Buderus Logano G234X Operating Instructions Manual

Brand: Buderus

Model: Logano G234X

Type: Operating Instructions Manual

Please read carefully before installing and servicing.

Operating Instructions

Gas boiler

Logano G234X

6 720 804 886-00.1T

Gas boiler

6 720 804 888 (2012/08) EN-US

UPON COMPLETION OF THE INSTALLATION THE INSTALLER MUST

INSTRUCT THE OWNER AND OPERATOR ON THE FUNCTIONALITY AND

THE PROPER OPERATION OF THE BOILER AND THE HEATING SYSTEM.

INSTALLER MUST REVIEW ALL SAFETY INSTRUCTIONS WITH THE

OWNER AND OPERATOR.

THIS MANUAL SHOULD BE HANDED TO THE QWNER AND OPERATOR OF

THE APPLIANCE.

DANGER!

The installation instructions included in this Manual are intended solely for

use by a trained and certified installer, service company or the gas supply

company. If the information in this manual is not followed, a fire or explosion

may result causing property damage, personal injury, or death.

Have installation and service performed by a trained and certified

installer or service company, or the gas supply company.

Buderus recommends signing a service and maintenance contract with

a trained and certified installer or service company that covers annual

servicing and condition-based maintenance. Proper maintenance is a

fundamental requirement for safe and efficient operation and long

service life.

The boiler must be serviced annually including the main burner, ignition

burner, the entire venting system, and the combustion air supply. All

parts that show any signs of damage or corrosion must be replaced



The owner and operator is responsible for the operational safety and

regulatory compliance of the heating system.

Improper installation, adjustment, alteration, service, or maintenance

can cause property damage, personal injury, or death. Refer to this

manual and consult a trained and certified installer or service company,

or the gas supply company before installation, service or maintenance.

Contents

Logano G234X – 6 720 804 888 (2012/08)2

Contents

1 Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Product information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Certification and testing mark . . . . . . . . . . . . . . . . . . . . . 4

2.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.4 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 Before operating the appliance . . . . . . . . . . . . . . . . . . . . 4

3.2 Checking the operating pressure, topping up

the boiler water, and purging air from the system . . . . . 4

3.2.1 Checking the operating pressure . . . . . . . . . . . . . . . . . . 4

3.2.2 Topping up the heating water and bleeding the system . 5

3.3 Start up instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.4 Shut down the heating system . . . . . . . . . . . . . . . . . . . . 7

3.4.1 Normal system shut-down . . . . . . . . . . . . . . . . . . . . . . . . 7

3.4.2 Emergency shut-down procedures . . . . . . . . . . . . . . . . . 7

3.5 Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.6 Why is annual maintenance important? . . . . . . . . . . . . . 7

1 Safety considerations

1.1 Key to symbols

Warnings

The following keywords are defined and can be used in this document:

• NOTICE indicates that property damage may occur.

• CAUTION indicates that personal injury may occur.

• WARNING indicates that severe personal injury may occur.

• DANGER indicates that severe personal injury or death may occur.

Important Information

Additional symbols

1.2 Safety instructions

If you hear gas leaking

▶ Leave the building immediately.

▶ Prevent others from entering the building.

▶ Notify the police and fire department from outside the building.

▶ From outside the building, call the gas supply company and a trained

and certified installer or service company.

If you smell gas

▶ Turn off the gas shut-off valve.

▶ Open windows and doors.

▶ Do not touch any electrical switch, telephone, and do not use outlets.

▶ Extinguish all open flames.

▶Do not smoke.

▶ Do not use lighters.

▶ Warn all occupants of the building that they need to leave the building.

▶ Do not ring doorbells.

▶ Notify the police and fire department from outside the building.

▶ From outside the building, call the gas supply company and a trained

and certified installer or service company.

Warnings in this document are identified by a warning

triangle printed against a grey background. Keywords at

the start of a warning indicate the type and seriousness

of the ensuing risk if measures to prevent the risk are not

taken.

Important information for the proper use of the boiler is

also provided in this manual. You will find the information

with a symbol shown on the left and bordered by

horizontal lines above and below the text.

Symbol Explanation

▶ Sequence of steps

 Cross-reference to other points in this document or to

other documents

• Listing/list entry

– Listing/list entry (2nd level)

Table 1

Safety considerations

Logano G234X – 6 720 804 888 (2012/08) 3

If you smell flue gas

▶ Switch off the heating system by shutting off the emergency shut-off

switch.

▶ Open windows and doors.

▶ Call a trained and certified installer or service company

DANGER: Risk of fatal injury from failing to consider your own

safety

▶ Never risk your own life. Your own safety must always take the highest

priority.

DANGER: Risk of fire when soldering and brazing

▶ Take appropriate protective measures when soldering and brazing

around combustible and flammable material.

DANGER: Risk of personal injury or death from flue gas poisoning

▶ Do not install a thermostatic flue gas damper downstream of the draft

hood.

▶ Do not tamper with, remove, or attempt to repair the blocked vent

switch.

▶ When replacing the blocked vent switch, install the new part in the

original location.

▶ A blocked vent switch tripping more than once indicates a problem

with the venting system or chimney which must be repaired

immediately.

▶ Ensure none of the vent pipes and chimneys are damaged or blocked.

▶ Connect only one appliance to each venting system or chimney.

▶ The venting system must not feed into or route through another air

extraction duct.

▶ The venting system must be inspected annually. All parts that show

any signs of damage or corrosion must be replaced.

DANGER: Risk of personal injury or death from explosion

▶ Work on gas components may only be carried out by a trained and

certified installer or service company.

▶ Appliance installation, the connection of gas and vent piping, initial

commissioning, electrical connections, and service and maintenance

must only be carried out by a trained and certified installer or service

company.

DANGER: Risk of personal injury or death from flue gas poisoning

▶ Never close off or reduce the size of the combustion air openings.

▶ The boiler must not be operated until any obstructions have been

removed.

DANGER: Risk of personal injury or death from fire

▶ Do nut use flammable or combustible material in the boiler room.

▶ It is recommended not to store any items within 16 inches (415 mm)

of the appliance.

DANGER: Risk of personal injury or death from electric shock

▶ Before removing the front panel, disconnect the heating system from

the electrical power supply by shutting off the emergency shutoff

switch or the heating system circuit breaker.

▶ It is not enough to switch off the control panel. Power to the panel

must be disconnected.

▶ Ensure that the power is not restored unintentionally by following

proper lock out/tag out procedures.

▶ Only qualified electricians are permitted to carry out electrical work.

DANGER: Safety devices

▶ Never shut off safety valves.

▶ Hot water may escape from the safety valve at any time when the

appliance is running.

DANGER: Risk of personal injury or death after a flood

▶ Do not attempt to operate an appliance if any part of it has been under

water.

▶ An appliance that was subject to flooding must be replaced.

CAUTION: Appliance damage from contaminated combustion air

▶ Keep the combustion air free of corrosive substances, e.g.

halogenated hydrocarbons from painting operations or beauty

salons.

▶ Keep combustion air free from dust and lint, e.g. from laundry or

agricultural operations.

▶ If clean room air is not available, fresh outdoor combustion air must be

provided.

NOTICE: Risk of appliance damage from improper operation of the

boiler

▶ Only use the boiler for its intended purpose.

▶ Only operate the boiler if it has been installed and maintained per the

instructions provided in the Installation Manual.

▶ Do not attempt to operate an appliance if any part of it is not in

working order or is damaged.

▶ Use only original spare parts. The use of parts not supplied by the

manufacturer may cause damage to the boiler, other property and

personal injury. Also, boiler damage caused by the use of

unauthorized parts is not covered by the warranty.

NOTICE:

▶ The installation must comply with all applicable national, state, and

local codes, rules, and regulations.

▶ The operator is responsible for the operational safety and regulatory

compliance of the heating system.

▶ In the Commonwealth of Massachusetts, the appliance must be

installed by a licensed plumber or gas fitter.

NOTICE:

▶ Upon completion of the installation, these instructions should be

handed to the owner and operator of the appliance.

▶ The installer must instruct the owner and operator on the functionality

of the components and the proper operation of the boiler and the

heating system.

▶ The boiler must be serviced annually including the main burner,

ignition burner, the entire venting system, and the combustion air

supply. All parts that show any signs of damage or corrosion must be

replaced.

Product information

Logano G234X – 6 720 804 888 (2012/08)4

2 Product information

To ensure safe, economical and environmentally friendly use of the

heating system, we recommend that you carefully read the safety

instructions and operating instructions.

These instructions provide the operator of the heating system with an

overview of the use and operation of the boiler.

2.1 Correct use

The boiler is designed for heating central heating system water and

indirect provision of domestic hot water (e.g. via a hot water storage

tank) in residential buildings or apartment buildings. Any other purpose

is considered improper use.

2.2 Certification and testing mark

This appliance has been tested and meets the basic standards for the US

and Canadian markets.

2.3 Disposal

▶ Dispose of boiler packaging in an environmentally-responsible

manner.

▶ All heating system components that have to be replaced should be

disposed of in environmentally-responsible manner at an authorized

disposal site.

2.4 Product description

The G234X model boiler is a low temperature atmospheric gas-fired

boiler.

The boiler consists of:

• Ignition module and boiler temperature controller

• Boiler jacket and front door

• Boiler block with insulation

•Gas burner

The ignition module and boiler temperature controller monitor and

control all electrical components of the boiler.

The boiler jacket prevents energy loss and acts as soundproofing.

The boiler block transfers the heat generated by the burner to the boiler

water. The insulation prevents energy loss.

Fig. 1 G234X boiler

[1] AquaSmart

[2] Burner control unit

[3] Boiler block with thermal insulation

[4] Boiler casing

[5] Burner

[6] Front panel of boiler

3 Operation

3.1 Before operating the appliance

Before starting up the appliance, make sure that

• the operating pressure is sufficient

• the fuel supply has been turned on at the main shut-off valve, and

• the heating system emergency shutoff switch is in the ON position.

3.2 Checking the operating pressure, topping up

the boiler water, and purging air from the system

The water used for filling the heating system loses a substantial amount

of volume in the first few days due to the release of its gas content. This

causes air pockets to form and the heating water starts to make noises.

▶ With new heating systems, check the operating pressure daily at first,

topping off the heating water and bleeding the radiators if needed.

▶ Later on, check the operating pressure monthly, topping off heating

water and purging the boiler and radiators if needed.

3.2.1 Checking the operating pressure

Your heating contractor will have set the system to the required

operating pressure of at least 15 psi (1 bar) and entered the setting in

Tab. 2, page 5.

▶ Read the current operating pressure and temperature from the

temperature/pressure gauge.

▶ If the temperature/pressure gauge needle drops below the minimum

pressure marker of 15 psi (1 bar), the operating pressure is too low.

Add water to the system.

The boiler is fully functional with the factory-installed

AquaSmart

If you are not comfortable performing the following

operations contact you trained and certified installer.

6 720 804 886-01.1T

Operation

Logano G234X – 6 720 804 888 (2012/08) 5

Fig. 2 Pressure/temperature gauge

3.2.2 Topping up the heating water and bleeding the system

Ask your heating contractor to show you where the boiler fill & drain

valve for topping off the heating system is located.

▶ Slowly fill the heating system. Observe the temperature/pressure

gauge while filling.

3.3 Start up instructions

For your safety, read before start up.

WARNING: Health risk from contaminated drinking

water!

▶ It is imperative that you observe all regulations and

standards applicable in your country regarding

prevention of drinking water contamination.

CAUTION: Risk of damage to system due to temperature

stress!

If you fill the heating system when it is hot, the resulting

temperature stress can cause stress cracks. The boiler

will then leak.

▶ Only top off the heating system when it is below a

supply temperature of 100 °F (38 °C).

CAUTION: Risk of system damage due to frequent

topping off!

If you have to top off the boiler water once a month, the

heating system may suffer damage from corrosion or

scale buildup, depending on the water quality.

▶ Ask your trained and certified installer if the local

water can be used untreated or whether it needs to be

treated.

▶ Notify your heating contractor if you find you need to

top off your heating system once a month.

Operating pressure

Design operating pressure

(optimum setting) _____________ psi

Maximum heating system operating

pressure

(standard = 30 psi/2bar) _____________ psi

Table 2 Operating pressure (entered by system installer)

7 747 010 720-24.2RS

DANGER: Risk of fatal injury due to not observing the

start-up instructions and resulting incorrect operation!

▶ If these instructions are not followed, a fire or

explosion may result.

DANGER: Risk of explosion!

If you smell gas there is a danger of explosio n.

▶ Close the gas shut-off valve.

▶ Open windows and doors.

▶ Do not operate any electrical switches or equipment

such as telephones, power plugs and doorbells.

▶ Extinguish all open flames. Do not smoke. Do not use

lighters.

▶ Warn all occupants of the building, but do not ring

doorbells.

▶ If you can actually hear gas escaping, leave the

building immediately. Prevent others from entering

and notify the police and fire department from

outside the building.

▶ From outside the building, call the gas utility

company and approved heating contractor.

WARNING: Risk of system damage!

This unit is fitted with an ignition module that

automatically starts the pilot burner.

▶ Do not attempt to ignite it manually.

WARNING: Risk of system damage!

This test must also be conducted at floor level, because

some types of gas are heavier than air and may

accumulate at floor level.

▶ Check for an odor of gas around the heating system.

WARNING: Risk of system damage!

Any attempt to use force or to repair the valve may cause

a fire or explosion.

▶ Switch on the ON/OFF switch on the gas valve by

hand only.

▶ Never use a tool as assistance.

▶ If you cannot actuate the ON/OFF switch on the gas

valve by hand, do not attempt to repair it.

▶ Contact a trained and certified installer.

WARNING: Risk of system damage!

▶ Do not operate the appliance if any part is under

water.

▶ Contact a trained and certified installer immediately.

Operation

Logano G234X – 6 720 804 888 (2012/08)6

STOP! First read the safety instructions on page 5 of these instructions.

▶ Set thermostat to the lowest value.

▶ Shut off the heating system from the power supply.

▶ Close main gas shut-off.

▶ Unscrew left and right screws [1] in the side panels, lift front panel of

boiler [3] up, pull outward and remove to the front.

Fig. 3 Remove front panel of boiler

[1] Locking screws

[2] Boiler jacket

[3] Front panel of boiler

▶ Turn the gas valve ON/OFF dial [1] clockwise to the OFF position. Do

not use force.

▶ Wait five (5) minutes until all gas residues have dissipated. Finally

check whether there is any smell of gas, including at floor level. If you

smell gas, STOP! Follow instructions in section “B” of the safety

instructions ( page 5).

If you do not smell gas, go to the next step.

▶ Turn gas valve ON/OFF dial[1] counterclockwise to ON position. Do

not use force.

▶ Replace front panel of boiler ( Fig. 3).

▶ Open main gas shut-off.

▶ Switch on electric power to heating system.

Fig. 4 Gas valve

[1] ON/OFF dial (at OFF position)

▶ Set thermostat to desired room temperature.

▶ If the heating system does not start up, follow the instructions above

for turning off the gas supply. After that, inform a customer service

technician or the gas utility company.

Flame roll-out switch

The boiler is equipped with a flame roll-out switch. If the flue duct in the

boiler is blocked, the flame roll-out switch responds.

Do not try to light the boiler in this case. Inform a qualified service

company. The flue duct in the boiler must be checked for blockage and

the flame baffle replaced.

The flame roll-out switch is for one-time use only. Do not try to use it

again.

Flue gas monitoring switch

The boiler is equipped with a flue gas monitor. If the flue gas escape of

the boiler is blocked the flue gas monitoring switch reacts. The flue gas

monitoring switch is mounted directly on the draft hood.

Fig. 5 Gas valve

[1] ON/OFF button (at OFF position)

Do not try to light the boiler if the flue gas escape of the boiler is blocked.

Inform a qualified service company. The flue gas path must be searched

for blockages. In order to start the boiler up again, the flue gas

monitoring switch must first be reset.

WARNING: Risk of fatal injury due to not observing the

start-up instructions and resulting incorrect operation!

▶ If these instructions are not followed, a fire or

explosion may result.

This unit is fitted with an ignition module that

automatically starts the pilot burner. Do not attempt to

ignite it manually.

Operation

Logano G234X – 6 720 804 888 (2012/08) 7

3.4 Shut down the heating system

3.4.1 Normal system shut-down

▶ Switch off the on/off switch ("OFF" position). This switches off the

boiler and all its components (e.g. burner).

▶ Further shut-down procedure refer to AquaSmart

documentation.

▶ Shut off fuel supply by closing main valve.

Fig. 6 Heating system shut-down

[1] ON/OFF switch (emergency shut off switch)

3.4.2 Emergency shut-down procedures

Action in an emergency

▶ Never risk your own life. Your own safety must always take the highest

priority.

▶ Shut off fuel supply by closing main valve.

▶ Disconnect the heating system from the electrical power supply by

means of the emergency shutoff switch or the appropriate circuit

breaker.

3.5 Operating Tips

The right fuel

To ensure it operates properly, the heating system requires fuel of the

correct type and grade.

Consult your trained and certified installer if you want to convert your

heating system to a different fuel or run the boiler on fuel with different

specifications.

Notes about the boiler room

3.6 Why is annual maintenance important?

Heating systems should be maintained annually for the following

reasons:

• to maintain high efficiency,

• to operate the system economically (low fuel consumption),

• to maintain the cleanest combustion.

CAUTION: Risk of system damage due to freezing!

If the heating system has been switched off, it may

freeze in cold weather conditions.

▶ Protect your system from freezing by draining the

boiler, the heating system and hot water pipes at the

lowest point.

Use the heating system emergency shut-off switch

located outside the boiler room or the heating system

circuit breaker for emergency shutdown.

CAUTION: Risk of system damage from use of incorrect

fuel!

▶ Only use the fuel specified. The correct fuel is entered

in Tab. 3 by the heating system installer.

Only use this fuel type

____________________________

____________________________________________ Stamp/Date/Signature

Table 3 Fuel to be used (entered by heating system installer)

CAUTION: Risk of boiler damage from contaminated

combustion air!

▶ Keep the combustion air free of corrosive substances

(e. g. halogenated hydrocarbons that contain

chlorine or fluorine compounds). This will help

prevent corrosion.

▶ Prevent heavy accumulation of dust.

CAUTION: Risk of system damage from water!

▶ In the event of severe risk of flooding, disconnect the

boiler from its power supply and shut off the fuel

supply before water enters the boiler room.

▶ All parts that have been in contact with water must be

replaced by a trained and certified installer.

CAUTION: Risk of damage to system due to lack of or

inadequate cleaning and maintenance!

▶ Have your heating system inspected, cleaned and

maintained by a trained and certified installer once a

year.

▶ We recommend you sign a contract covering an

annual inspection and maintenance.

United States and Canada

Bosch Thermotechnology Corp.

50 Wentworth Avenue

Londonderry, NH 03053

Tel. 603-552-1100

Fax 603-584-1681

www.buderus.us

U.S.A.

Products manufactured by

Bosch Thermotechnik GmbH

Sophienstrasse 30-32

D-35576 Wetzlar

www.buderus.com

Bosch Thermotechnology Corp. reserves the right

to make changes without notice due to continuing

engineering and technological advances.

Buderus Logano G234X Operating Instructions Manual

Buderus Logano G234X Operating Instructions Manual

Buderus Logano G234X Operating Instructions Manual

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