Buderus Logano G225 Installation And Service Instructions Manual

Brand: Buderus

Model: Logano G225

Type: Installation And Service Instructions Manual

This manual is also suitable for

Logano plus GB225

For contractors

Please read carefully before

use.

Installation and service

instructions

Fan-assisted

low temperature/

condensing boiler

6 720 615 876-00.1RS

Logano G225/Logano plus

GB225 with BE burner

6 720 616 282 - 02/2008 EN

Contents

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

Contents

1 General safety instructions and

explanation of symbols 4

1.1 Safety instructions 4

1.2 Explanation of symbols 5

2 Product details 6

2.1 EU Declaration of Conformity 6

2.2 Intended use 6

2.3 Standards, regulations and directives 6

2.4 Notes on installation and operation 6

2.5 Heating system water quality 6

2.6 Tools, materials and equipment 6

2.7 Disposal 7

2.8 Product description 8

2.9 Contents 9

2.10 Dimensions and specifications 10

2.10.1 Logano G225 BE dimensions 10

2.10.2 Boiler room and ambient conditions 11

2.10.3 Conditions for combustion air supply 12

2.10.4 Conditions for fuel 12

2.10.5 Conditions for the power supply 13

2.10.6 Conditions for the system configuration and

water quality 13

3 Transporting the boiler 14

4 Boiler positioning 15

5 Boiler block assembly 16

5.1 Assembly when delivered in sections 16

5.1.1 Preparation of boiler sections 16

5.1.2 Driving nipples home 17

5.1.3 Preparing the centre section 18

5.1.4 Inserting the packing cord 18

5.1.5 Knocking the centre section into place 19

5.1.6 Boiler section alignment 19

5.1.7 Joining the boiler sections at the upper

and lower boiler hubs with nipples 20

5.1.8 Fitting the anchor rods 22

5.1.9 Installation of the feed pipe and connection

profile 23

5.1.10 Fitting the temperature sensor 25

5.1.11 Fitting the flue outlet 26

5.1.12 Closing the boiler hubs 26

5.2 Checking for leaks 27

5.2.1 Preparing for a leak test 27

5.2.2 Carrying out the leak test 27

5.3 Installation of pre-assembled boiler heat

exchanger 28

5.4 Assembly steps for boilers supplied in

sections and as ready assembled block 28

5.4.1 Fitting the adjustable feet 28

5.4.2 Inserting the hot gas baffle plates 28

5.4.3 Installing the burner door 29

5.4.4 Installing the boiler casing 30

5.5 Positioning and levelling the boiler 37

6 Installing the boiler 38

6.1 Installing the flue pipe 38

6.1.1 Flue pipe sealing collar for negative pressure

flue (pressure at boiler outlet < 0 mbar) 38

6.1.2 Flue pipe sealing collar for positive pressure

flue (pressure at boiler outlet > 0 mbar) 39

6.2 Fitting the water connections 39

6.2.1 Connecting the central heating flow

and return 39

6.2.2 Connecting the safety flow and return 40

6.2.3 Connecting the DHW cylinder 40

6.2.4 Fitting the boiler fill & drain valve

(not supplied) 40

6.3 Filling the heating system and checking

for leaks 41

6.4 Connecting the fuel supply 42

6.5 Electricity connection 42

6.5.1 Fitting the control unit 42

6.5.2 Connecting the mains power supply and other

components 43

6.5.3 Fitting a strain relief 43

6.6 Installing casing parts 44

7 Commissioning the heating system 45

7.1 Bringing the system up to operating pressure 45

7.2 Preparing the heating system for operation 46

7.3 Switching on the heating system 46

7.4 Starting the burner 46

7.5 Raising the flue gas temperature 47

7.5.1 Removing hot gas baffle plates 47

7.5.2 Removing the hot gas check plate 47

7.6 Installing the burner hood 48

7.7 Setting the room controller/control unit 48

7.8 Commissioning report 49

8 Shutting down the heating system 50

8.1 Normal shutdown 50

8.2 Shutting down the heating system

in emergencies 50

8.2.1 What to do in an emergency 50

9 Heating system servicing 51

9.1 Why is regular servicing important? 51

9.2 Preparing the boiler for servicing 51

Contents

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

9.3 Cleaning the boiler 52

9.3.1 Cleaning the boiler with cleaning brushes 52

9.3.2 Wet cleaning (chemical cleaning) 53

9.4 Checking the heating system operating

pressure 54

9.5 Servicing and maintenance reports 55

10 Troubleshooting 58

Index 59

General safety instructions and explanation of symbols

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

1 General safety instructions and explanation of symbols

1.1 Safety instructions

If you smell flue gas

V Switch off the heating system (Æ page 50).

V Open windows and doors.

V Inform an authorised contractor.

Risk of poisoning. An insufficient supply of air can

result in dangerous escape of flue gas.

V Ensure that air inlet or outlet vents are not closed off or

their size is reduced.

V Ensure that no mechanical air extraction equipment

draws combustion air from the boiler room, e.g. cooker

extractor hoods, tumble dryers, ventilation equipment.

V Only operate the boiler with chimneys that provide the

required draught during operation.

V The boiler must not be operated until any deficiency

has been rectified.

V Inform the system operator in writing of the problem

and associated danger.

Danger from escaping flue gases

V Ensure that the flue pipes and seals are not damaged.

V Use silicon as sealing compound.

Dangers posed by explosive and easily

combustible materials

V Never use or store combustible materials (paper, lace

curtains, clothing, thinners, paints, etc.) in the vicinity of

the boiler.

Combustion air

V Keep the combustion air free of corrosive substances

(e.g. halogenated hydrocarbons that contain chlorine

or fluorine compounds). In that way you will prevent

corrosion.

Risk of electric shock when the boiler is open

V Before opening the boiler:

Disconnect the heating system from the power supply

by means of the emergency stop switch or the relevant

circuit breaker in the main fuse board.

V It is not sufficient just to switch off the control unit.

V Safeguard the heating system to prevent unintentional

re-connection.

Danger due to short-circuits

To prevent short circuits:

V Only use genuine Buderus wiring.

Installation and conversion

V Correct and proper installation and adjustment of the

burner and the control unit are the fundamental

requirements for safe and economical operation of the

boiler.

V The boiler may only be installed or converted by an

approved heating contractor.

V Never modify any parts that carry flue gas.

V Only qualified electricians are permitted to carry out

electrical work. Installation regulations must be

complied with.

V With open flue appliances: do not cover or reduce

the size of air vents in doors, windows or walls. If

draught-proof windows are fitted, ensure there is an

adequate supply of combustion air to the room.

V The DHW cylinder may only be used for storing

domestic hot water.

Inspection/maintenance

Heating systems must be regularly maintained.

In that way, you will obtain a high level of efficiency and

low fuel consumption.

You will achieve a high level of operational safety and

reliability.

And you will obtain the cleanest possible combustion.

V Recommendation for users: take out a maintenance

and service contract with an approved heating

contractor covering annual servicing and demand-

dependent maintenance.

V Servicing and repairs may only be carried out by a

approved heating contractor.

V Have any faults immediately rectified to prevent

damage to the system.

V The operator is responsible for the general and

environmental safety of the heating system.

V Use only genuine spare parts. Damage caused by the

use of parts not supplied by Buderus is not covered by

the Buderus warranty.

Instructing the customer

V Explain to the customer how the boiler works and how

to operate it.

V Inform the customer not to carry out any alterations or

repairs.

General safety instructions and explanation of symbols

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

1.2 Explanation of symbols

The terms indicate the seriousness of the ensuing risk if

measures for minimising losses are not taken.

– Caution means that minor material losses may occur.

– Warning means that minor injury or severe material

losses may occur.

– Danger means that severe injury may occur. Very

serious cases may result in death.

Notes contain important information for situations in

which there is no risk to the user or the appliance.

Cross-references to particular places in the document or

to other documents are marked with an arrow Æ.

Warnings are indicated by a warning

triangle and a grey background.

Notes are identified in the text by this

symbol. They are bounded by horizontal lines

above and below the text.

Product details

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

2 Product details

These installation and servicing instructions contain

important information regarding the safe and proper

installation, commissioning and servicing of the boiler.

Product designation:

Logano G225 = fan-assisted, low temperature boiler

Logano plus GB225 = fan-assisted, low temperature

condensing boiler (complete system consisting of Logano

G225 with fitted oil condensing heat exchanger)

The Logano G225 fan-assisted, low temperature boiler

and the Logano plus GB225 fan-assisted, low

temperature condensing boiler are generally referred to in

the remainder of this document simply as the boiler.

These installation and servicing instructions are intended

for qualified heating contractors, who – as a result of their

technical training and experience – are skilled in dealing

with heating systems and oil installations.

2.1 EU Declaration of Conformity

The design and operation of this product conforms to

European Directives and the supplementary national

requirements. Its conformity is demonstrated by the

CE designation. You can view the Declaration of

Conformity on the Internet at www.buderus.de/konfo

or request a copy from your local Buderus office.

2.2 Intended use

The boiler is designed for heating central heating system

water and indirect heating of domestic hot water (e.g. in a

DHW cylinder) in detached houses or apartment

buildings.

Please note the details on the rating plate and the

specifications (Æ Chapter 2.10, page 10) to ensure the

correct use of this appliance.

2.3 Standards, regulations and

directives

2.4 Notes on installation and operation

When installing and operating the heating system

observe the following:

– Local building regulations regarding the installation

conditions

– Local building regulations regarding air supply and

venting systems and the chimney flue connection

– Regulations governing electrical connection to the

mains power supply

– Regulations and standards relating to the safety

systems for the central heating system

– Remember that regional approvals may be required for

the flue system and connecting the condensate outlet

to the public sewer system.

2.5 Heating system water quality

As pure water cannot be used for heat transfer, water

quality is important. Poor water quality can damage

heating systems due to scale formation and corrosion.

2.6 Tools, materials and equipment

For the installation and maintenance of the boiler, you will

need the standard tools used for central heating, gas and

water systems plus set of a metric open-ended spanners

and Allen keys.

The following may also prove useful:

– Sack truck with securing strap or Buderus boiler trolley

–Timber supports

– Cleaning brushes and/or chemical cleaning agent for

wet cleaning

The operations to be carried out for assembly

and installation are identical for the Logano

G225 and the Logano plus GB225 and are

described in these instructions for the

Logano G225.

The differing dimensions, technical

specifications and wall clearances, and the

additional operations for commissioning,

maintenance and servicing of the Logano

plus GB225 can be found in the enclosed

supplement.

Observe all standards and guidelines

applicable to the installation and operation of

this heating system in the country in which it

is used.

Caution: Risk of system damage due to

unsuitable heating system water.

V If oxygen-permeable pipes are used, e.g.

for underfloor heating systems, the

systems must be separated from one

another by heat exchangers. Unsuitable

heating system water promotes sludge

and corrosion formation. That may result in

heat exchanger malfunction and damage.

Product details

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

If the boiler is delivered in sections, you will also require

the following:

– Size 1.2 compression tool (compression tool docu-

mentation)

– Flat board

– White spirit

– Installation kit (accessory)

– Steel hammer and wooden or rubber mallet

– Half-round bastard file

– Screwdriver (Philips and flat head)

– Flat chisel

– Spanners, sizes 13 mm, 19 mm, 24 mm and 36 mm,

and socket size 19 mm

– Support wedge, flat iron

– Cleaning rags and cloth

– Fine emery cloth

– Wire brush

– Lubricating oil

– Spirit level, ruler, chalk, straight edge

– Blanking flange with vent facility (for pressure test)

2.7 Disposal

V Dispose of boiler packaging in an environmentally

responsible manner.

V All heating system components that have to be

replaced should be disposed of in an environmentally

responsible manner at an authorised disposal site.

Product details

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

2.8 Product description

The G225 boiler is a fan-assisted, low temperature boiler

and the GB225 boiler is fan-assisted, low temperature

condensing boiler; both of them feature modulating

control of boiler-water temperature.

The boiler comprises:

– Control unit [1]

– Boiler casing [2]

– Boiler heat exchanger and insulation [3]

– Burner [4]

– Heat exchanger system (GB225 only)

The control unit [1] monitors and regulates all electrical

boiler components.

The boiler outer casing [2] prevents heat loss and acts as

a noise insulator.

The boiler heat exchanger [3] transfers the heat

generated by the burner to the heating water.

The insulation [3] prevents radiation losses.

Fig. 1 G225/GB225 boiler

1 Control unit

2 Boiler casing

3 Boiler heat exchanger and insulation

4 Burner

5 Burner hood

6 720 615 876-01.1RS

Product details

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

2.9 Contents

V Upon delivery, check that the packaging is

undamaged.

V Check that all components have been delivered.

Boiler as assembled block

Boiler supplied in sections

Component

Quan-

tity

Packaging

Boiler block 1 1 pallet

Boiler casing 1 1 box

Thermal insulation 1 1 shrink-

wrapped pack

Burner, burner hood,

burner door and fixings

technical documentation

for burner and boiler.

1) The adjustable feet are packed with the burner hood

11 box

Control unit, technical

documentation for

controller

11 box

Tab. 1 Contents

Component

Quan-

tity

Packaging

Front and rear boiler sec-

tions

11 pallet

Centre sections loose

Furniture 1 1 box

Boiler casing 1 1 box

Thermal insulation 1 1 shrink-

wrapped pack

Burner, burner hood,

burner door and fixings

technical documentation

for burner and boiler.

1) The adjustable feet are packed with the burner hood

11 box

Control unit, technical

documentation for

controller

11 box

Tab. 2 Contents

Product details

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

2.10 Dimensions and specifications

2.10.1 Logano G225 BE dimensions

Fig. 2 Connections and dimensions (sizes in mm)

Connections (for sizes see tables below):

VK = Boiler flow

RK = Boiler return

EL = Boiler drain (connection for drain tap)

VS = DHW cylinder flow

RS = DHW cylinder return

VSL = Pressure relief flow pipe (connection for automatic air

vent valve provided by installer)

Connections and sizes:

6 720 615 876-02.1RS

Boiler size 45 55 68

Oil burner Type BE2.3-45 BE2.3-55 BE2.3-68

Boiler sections Number 456

Rated output KW 45 55 68

1) 65 kW (for Spain)

Combustion output KW 48.1 59.0 73.0

2) 69.8 kW (for Spain)

Boiler water content l Approx. 61 Approx. 73 Approx. 85

Gas content l 68.8 85.1 101.4

Flue gas temperature

3) Flue gas temperature to EN 303.

°C 165 180 180

Flue gas mass flow rate kg/s 0.0197 0.0242 0.0299

4) 0.0287 kg/s (for Spain)

content, oil % 13.5

Available draught Pa 50 50 30

Flue gas back pressure mbar 0.35 0.20 0.35

Permissible flow temperature

5)Safety limit (high limit safety cut-out, STB)

Maximum possible flow temperature = Safety limit (STB) - 10 K

Example: Safety limit (STB) = 100 °C, maximum possible flow temperature = 100 - 10 = 90 °C

The safety limit must meet the national regulations of the country concerned.

°C 100

Permissible operating pressure bar 4

Maximum time constant of temperature control s ≤ 1

Maximum time constant of temperature

monitor and high limit safety cut-out (STB)

s ≤ 1.2

Power supply rating 230 VAC, 50 Hz, 10 A IP 40

Tab. 3 Specifications

Product details

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

2.10.2 Boiler room and ambient conditions

Boiler size 45 55 68

Boiler overall length (L) mm 1102 1222 1342

Boiler heat exchanger length (L

) mm 626 746 866

Boiler section handling clearance

(width/height/depth)

mm 460/820/150

Boiler heat exchanger handling clearance

(width/height/depth)

mm 460/820/L

Combustion chamber length mm 548 668 788

Combustion chamber diameter mm 337

Burner door depth mm 95

Distance between boiler feet (F

) mm 455 575 695

Net weight

kg 246 291 336

Tab. 4 Dimensions, weight and other details

1) Weight inc. packaging approx. 6 – 8 % greater.

Operating conditions Notes - detailed requirements

Temperature in the installation

room

+5 to +40 °C

Relative air humidity max. 90 % No condensation or dripping damp inside the boiler room

Dust/airborne seed − When the boiler is in operation, it is essential to prevent excessive dust levels in

the boiler room, e.g.

– building dust through very dusty building work

The supply of combustion air must not contain excessive amounts of dust or

airborne seed; if necessary, entry should be prevented by means of air filters,

e.g.:

– Air supply loaded with dust from dirt roads and paths.

– Air supply contaminated with dust from production and processing facilities, e.g.

quarries mines, etc.

– Airborne seed from plants.

Halogenated hydrocarbon

compounds

− The combustion air must be free of halogen-hydrocarbon compounds.

– Identify the source of halogenated hydrocarbon compounds and eliminate their ingress.

Where this is impossible, route combustion air from areas which are not contaminated

by halogenated hydrocarbon compounds.

Observe the following:

– Buderus catalogue - Heating Technology Germany

– Code of Practice K3 in the Buderus catalogue

Fans, which extract air from the

installation room.

− While the burner is in operation, no mechanical air extraction equipment that draws air from

the boiler room must be operated, e.g.:

– cooker hood

–dryer

– ventilation equipment

Small animals − Prevent small animals from entering the boiler room, particularly through the air inlet vents –

by fitting the vents with grilles.

Fire safety − Maintain clearances between the boiler and flammable materials in accordance with local

regulations. A minimum clearance of 40 cm should always be maintained. Never store

flammable materials or liquids in the vicinity of the boiler.

Flooding − If flooding is imminent, disconnect the boiler in good time from its fuel and power supply

before water enters the room. Any general and burner components or control equipment,

which come into contact with water, must be replaced before re-commissioning.

Tab. 5 Installation room and environment

Product details

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

2.10.3 Conditions for combustion air supply

2.10.4 Conditions for fuel

Country-specific fuels

Operating conditions

Boiler output (in case of

multi-boiler systems = total output)

Air intake flow cross-sectional area in cm

(clear area)

Air intake flow cross-sectional

area for combustion air drawn

from outside (divided between

max. two apertures)

<50 kW min. 150cm

> 50 kW min. 150 cm

plus 2 cm

for each kW

in excess of 50 kW

Tab. 6 Combustion air supply – observe national regulations for boilers which draw their air supply from the boiler

room.

Operating conditions Notes – detailed requirements

Permissible fuels for boilers

with Logatop oil burner

– Boilers with a built-in oil burner may only be run on domestic fuel oil (DIN 51603). The

kinematic viscosity of the oil must not exceed 6 mm

/s (at 20 °C). That is equivalent to a

Redwood I viscosity of 41.0 s (UK) or Sayboldt viscosity of 45.5 s (USA). If oil of poorer

quality is used, the service/cleaning intervals should be reduced accordingly.

Contamination – Technically free of contamination (e.g. dust, moisture, fluids), i.e. continuous operation will

not result in any accumulations likely to restrict the flow through valves or filters.

Tab. 7 Fuels and remarks

Country Germany

Fuels Domestic fuel oil type EL to DIN 51 603

Remarks The boiler may only be operated with the specified fuel.

Country Austria

Fuels EL fuel oil

Remarks The boiler may only be operated with the fuel specified.

The requirements as per Art. 15 a B-VG regarding emissions and efficiency are satisfied.

Country Switzerland

Fuels EL fuel oil

Remarks The boiler may only be operated with the fuel specified.

The output figures shown in the table "Specifications" are rated output figures.

In some cases, the actual figures attained in practice will be below those stated to comply with LRV

requirements within the specified output range.

Tab. 8 Country-specific fuels and remarks

Product details

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

2.10.5 Conditions for the power supply

2.10.6 Conditions for the system configuration and water quality

Operating conditions Notes – detailed requirements

Supply voltage 195 – 253 V The outer casing/boiler must be earthed for safety reasons and to function correctly.

Fuse 10 A

Frequency 47.5 – 52.5 Hz Sine wave

Enclosure rating − IP40 (protected against penetration by foreign bodies > 1 mm dia., not protected against

water ingress)

Tab. 9 Mains power supply

Operating conditions Notes – detailed requirements

Operating pressure (above

atmospheric)

0.5 – 4.0 bar

Permissible testing pressure 1.0 – 5.2 bar

Protection against excess

temperatures via TR thermostat

50–90°C

Protection against excess

temperatures via STB high limit

safety cut-out

100 °C

Water quality − The heating system may only be filled and topped up with water of domestic water quality.

We recommend a pH value of 8.2 – 9.5.

Tab. 10 System configuration and water quality

Transporting the boiler

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

3 Transporting the boiler

This chapter details how you safely transport your boiler.

Caution: Risk of system damage from

impact shocks.

Fragile components could be damaged.

V Observe the transport instructions on the

packaging.

Protect boiler connections from damage and

dirt if the boiler is not to be installed

immediately.

Dispose of packaging in an environmentally

responsible manner.

Warning: Risk of injury if load is

inadequately secured during transportation.

V Use suitable means of transportation, e.g.

the Buderus boiler hand truck with strap.

V Secure the load against falling.

Boiler positioning

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

4 Boiler positioning

This section explains how to erect and position the boiler

in the boiler room.

Wall clearances

Wherever possible, position the boiler with the

recommended wall clearances. Reducing the clearances

to the minimum makes the boiler more difficult to access.

The boiler base or foundation must be perfectly flat and

level.

At the factory, the burner door hinges are fitted on the

right hand side. The burner door can be reversed so as to

hinge on the left.

Fig. 3 Boiler room clearances (boiler positioned on the

left-hand or right-hand side)

Caution: Risk of system damage due to

frost!

V Set up the heating system in a room safe

from the risk of frost.

Dimen-

sion

Wall clearance

A Recommended 1300

minimum 1000

B Recommended 700

minimum 400

C Recommended 400

minimum 100

L Æ Chapter 2.10.1, page 10

Tab. 11 Recommended and minimum wall clearances

(dimensions in mm)

6 720 615 876-03.1RS

Where applicable, allow extra wall

clearances for additional components such

as DHW cylinder, pipe connections, flue

silencer or other flue components, etc.

Boiler block assembly

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

5 Boiler block assembly

The on-site installation is carried out using individual

sections if, because of physical limitations, a boiler block

cannot be handled as a complete unit.

For details of assembling the remainder of the boiler if the

heat exchanger is delivered pre-assembled,

Æ Chapter 5.4, page 28.

Fig. 4 Fully assembled boiler heat exchanger

1 Foundation/installation location

2 Drain

3 Rear section

4 Flue outlet

5 Connecting block

6 Centre sections

7 Anchor rods

8 Front section

9 Burner door

5.1 Assembly when delivered in

sections

V Assemble all boiler sections in accordance with the

following instructions and illustrations.

5.1.1 Preparation of boiler sections

V Lay rear section [2] across two wooden battens [3].

V Clean the boiler bosses [1] with emery paper and a rag.

V Remove any burrs which might have been created with

a file.

V Clean the joint lip/groove [4] using a wire brush and

rag.

Fig. 5 Filing off flash

1 Boiler bosses

2 Rear section

3 Wooden battens

4 Joint lip

Warning: Risk of injury if load is

inadequately secured during transportation.

V Use suitable means of transportation, e.g.

the Buderus boiler hand truck with strap.

V Secure the load against falling.

6 720 615 876-04.1RS

Warning: Health risk and risk of injury from

release of vapours and easily combustible

cleaning agents.

V Ensure adequate ventilation inside the

boiler room when using red lead putty,

adhesives and cleaning agents.

V When using a cleaning agent, avoid naked

flames, glowing embers and sparks.

V Observe the manufacturer's handling and

safety instructions.

6 720 615 876-05.1RS

Boiler block assembly

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

V Clean the sealing faces of the boiler bosses [1] with a

cloth soaked in white spirit.

V Evenly coat the boiler boss sealing faces with red lead

putty.

V Coat the joint lip/groove [2] with adhesive (primer).

Fig. 6 Coating the boiler hubs with red lead putty

1 Boiler boss sealing face

2 Packing groove

5.1.2 Driving boss liners home

V Clean the boss liners with a cloth soaked in white spirit.

V Evenly coat the boss liners with red lead putty.

V Insert the boss liners straight into the upper and lower

hub of the rear section and hammer home securely with

alternate heavy blows.

V Remove any burrs with a file.

Fig. 7 Driving boss liners home

1 Boss liner in the upper boiler hub

2 Boss liner in the lower boiler hub

6 720 615 876-06.1RS

Leave the two boss liners protruding approx.

30 mm from the boiler boss in each case.

6 720 615 876-07.1RS

Boiler block assembly

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

5.1.3 Preparing the centre section

Prepare the centre section in the same way as the rear

section (Æ 5.1.1, page 16).

Fig. 8 Preparing the centre section

1 Boiler boss sealing face

2 Packing grooves

5.1.4 Inserting the packing cord

V Unroll the required length of packing cord from the roll

supplied.

V Peel the backing paper from the packing cord, as you

insert the cord into the packing groove.

V Insert the flexible packing cord into the packing groove,

starting in the upper boiler hub area, and lightly press

in.

V Where the 2 ends meet, overlap the packing cord by

2 cm and press firmly together.

Fig. 9 Inserting the packing cord

6 720 615 876-08.1RS

Caution: Risk of system damage due to

leaking boiler sections.

V To ensure that the joint faces between the

boiler sections are properly sealed, the

packing cord must not be stretched

during fitting.

V Carefully insert the packing cord into the

boiler packing grooves.

6 720 615 876-09.1RS

Boiler block assembly

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

5.1.5 Knocking the centre section into place

V Turn the centre section around and locate with the

upper and lower boiler hubs on the boss liners of the

rear section.

V Drive the centre section onto the rear section [2] using

a wooden or a rubber mallet [1].

Fig. 10 Knocking the centre section into place

1 Wooden or rubber mallet

2 Rear section

5.1.6 Boiler section alignment

V Right the part assembled block comprising two boiler

sections.

V Position a flat board [1] underneath the centre section

[2] so that the boiler heat exchanger is slightly tilted to

the rear for the subsequent assembly process.

Fig. 11 Righting the part assembled block

1 Flat board

2 Centre section

6 720 615 876-10.1RS

Warning: Risk of injury due to inadequately

secured boiler sections.

V Secure the partly assembled boiler heat

exchanger against tipping over.

6 720 615 876-11.1RS

Boiler block assembly

Logano G225/Logano plus GB225 - We reserve the right to make any changes due to technical modifications.

5.1.7 Joining the boiler sections at the upper and

lower boiler bosses with boss liners

Fig. 12 Assembling the pull rods

1 Pull rod threaded connection (incorrectly joined)

2 Pull rod threaded connection (correctly joined)

V Push one pull rod each through the lower and the

upper boiler hub of the part assembled block.

Fig. 13 compression tool fitted to the top boiler boss

1 Compression unit

2 Pressure plate (dia. 135 × 25, top boiler boss)

3 Brace plate (dia. 135 x 25, top boiler boss)

4 Wedge

5 Pull rod in the upper boiler hub

Caution: Risk of boiler damage due to

unsuitable compression tool.

V Use only the size 1.2 compression tool

suitable for your boiler (Æ observe

documentation supplied with

compression tool).

Caution: Risk of damage to compression

tool

The compression tool may be damaged or

destroyed, if you compress pull rods with

loose threaded connections.

V After each compression operation, check

the screwed joints of the pull rods [1, 2]

and tighten if necessary.

The pull rods [2] is correctly assembled

when it is fully fitted together and no

thread is visible.

V Keep the thread of the compression tool

clean. Dirty threads can cause damage to

the compression tool when in use.

6 720 615 876-12.1RS

Caution: Risk of boiler damage due to

incorrectly positioned pressure plate.

If the pressure plate is seated against the

joint lip/groove of the boiler section during

the compression operation, the joint may be

damaged and subsequently leak.

V Ensure that the pressure plate is seated

flat against the boiler boss.

6 720 615 876-13.1RS

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Buderus Logano G225 Installation And Service Instructions Manual

Brand: Buderus

Model: Logano G225

Type: Installation And Service Instructions Manual

This manual is also suitable for

Logano plus GB225

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Buderus Logano G225 Installation And Service Instructions Manual

This manual is also suitable for

Buderus Logano G225 Installation And Service Instructions Manual

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