to make any changes due to technical modifications.82 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005

Wiring diagrams 14Fig. 67Wiring diagram – GA124 with Logamatic 2107 or Logamatic 2109 controlWe reserve the right to make any changes due to technical modifications.Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/200583

Heating Contractor:PRODUCTS MANUFACTURED BYBBT Thermotechnik GmbH35573 Wetzlarwww.buderus.deBBT North America Corporation50 Wentworth AvenueLondonderry, NH 03053Tel: 603-552-1100 ● Fax: 603-584-1681www.buderus.netBBT North America Corporation reserves the right to make changes without noticedue to continuing engineering and technological advances.