Buderus Logano G334 X User manual

Please read carefully before conversion
6304 2382 – 2012/11 US/CA For heating engineers
Instructions for High Altitude
Conversion
Logano G334 X gas-fired boiler
Required Sealevel Input Rates of 0-8500 feet
G334 X-73
301 MBtu/hr
G334 X-92
387 MBtu/hr
G334 X-116
476 MBtu/hr
G334 X-132
541 MBtu/hr
This conversion kit and the accompanying instructions are for conversion of
G334 X gas-fired boilers for operation at altitudes above 8500 feet.
Note: Please keep these instructions for future reference.
WARNING!
This conversion kit is intended for use by a
qualified service company only as
specified by the manufacturer’s
instructions and the current applicable
rules and regulations of the local
authorities and the regulations of NFPA54,
CAN/CGA B149.1 and 2, Installation
Code, must also be observed. If these
instructions are not followed exactly, a fire,
explosion or release of carbon monoxide
may occur with serious property damage
or loss of life and serious injury. The
heating contractor is liable for correct
conversion of the heating system with this
conversion kit.
WARNING!
Please use the enclosed instructions for
conversion from natural gas to propane.

Contents
2Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11
We reserve the right to make any changes due to technical modifications.
1Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Notes structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Please observe these notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Conversion of the boiler at altitudes over 8500 feet . . . . . . . . . . . . . . . . . 4
4 Start-up instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Making boiler ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Then carry out start-up procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety 1
3
We reserve the right to make any changes due to technical modifications.
Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11
1 Safety
Observe these instructions for your safety.
1.1 Correct use
The conversion kit is for conversion of the G334 X gas-
fired boiler for operation at altitudes above 8500 feet.
1.2 Notes structure
Additional symbols for identification of dangers and user
instructions.
1.3 Please observe these notes
2 Scope of delivery
The conversion kit for high altitudes includes the
following components:
–main gas orifices and seals
–conversion date label (to be filled out and attached to
the unit)
–conversion instructions
–Technical documents
WARNING!
RISK TO LIFE
Identifies possible dangers emanating
from a product, which might lead to serious
injury or death if appropriate care is not
taken.
WARNING!
RISK TO LIFE
from electric shock.
USER NOTE
Tip for the optimum utilization and setting
of the control(s) plus other useful
information.
WARNING!
RISK TO LIFE
from explosion of flammable gases.
zNever work on gas lines unless you are
licensed for this type of work.
WARNING!
RISK TO LIFE
from electric shock.
zDisconnect the power supply to the
heating system before conducting any
work on it, e.g. switch off the heating
emergency switch outside the boiler
room.
zIt is not sufficient just to switch off the
control.

4Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11
We reserve the right to make any changes due to technical modifications.
Conversion of the boiler at altitudes over 8500 feet3
3 Conversion of the boiler at altitudes over 8500 feet
Read the instructions before conversion for your
safety.
When converting the boiler for operation at high
altitudes observe the following directions:
The boiler must be converted before installation.
1. If the boiler has been operating, close the gas valve.
Otherwise continue with step 3.
2. Disconnect heating system from the power supply
and set the thermostat to the lowest setting.
3. Remove safety screws from the left and right side
panels, then lift the front panel of the boiler and pull
it forward.
WARNING!
RISK TO LIFE
due to not observing the attached
conversion instructions.
zIf you wish to convert the boiler for
operation with propane, the conversion
from natural gas to propane must be
carried out first as specified by the
attached conversion instructions. The
conversion for high altitudes can only
be made after this.
Fig. 1 Removing front panel of boiler
1Screws
2Boiler front panel
1
2
1

Conversion of the boiler at altitudes over 8500 feet 3
5
We reserve the right to make any changes due to technical modifications.
Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11
4. Turn gas valve ON/OFF button clockwise to OFF
position. Do not use force.
Replacing main gas orifices
5. Disconnect pilot gas line from gas valve.
6. Disconnect ignition cable from automatic ignition.
7. Tie gas line with wire or cord (secure).
8. Unscrew retaining screws of gas feed line at burner.
Place the gas connection pipe gasket in a safe
place.
9. Check gasket for damage and replace if damaged.
10. Label connection lines of flame roll-out switch and
disconnect from the flame roll-out switch.
Fig. 2 Gas valve
WARNING!
RISK TO LIFE
from explosion of flammable gases.
zWait five (5) minutes until all gas
residues have dissipated. Check
whether there is any smell of gas,
including at floor level. If there is a gas
odor: STOP! Follow instructions in
section "B" of the safety instructions on
page 8. If there is no sign of a gas odor,
continue with the next step.
USER NOTE
When converting the boiler for high
altitudes it is only necessary to replace the
main gas orifices, not the pilot gas orifice.
Fig. 3 Front view
1Ignition cable
2Flame roll-out switch
3Connection lines to the gas valve
4Gas valve
5Connection lines to the flame roll-out switch
6Gas supply line
7Retaining screw on the gas feed line
8Pilot gas line
1
1
2
3
5
4
7
5
4
3
2
6
8
WARNING!
RISK TO LIFE
due to incorrectly connected wiring.
zWhen conducting maintenance work
label all cables before disconnecting
them.

6Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11
We reserve the right to make any changes due to technical modifications.
Conversion of the boiler at altitudes over 8500 feet3
11. Unscrew retaining nuts on burner plate and pull gas
burner straight out.
12. When removing the burner make sure that the
spacers remain on the studs.
13. Install the new main gas orifices and copper gasket.
Check with ÎTab. 1 and ÎTab. 2 to ensure that
the correct orifices for operation of the boiler are
installed.
14. Install gas burners in boiler in reverse order of
removal. Tighten the fixing nuts well.
15. Tighten the screws (ÎFig. 3, page 5) between the
gas valve and the burner again. Make sure that the
connection pipe gasket removed in step 8 is
replaced.
16. Check gasket for damage and replace if damaged.
17. Attach connection lines for the flame roll-out switch.
18. Remove wire or rope that was used to hold the gas
supply line in step 7.
19. Connect ignition gas line (ÎFig. 3, page 5) to the
gas valve again.
20. Connect ignition cables (ÎFig. 3, page 5) to the
automatic igniters.
21. Enter the required information on the conversion
label and attach on the outside of the boiler jacket as
close as possible to the name plate.
Fig. 4 Removing burner
1Fixing nuts
2Threaded studs
1
1
1
1
22
Orifice sizes for natural gas
Altitude in feet
Model 0–8500 8501–12000
G334 X-73 3.60 3.55
G334 X-92 3.70 3.65
G334 X-116 3.90 3.85
G334 X-132 3.90 3.85
Tab. 1 Orifice size for natural gas
Orifice sizes for propane
Altitude in feet
Model 0–8500 8501–12000
G334 X-73 2.35 2.30
G334 X-92 2.40 2.35
G334 X-116 2.50 2.45
G334 X-132 2.50 2.45
Tab. 2 Orifice size for propane

Conversion of the boiler at altitudes over 8500 feet 3
7
We reserve the right to make any changes due to technical modifications.
Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11
Carrying out leak test
22. Open gas valve in the gas line.
23. Check the gas connection line to the gas valve for
leaks with soap solution. If no leaks are found,
continue with step 25. If any leaks are found, close
gas valve.
24. Seal leaks and repeat step 23.
25. Close main gas valve. Remove the screw plug for
the gas connection port on the gas valve. Install
pressure measuring nipple and attach a pressure
gauge to measure the gas pressure.
26. Remove the screw plug for the manifold pressure
port on the gas valve. Install pressure measuring
nipple and attach a pressure gauge to measure the
manifold pressure.
27. Open gas valve and measure the gas pressure of
the boiler. The supply pressure for natural gas must
be between 7" and 10.5" W.C. and between 11" and
13" W.C. for propane gas. If the supply pressure for
natural gas is not between 7" and 10.5" W.C. and not
between 11" and 13" W.C. for propane gas, contact
the customer service technician or the gas
company.
28. Always follow the start-up instructions on the next
page.
USER NOTE
The boiler has two gas valves. Make all
measurements and adjustments on both
gas valves.
CAUTION!
SYSTEM DAMAGE
due to short-circuit.
zCover the hazardous locations before
checking for leaks.
zDo not spray the leak solution on wiring
openings, plugs or electrical
connections. Do not allow the solution
to drip on these locations.
Fig. 5 Gas valve
1ON/OFF button (at ON position)
2Screw plug for gas supply pressure measuring port
3Screw plug for manifold pressure measuring port
3
2
1

8Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11
We reserve the right to make any changes due to technical modifications.
Start-up instructions4
4 Start-up instructions
Read the instructions before start-up for your
safety.
AThis unit is equipped with an igniter that automatically
starts the pilot burner. Do not attempt to ignite it manually.
BCheck for an odor of gas around the heating system. This
test must also be conducted at floor level, because some
types of gas are heavier than air and may accumulate at
floor level.
CSwitch 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 qualified technician. Any
attempt to use force or to repair the switch may cause a fire
or explosion.
DDo not operate the unit if any part is under water. Contact
a qualified customer service technician immediately to
have the unit checked and to replace the parts of the
control and gas valves that were under water.
WARNING!
RISK TO LIFE
due to not observing the start-up
instructions and resulting incorrect
operation.
zIf these instructions are not followed
exactly, a fire or explosion may be
caused with serious property damage
or loss of life or serious injury.
zObserve the start-up instructions.
WARNING!
DANGER OF EXPLOSION
If you smell gas there is a danger of
explosion.
zNo open flame. No smoking.
zPrevent spark formation.
Do not operate electrical switches,
including telephones, plugs or door
bells.
zShut off main gas supply valve.
zOpen doors and windows.
zWarn other occupants of the building.
zEvacuate the building.
zCall gas company or fire department
from outside the building.

Start-up instructions 4
9
We reserve the right to make any changes due to technical modifications.
Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11
4.1 Making boiler ready for operation
STOP! First read the safety instructions on Îpage 8 of
this manual.
1. Carry out leak test (Îpage 7). Wait five (5) minutes
until all gas residues have dissipated. Finally check
whether there is any smell of gas, including at floor
level. If there is a gas odor: STOP! Follow
instructions in section "B" of the safety instructions
on Îpage 8 of this manual. If there is no sign of a
gas odor, continue with the next step.
2. Open main gas valve.
4.1.1 Placing heating system with aquastat control in operation
The boiler is fully functional with the factory-installed
aquastat.
3. Switch on ON/OFF switch (building side)
(ON position). This switches on the boiler with all its
components. Then continue with step 7.
4. Make sure that the room thermostat signals a heat
requirement (set thermostat at least 10 °F above
room temperature).
Fig. 6 Switching on heating system (with aquastat)
1ON/OFF switch (main switch)
1

10 Conversion instructions for G334 X gas-fired boiler conversion kit - High altitudes • Issue 2012/11
We reserve the right to make any changes due to technical modifications.
Start-up instructions4
4.1.2 Placing heating system with Logamatic 2107 (accessory) in operation
The boiler is fully functional with the factory-installed
aquastat. The Logamatic 2107 control can also be
installed in addition to the factory-installed aquastat.
Switch on the heating system with the ON/OFF switch
on the control. The burner starts operating if heat is
required (Îobserve control service manual).
5. Make sure that heat is required at the control. Select
"Manual operation" (hand symbol) with the mode
selector switch.
6. Switch on ON/OFF switch ("I" position). Then
continue with step 7.
4.2 Then carry out start-up procedures.
The following start-up procedures must be carried out
regardless of the control type.
7. Look at the igniter through the sight glass in the
burner housing.
Fig. 7 Switching on heating system (with Logamatic 2107
control)
1Mode selection switch
2ON/OFF switch
2
1
USER NOTE
After carrying out the instructions for
starting described below, the control must
be set to "AUT" mode (automatic
operation) with the mode selector.
Fig. 8 Front view
1Sight glass
1