Buderus Logano GA244-37 Manual

6302 9763 – 02/2004 US/CA For the contractor
Please read these instructions carefully
Instructions for High Altitude
Conversion
Sealed Combustion
Gas Boiler Logano GA244
Required Sealevel Input Rates 0–2000 ft
GA244-37
156 MBtu/hr
GA244-44
182 MBtu/hr
GA244-53
220 MBtu/hr
GA244-62
259 MBtu/hr
Warning!
This conversion kit shall be installed by
a qualified service agency in
accordance with the manufacturer's
instructions and all applicable codes
and requirements of the authority
having jurisdiction and in accordance
with the requirements of the CAN/CSA
B149.1 or CAN/CSA B149.2 installation
codes.
Warning!
Please observe the instructions
regarding conversion from natural gas
to propane.
This kit and instructions are for converting the GA244 model Boilers to high
altitude operation.
Notice! Save these instructions for later use.

Instructions for High Altitude Conversion
2
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 02/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
1 Safety Considerations
Please observe the following safety instructions.
1.1 Application purpose
This kit and instructions are for high altitude converting
the GA244 model boiler over 2000 ft.
1.2 Guideline of notices
Two levels of danger are identified by the following
warning labels:
1.3 Observe the following symbols
2 Parts List for High Altitude
Conversion
This kit contains the following parts:
–Main orifices and gaskets.
–Conversion data plate to be filled out and affixed to
the appliance.
–Conversion instructions.
–Technical documents.
WARNING!
DANGER
Denotes a possible severely dangerous
situation where, without proper caution,
bodily injury or loss of life may result.
WARNING!
DANGER
due to electricity.
APPLICATION NOTICE
Application comment for optimum use of
equipment and adjustment as well as useful
information.
WARNING!
DANGER
due to explosion of gas.
zWork only on gas components when
you have a license to do so.
zNote that the assembly of gas and vent
connections, the initial start-up, the
electrical connections, the
maintenance and service can only be
performed by a licensed service
contractor or technician.
WARNING!
DANGER
due to electricity.
zPrior to doing any work on the heating
system, disconnect all electrical power
to the boiler at the emergency switch.
zIt is NOT sufficient to shut off only the
boiler control!

Instructions for High Altitude Conversion
3
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 02/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
3 High Altitude Conversion over 2000 feet
For your safety, read these instructions before
converting the boiler.
To convert the boiler for use at high altitude, the
following instructions shall be adhered to:
The boiler shall be converted prior to installation.
1. If the boiler has been in operation, shut off the main
gas shut-off valve. If the boiler has not been
placed into service, go to step 3.
2. Turn off all electric power to the appliance and set
the thermostat to its lowest setting.
3. Remove jacket panel screws (Fig. 1, Pos. 1) from
left and right side, tilt forward top of the front panel
(Fig. 1, Pos. 2) then lift up from the bottom and
remove.
4. Remove side cover plate screws (Fig. 2, Pos. 1)
from the right jacket panel (Fig. 2, Pos. 3), and
remove the side cover plate (Fig. 2, Pos. 2).
Fig. 1 Removal of front jacket panel
Item. 1: Jacket panel screws
Item. 2: Front jacket panel
1
2
1
WARNING!
DANGER
When these instructions are not followed.
zWhen the boiler must be converted to
Propane, you should first convert the
boiler from natural gas to propane by
following the Propane Conversion Kit
Instructions. Afterwards convert the
boiler to high altitude.
Fig. 2 Removal of side cover plate
Item. 1: Side cover plate screws
Item. 2: Side cover plate
Item. 3: Right hand jacket panel
1
1
2
3

Instructions for High Altitude Conversion
4
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 02/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
5. Turn the gas control valve knob (Fig. 3, Pos. 1)
clockwise to the “OFF“ position. Do not use
excessive force.
Change out main orifices
6. Remove the burner tray cover plate screws (Fig. 4,
Pos. 1) from the cover plate (Fig. 4, Pos. 2) and
remove this cover plate (Fig. 4, Pos. 2).
Fig. 3 Gas control valve
Item. 1: Gas control valve knob (set to “ON“)
1
WARNING!
DANGER
For explosion due to gas.
zWait five (5) minutes to clear out any
gas. Then smell for gas, including near
the floor. If you smell gas, STOP!
Follow "B" instructions in the safety
information printed on page 7. If you do
not smell gas, go to the next step.
NOTICE
For the conversion to high altitude, you
only need to change out the main orifices
and not the pilot orifice.
DANGER!
DANGER
due to incorrect wiring.
zLabel all wires prior to disconnecting
when servicing controls.
Fig. 4 Gas burner
Item. 1: Burner tray cover plate screws
Item. 2: Burner cover plate
2
1

Instructions for High Altitude Conversion
5
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 02/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
7. Install the new orifices (Fig. 5, Pos. 1) and washers
(Fig. 5, Pos. 2) supplied with the kit. Ensure orifices
are the proper size for your boiler application per
Table. 1 and Table. 2.
8. Install the burner tray cover plate on the burner tray
assembly in reverse order of removal. Ensure the
nuts are tightened firmly.
9. Fill out the required information on the conversion
plate and affix the plate to the outside of the boiler
jacket as close as possible to the existing rating
label.
Testing for Leaks
10. If the boiler has not been placed in operation, follow
the installation instructions in GA244 Installation,
Operation and Maintenance Manual supplied with
the boiler. If the boiler has been in operation, then
open the main gas shut-off valve. Test the gas
piping on the input side of the gas control (Fig. 6) for
leaks by applying a soap and water solution. If no
leaks are found, go to step 12. If any leaks are found,
shut off the main gas shut-off valve.
11. Repair leaks and repeat step 10.
Fig. 5 Installation fo main orifices
Item. 1: Main orifice
Item. 2: Washer (copper)
1
2
Orifice Sizes for Natural Gas Firing
at High Altitude in Feet
Model
GA244-37
GA244-44
GA244-53
GA244-62
Table. 1 Orifice sizes for Natural gas
Orifice Sizes for Propane Conversion
at High Altitude in Feet
Model
GA244-37
GA244-44
GA244-53
GA244-62
Table. 2 Orifice sizes for Propane
0–8500 8501–12000
3.00 2.95
3.25 3.20
3.20 3.15
3.15 3.10
0–8500
1.95
2.15
2.10
2.20
8501–12000
1.90
2.10
2.05
2.15

Instructions for High Altitude Conversion
6
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 02/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
12. Shut off the main gas supply shut-off valve. Remove
the line pressure tapping plug (Fig. 6, Pos. 2) from
the gas control. Install a test fitting and hook up a
manometer to measure the supply pressure.
13. Remove the manifold pressure tapping plug (Fig. 6,
Pos. 3) from the gas control. Install a test fitting and
hook up a manometer to measure the manifold
pressure.
14. Open the main gas piping shut-off valve and
measure the supply pressure of the boiler. The
supply pressure must be between 4.7 and 10.5
inches of water column for Natural gas or 11 and 13
inches water column for Propane. If the pressure is
not between 4.7 and 10.5 inches water column for
Natural gas (or 11 and 13 inches water column for
Propane), when boiler is running, call your service
technician or gas supplier.
15. Follow the lighting instructions on the next page.
Fig. 6 Gas control valve
Item. 1: Gas control knob (set to “ON“)
Item. 2: Supply pressure test port
Item. 3: Manifold pressure test port
3
2
1

High Altitude Conversion over 2000 feet 3
7
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 02/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
3.1 Lighting Instructions
For your safety, read belore lighting. A) This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
B) Check for smell of gas around the appliance area.
Be sure to smell next to the floor because some gas
is heavier than air and will settle on the floor.
C) Use only your hand to turn the gas control knob.
Never use tools. If the knob will not turn by hand,
don't try to repair it, call a qualified service
technician. Force or attempted repair may result in
a fire or explosion.
D) Do not use this appliance if any part has been under
water. Immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.
WARNING!
DANGER
due to incorrect service and maintenance.
zIf you do not follow these instructions
exactly, a fire or explosion may result
causing property damage, personal in-
jury or loss of life.
zFollow these operating instructions.
WARNING!
DANGER !
What to do if you smell gas:
zNo open fire! Do not smoke!
zAvoid formation of sparks! Do not
touch any electric switch, phone,
electric plug or bell!
zShut off main gas supply.
zOpen windows and doors!
zNotify all occupants!
zLeave the building!
zImmediately call your gas supplier,
heating contractor or fire department
from a phone outside the building!!

Instructions for High Altitude Conversion
8
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 02/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
4 Operating Instructions
STOP! Read the safety precautions on page 7 of this
manual.
1. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "B" in the safety information on
page 7. If you do not smell gas, go to the next step.
2. Locate the pilot assembly by looking through the
access viewing port (Fig. 7, Pos. 1) on the burner
front plate.
3. Turn the gas control knob (Fig. 8, Pos. 1)
counterclockwise to “ON“.
4. Turn on the electrical power to the application.
5. Set the thermostat to the desired setting to activate
the boiler (Thermostat should be at least 10 °F
above the desired room tmeprature).
6. The ignition control should initiate sparking at the
pilot. The pilot should light and then the main
burners should light. If the main burners do not light,
shut off the main gas piping shutoff valve. Shut off
all electric power to the appliance and call your
service technician or gas supplier.
7. If the main burners light, then the gas fittings, union
and orifices must be tested for leaks with a soap and
water solution. If no leaks are found then go to step
9. If any leaks are found, turn off gas control knob
(Fig. 8, Pos. 1) clockwise to “OFF“. Turn off all
electric power to the appliance, set the thermostat to
lowest setting.
8. Repair leaks. Repeat steps 1 through 7.
9. Check the supply pressure while the boiler is
running. Pressure must be between 4.7 and 10.5
inches water column for Natural gas or 11 and 13
inches water column for Propane gas. Record
supply pressure on the boiler start-up procedure.
Fig. 7 Front view
Item. 1: Viewing port
1
Fig. 8 Gas control valve
Item. 1: Gas control knob (set to “ON“)
Item. 2: Test port for gas supply measurements
Item. 3: Test port for manifold pressure measurement
Item. 4: Protective screw for pilot pressure adjustment
Item. 5: Protective screw for manifold pressure adjustment
1
2
3
4
5

Instructions for High Altitude Conversion
9
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 02/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
10. Check manifold pressure. Set the manifold pressure
according to the values in Table 3. To adjust the
manifold pressure (Fig. 8, Pos. 5) remove the
capscrew from the gas control. Turn the pressure
regulating adjusting screw clockwise to increase, or
counterclockwise to decrease the manifold
pressure. This adjustment must be made while the
boiler is in operation.
11. After adjustment, record pressure in the start-up
procedure, and install the capscrew on the gas
control (Fig. 8, Pos. 5).
12. Observe the pilot flame (Fig. 9, Pos. 2) through
viewing port (Fig. 7, Pos. 1) in the burner cover
plate. The flame should envelop the flame sensor ½
- 1-½ inch, see (Fig. 9, Pos. 1). If the pilot flame is
satisfactory then go to step 13. If the pilot flame is
too small or too large, adjust the pilot using pilot
adjustment. Turn the inner adjustment screw
(Fig. 8, Pos. 4) clockwise to decrease, or
counterclockwise to increase the pilot flame. After
adjustment, replace the cover screw and tighten
firmly (Fig. 8, Pos. 4).
13. Observe the main burner flame (Fig. 10, Pos. 1)
through the viewing port (Fig. 7, Pos. 1) in the
burner cover plate. The flame should have a
smooth, firm contour and must be mostly blue in
color. If the main flame is satisfactory, go to step 14.
If the main burner flame is lazy, yellow, or lifting off
the burners, turn the gas control knob (Fig. 8,
Pos. 1) clockwise to “OFF“. Shut off the main gas
piping shutoff valve. Disconnect all electric power to
the appliance and call your service technician or gas
supplier.
14. The ignition safety shut-off must be tested. Test the
safety shut-off by shutting off the main gas piping
shut-off valve.
The main burner and pilot flame (Fig. 9, Pos. 2) will
extinguish. Within six (6) seconds the gas control
main gas solenoid should close and make an
audible sound. The ignition will spark.
After 90 seconds, the module should go into lock out
mode and the spark should stop. Disconnect the
electric power to the appliance. Open the main gas
shutoff valve. Turn on the electric power to the unit.
A normal operating sequence should occur. If the
gas control functions satisfactorily then go to step
15. If the gas control does not function satisfactorily,
immediately turn the gas control knob (Fig. 11,
Pos. 1) clockwise to "OFF".
GA244 Natural gas
[inch W.C.]
Propane
[inch W.C.]
37 3.77 8.03
44 3.65 7.63
53 3.73 8.11
62 3.77 6.15
Table. 3 Required manifold pressure
Fig. 9 Proper pilot flame
Item. 1: 1/2“ to1 1/2“
Item. 2: Flame
12
Fig. 10 Main burner
Item. 1: Main burner flame
1

Instructions for High Altitude Conversion
10
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 02/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Shut off the main gas piping shut-off valve.
Disconnect all electric power to the appliance and
call your service technician or gas supplier.
15. Turn the gas control knob (Fig. 11, Pos. 1)
clockwise to “OFF“.
16. Shut the main gas piping shut-off valve.
17. Turn off electric power to the appliance, and set the
thermostat to the lowest setting.
18. Remove the pressure test fittings from the gas
supply and manifold pressure tabs in the gas control
and replace the plugs.
19. Repeat steps 1 to 6, and 13 to place the appliance
back in operation. Check the plugs in the gas control
with a soap and water solution. If no leaks are found
go to step 21. If any leaks are found, shut off the
main gas piping shutoff valve and turn off all electric
power to the appliance and turn the gas control knob
(Fig. 11, Pos. 1) clockwise to "OFF“.
20. Repair leaks. Open the main gas shut-off valve and
repeat step 19.
21. Wash off the soap and water solution used to test for
leaks to ensure no corrosive effects from the soap.
22. Check the high limit aquastat operation to ensure
that it shuts off the boiler when the boiler water
temperature reaches the setpoint of the aquastat.
Record on start-up procedure form.
23. Replace the front boiler jacket panel.
Fig. 11 Gas control valve
Item. 1: Gas control knob
1

Notice
11
We reserve the right to make any changes due to technical modifications!
Instructions for High Altitude Conversion for Sealed Combustion Gas Boiler GA244 • Issue 04/2004
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

Buderus Hydronic Systems
50 Wentworth Avenue
Londonderry, NH 03053
Tel: [phone] • Fax: [phone]
www.buderus.net
Buderus Hydronic Systems, reserves the right to make changes without
notice due to continuing engineering and technological advances
Contractor: