Buderus Logano GA124 User manual

6304 0309 – 04/2005 US For heating engineers
Please read carefully prior to installation and maintenance.
Installation and maintenance
instructions
Sealed combustion gas boiler
Logano GA124
CAUTION!
Observe the safety instructions of this
installation and maintenance manual
before placing the boiler in operation.
WARNING!
If installation, adjustment, modification,
operation or maintenance of the
heating system is carried out by an
unqualified person, this may result in
danger to life and limb or property
damage. The directions of this
installation and maintenance manual
must be followed precisely. Contact a
qualified service company, service
provider or the gas company if support
or additional information is required.
CAUTION!
The operating manual is a component
of the technical documentation handed
over to the operator of the heating
system. Discuss the instruction in this
manual with the owner or operator of
the heating system to ensure that they
are familiar with all information required
for operation of the heating system.
Note: Keep this installation and maintenance manual available for future
reference.

Contents
2Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005
We reserve the right to make any changes due to technical
1Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Observe the following symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Please observe these notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Tools, materials and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Dimensions and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Moving the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Moving the boiler with boiler cart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Lifting and carrying the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Placing the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Leveling the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Boiler installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.1 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.2 Heating circuit connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.3 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.4 Installation of Logamatic 2107 control (optional accessory) . . . . . . . . . . . . . . . . 18
7.5 Fuel supply connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.6 Installation of flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.7 Filling heating system and checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . 32
8 Openings for combustion air supply and venting . . . . . . . . . . . . . . . . . . 34
9 Placing the heating system in operation . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.1 Start-up instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2 Making boiler ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.3 Then carry out start-up procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.4 Shutting off gas supply to boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.5 Instruct owner/operator and hand over technical documentation . . . . . . . . . . . . . 45
9.6 Start-up protocol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10 Taking the boiler out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1 Normal boiler shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.2 Emergency shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11 Boiler inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.1 Why is regular maintenance important? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.2 Testing the flue system, including combustion air, air inlets and
Ventilation openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Contents
3
We reserve the right to make any changes due to technical modifications.
Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005
11.3 Inspection of the boiler and burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.4 Preparing boiler for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.5 Cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.6 Cleaning the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11.8 Maintenance protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12 Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
13 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
14 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Safety1
4Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005
We reserve the right to make any changes due to technical modifications.
1 Safety
Observe these instructions for your safety.
The burner and control must be correctly installed and
adjusted to ensure safe and economical operation of the
gas-fired boiler.
Read this installation and maintenance manual carefully
and note the details on the boiler nameplate before
placing the boiler in operation.
1.1 Correct use
The Logano GA124 gas-fired boiler is designed to heat
water for a hot water heating system for heating single
or multiple occupancy buildings.
1.2 Observe the following symbols
Two levels of danger are identified and signified by the
following terms:
Additional symbols for identification of dangers and user
instructions:.
1.3 Please observe these notes
1.3.1 National regulations
The heating system must comply with the relevant
regulations issued by national authorities, or the
regulations issued by the National Fuel Gas Code, ANSI
Z 223.1. In Canada the regulations of CAN/CGA B 149.1
or 2, Installation Code for Gas Burning Appliances and
Equipment, must be observed.
If specified by the local regulatory authorities the heating
system must comply with the regulations of the
"Standard for Controls and Safety Devices for
Automatically Fired Boilers", ANSI/ASME CSD-1.
Carbon monoxide detectors must be installed as
specified by the local regulations. The boiler must be
serviced annually; see Chapter 11 "Boiler inspection
and maintenance", page 48.
Boiler operating conditions
The hot water pipe system must comply with the current
legislation and regulations. If an existing boiler is
replaced, the complete hot water pipe system must be
inspected to ensure that it is in perfect condition to
ensure safe operation.
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.
CAUTION!
RISK OF INJURY/
SYSTEM DAMAGE
Identifies potentially dangerous situations,
which might lead to medium or slight
injuries or to material losses.
WARNING!
RISK TO LIFE
from electric shock.
USER NOTE
Tip for the optimum utilization and setting
of the control(s) plus other useful
information.
Maximum boiler temperature 220 °F
Maximum operating pressure 58 psi
WARNING!
RISK TO LIFE
due to neglecting your own safety in case
of emergency, such as with a fire.
zNever put yourself at risk. Your own
safety must always take priority.

Safety 1
5
We reserve the right to make any changes due to technical modifications.
Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005
1.3.2 Installation notes
WARNING!
RISK TO LIFE
from explosion of flammable gases.
If you smell gas there is a danger of
explosion..
zNever work on gas lines unless you are
licensed for this type of work..
zMake sure that a qualified company
installs the boiler, connects gas and
venting, places the boiler in operation,
connects the electrical power, and
maintains and repairs the boiler.
zNo open flame. No smoking. Do not
use lighters.
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,
but do not use door bells.
zCall gas company from outside the
building.
zIf gas can be heard escaping, leave the
building immediately, prevent other
people from entering, notify police and
fire from outside the building.
CAUTION!
SYSTEM DAMAGE
due to incorrect installation.
zObserve all current standards and
guidelines applicable to the installation
and operation of the heating system as
applicable in your country.
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.
CAUTION!
SYSTEM DAMAGE
due to unsatisfactory cleaning and
maintenance.
zClean and service the system once a
year. Check that the complete heating
system operates correctly.
zImmediately correct all faults to prevent
system damage.
USER NOTE
Only use original Buderus spare parts.
Losses caused by the use of parts not
supplied by Buderus are excluded from the
Buderus warranty.
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.
zDo not carry out electrical work unless
you are qualified for this type of work.
zBefore opening a unit: disconnect
electrical power completely and lock to
prevent accidental reconnection.
zObserve the installation regulations.

Safety1
6Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005
We reserve the right to make any changes due to technical modifications.
1.3.3 Information on the boiler room 1.4 Tools, materials and accessories
You need standard tools for the installation and
maintenance of the boiler as used in heating system
installation 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 agents
for wet cleaning
1.5 Disposal
zDispose of the packaging material in an
environmentally compatible fashion.
zDispose of any components of the heating system
that require replacement in an environmentally
compatible fashion.
WARNING!
RISK TO LIFE
by poisoning.
Insufficient ventilation during operation
requiring room ventilation may cause
dangerous flue gas leaks.
zMake sure that inlets and outlets are not
reduced in size or closed.
zIf faults are not corrected immediately,
the boiler must not be operated.
zInform the system operator of the fault
and the danger in writing.
WARNING!
RISK TO LIFE
by poisoning.
When working on the flue gas monitoring
equipment leaking flue gas may endanger
the lives of people.
zDo not attempt to repair the flue gas
temperature sensor.
zUse only original parts when replacing
parts.
zWhen replacing the flue gas
temperature sensor install the new one
in the specified position.
WARNING!
RISK TO LIFE
by poisoning by leaking flue gas.
If the flue gas monitor trips frequently,
there may be a problem with the chimney
or the flue gas venting.
zIf the flue gas monitor trips frequently
the fault must be corrected and a
function test must be conducted.
WARNING!
RISK TO LIFE
by poisoning by leaking flue gas.
zMake sure that the boiler is not fitted
with a thermally controlled flue gas
baffle after the back flow check.
WARNING!
FIRE DANGER
due to flammable materials or liquids.
zMake sure that there are no flammable
materials or liquids in the immediate
vicinity of the boiler.

Product description 2
7
We reserve the right to make any changes due to technical modifications.
Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005
2 Product description
The boiler is a low temperature gas-fired boiler.
The boiler consists of:
–Aquastat (control unit)
–Logamatic 2107 control (optional control)
–Boiler jacket and front panel
–Boiler block with insulation
–Burner
The control monitors and controls 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 heater water. The insulation prevents
energy loss.
Fig. 1 Logano GA124 boiler
1Burner
2Boiler jacket
3Boiler block with insulation
4Logamatic 2107 control (optional)
5Aquastat (control unit)
6Boiler front panel
6
1
3
5
2
4
USER NOTE
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.

8Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005
We reserve the right to make any changes due to technical modifications.
Dimensions and connections3
3 Dimensions and connections
Tab. 1 Dimensions
Fig. 2 Back, side and front view, measurements in inches
1Combustion air line connection
2Flue gas line
VK
RK
1
2
GAS
EL
Connections (measurements see the following tables):
VK = Boiler supply - 1"
RK = Boiler return - 1"
EL = Drain - 1/2"
GAS = Gas connection - 1/2"
Boiler
size
Boiler
output
Combustion
air
connection
Flue gas
connecti
on
A B Min. overflow
valve cap.
Number of
orifices
Water
volume
Empty
weight
MBtu/hr Inches Inches Inches Inches lb/hr Qty US gal. lbs
17 59 3" 3" 7 1/5" 3 1/10" 62 2 2.4 229
23 79 3" 3" 8" 6 2/3" 86 32.9 240
30 104 3" 3" 9 1/5" 10 1/5" 110 4 3.4 337
Fig. 3 Pressure gradient
flowrate in GPM
Pressure drop
USER NOTE
For the size and dimensions of the main
gas orifice see ÎChapter 13, page 80.

Scope of delivery 4
9
We reserve the right to make any changes due to technical modifications.
Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005
4 Scope of delivery
zCheck packaging on delivery for damage.
zCheck delivery for completeness.
1On pallet
Component Qty Packaging
Boiler, complete 1 1 pallet
B-kit components:
- supply manifold
11 foil package1
- 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 for
horizontal flue system
1 separate
packaging unit
- technical documents 11 foil package
Tab. 2 Scope of delivery
Optional Accessories1Unit
Logamatic 2107 control 1
Heat circulation pump 1
Cleaning brush 1
Vertical flue system 1
Tab. 3 Accessories
1Accessories available by separate order

10 Installation and maintenance instructions Logano GA124 special gas-fired boiler • Issue 04/2005
We reserve the right to make any changes due to technical modifications.
Moving the boiler5
5 Moving the boiler
This chapter describes how to move the boiler safely,
5.1 Moving the boiler with boiler cart
Move the boiler with packaging and on pallet as much as
possible.
zPosition transport equipment (e.g. boiler cart) at the
back of the boiler.
zSecure boiler to cart.
zMove the boiler to the installation location.
CAUTION!
SYSTEM DAMAGE
due to bumps.
zCheck the transport diagrams on the
packaging to protect the sensitive
components from damage by bumping.
USER NOTE
zProtect the boiler connections from dirt
if the boiler is not installed immediately.
USER NOTE
Dispose of the packaging material in an
environmentally compatible fashion.
Fig. 4 Moving boiler with trolley
CAUTION!
RISK OF INJURY
if the boiler is not properly secured to the
boiler cart.
zUse suitable transport equipment, such
as a boiler cart with a belt.
zSecure the boiler to prevent it from
falling.