Buderus Logano GE515 User manual

Installation and maintenance
instructions
Oil- and gas-fired
boilers
Logano GE515
6 720 617 718 - 07/2008 GB
For heating engineers
Please read carefully prior
to installation and
maintenance.

Preamble
Logano GE515 - We reserve the right to make any changes due to technical modifications.2
Regarding these instructions
These installation and maintenance instructions contain
important information for the safe and correct
installation, initial start-up and maintenance of the
Logano GE515 oil- and gas-fired special boiler.
These installation and maintenance instructions are
designed for specialists, who, due to their vocational
training, are knowledgeable and experienced in
handling heating systems and oil/gas installations.
The Logano GE515 oil- and gas-fired special boiler may
be supplied as one of two versions (in loose sections or
pre-assembled).
These installation and maintenance instructions explain
the installation and maintenance on the example of boi-
lers supplied as loose sections and as pre-assembled
blocks.
This device meets all basic requirements of
relevant European standards and
guidelines.
Its conformity has been verified. All
associated documents and the original of
the Declaration of Conformity are available
from the manufacturer.
Subject to technical modifications.
Constant development may lead to minor deviations in
the illustrations, functional steps and specifications
described/shown.
Updating your documentation
Please let us know if you would like to make suggestions
to improve our documentation or if you have noticed any
errors.

Index
Logano GE515 - We reserve the right to make any changes due to technical modifications. 3
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.2 Notes structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.3 Please observe these notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.1 Operating conditions for Buderus G and GE cast iron boilers. . . . . . . . . . . . . . . . .9
3.2 Operating conditions GE 515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Logano GE515 – delivery as ready assembled unit . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Logano GE515 – delivery in sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Boiler handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Boiler positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.1 Tools and accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.2 Recommended wall clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.3 Positioning the boiler on a sub-structure or on foundations . . . . . . . . . . . . . . . . . 17
8 Boiler block assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.1 Arrangement of boiler sections within the boiler block . . . . . . . . . . . . . . . . . . . . 19
8.2 Joining the boiler block assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.3 Positioning the boiler block – for pre-assembled deliveries . . . . . . . . . . . . . . . . . 26
8.4 Sliding the feed pipe into place (carton of installation components) . . . . . . . . . . . . 27
8.5 Seal-in the sensor well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.6 Leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.7 Boiler water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.8 Installing boiler fittings and the burner door . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.9 Installing the boiler shell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9 Boiler flue connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.1 Fit the flue pipe sealing collar (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.2 Fitting the flue gas temperature sensor (accessory) . . . . . . . . . . . . . . . . . . . . . 45
10 Installing the control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10.1 Installing the control device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10.2 Installing the temperature sensor set and burner cable . . . . . . . . . . . . . . . . . . . 47
11 Burner installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12 System start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.1 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.2 Making the system operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Index
Logano GE515 - We reserve the right to make any changes due to technical modifications.4
12.3 Commissioning the control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.4 Start up the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.5 Raising the flue gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12.6 Commissioning report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13 System shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
13.1 Shutting down the system via the control device . . . . . . . . . . . . . . . . . . . . . . . 55
13.2 Shutting down the system in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . 55
14 System inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14.2 Why is regular maintenance important? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14.3 Cleaning the boiler with cleaning brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
14.4 Wet-cleaning the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
14.5 Checking the system water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
14.6 Inspection and maintenance reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
15 Correcting burner faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
16 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

General 1
Logano GE515 - We reserve the right to make any changes due to technical modifications. 5
1 General
USER NOTE
Observe any standards and guidelines
applicable to the installation and operation
of this system, as may apply in your
country.
Please note the details on the boiler rating
plate. These are decisive and must be
observed.
Operating conditions and time constants Switzerland All other countries
Maximum flow temperature °C 110 100–1201
Maximum operating pressure bar 6 6
Control thermostat s40 40
Contactor/limiter s40 40
Fuels
Logano GE515 Fuel oil EL LPG Natural gas Bio gas (special
operating conditions)
Comments
The Logano GE515 boilers can be operated with the indicated fuels. Select a burner which operates with
one of the fuels listed as suitable for the Logano GE515 boiler.
The rated output details listed in the "Specification" table are nominal ratings.
Please note for
Switzerland In reality the stated values will – regarding compliance with the LRV – not always be achieved.
Please note for
Poland
In accordance with PN-91/B-2414 (p.2.5), boilers with a rated output higher than 100 kW should be
equipped with a low water indicator (SYR type 933.1) on site.
1 In accordance with national standards and guidelines.

Safety
2
Logano GE515 - We reserve the right to make any changes due to technical modifications.6
2 Safety
For your own safety, observe these safety instructions.
2.1 Correct use
The Logano GE515 oil- and gas-fired special boiler was
designed for the heating of central heating water. You
may use any type-tested oil-fired or gas-fired burners
acc. to EN 267 or EN 676 provided their operating range
correlates with the boiler specification.
These boilers are operated with the 4000 series control
systems.
2.2 Notes structure
Two levels are identified and identified by signal terms:
Further symbols identifying dangers and user notes:
WARNING!
DANGER TO LIFE
Identifies possible dangers emanating
from a product, which might lead to serious
injury or death, if appropriate care is not
taken.
CAUTION!
DANGER OF INJURY/
SYSTEM DAMAGE
Identifies potentially dangerous situations,
which might lead to medium or slight
injuries or to material losses.
WARNING!
DANGER TO LIFE
from risk of electric shock.
USER NOTE
User tip for the optimum utilisation and
setting of the device(s) plus useful
information.

Safety 2
Logano GE515 - We reserve the right to make any changes due to technical modifications. 7
2.3 Please observe these notes
WARNING!
DANGER TO LIFE
through the explosion of volatile gases.
zWork on gas components must only be
carried out by qualified and authorised
personnel.
WARNING!
DANGER TO LIFE
from risk of electric shock.
zBefore work is undertaken on the
heating equipment, isolate the system
from the mains supply, e.g. by
switching the off the emergency stop
switch outside the boiler room.
zSwitching off control devices does not
provide sufficient isolation.
CAUTION!
SYSTEM DAMAGE
through inadequate cleaning and
maintenance.
zCarry out cleaning and maintenance
annually. In the course of this work,
check the entire system for perfect
function.
zImmediately remedy all faults to prevent
damage to the system.
USER NOTE
To prevent boiler contamination, we
strongly recommend the installation of a
dirt trap on the water supply side.
CAUTION!
SYSTEM DAMAGE
through deposits, local overheating, noise
and corrosion.
zFlush existing systems before
connecting the boiler.
zPrevent boiler damage by installing de-
sludging equipment into the system
return.

Product description
3
Logano GE515 - We reserve the right to make any changes due to technical modifications.8
3 Product description
The special Logano GE515 oil- and gas-fired boiler may
be supplied with or without burner. The burner plate is
supplied without holes. However, Buderus can supply
drilled burner plates (hole pattern subject to burner) as
accessory.
For Logano GE515 with pressure jet oil or gas burner, a
drilled burner plate is part of the standard delivery.
The main components of the Logano GE515 oil- and
gas-fired special boiler are:
–Boiler block (Fig. 1, [3]).
The boiler block transfers the heat generated by the
burner to the heating water.
–Boiler shell (casing, Fig. 1 and Fig. 2, [1]), thermal
insulation (Fig. 1, [2]).
Boiler shell and thermal insulation prevent energy
loss.
–Control device (Fig. 1, [4]).
The control device is designed to monitor and control
all electrical components of the Logano GE515 oil-
and gas-fired special boiler.
Fig. 1 Logano GE515 oil- and gas-fired special boiler
1Boiler shell (casing)
2Thermal insulation
3Boiler block
4Control device
Fig. 2 Logano GE515 oil- and gas-fired special boiler
1Boiler shell (casing)
2
3
4
1
1
1
1
1
CAUTION!
SYSTEM DAMAGE
through incorrect burner.
zOnly use burners which meet the
technical preconditions of the Logano
GE515 oil- and gas-fired special boiler
(see chapter 4 "Specification",
page 10).

Product description 3
Logano GE515 - We reserve the right to make any changes due to technical modifications. 9
3.1 Operating conditions for Buderus G and GE cast iron boilers
Thermostream technology is a unique feature of Buderus cast iron boilers. Return water is preheated and mixed within
the boiler before it comes in contact with the heated surface of the combustion chamber. The Thermostream technology
ensures there is an even temperature distribution in the boiler and avoids condensate forming within the combustion
chamber. This reduces thermal stress, the main cause of failure of normal cast iron boilers. The benefit of this
technology is that if the minimum boiler operating temperature of the boiler is maintained (Ætable below), there is no
need for a conventional shunt pump to be installed, saving the cost of a pump, the electricity it consumes and the
breakdown it can cause. The minimum boiler operating temperature as shown in the table below must be reached within
10 minutes and then be maintained while the burner is running.
3.2 Operating conditions GE 515
1) This temperature has to be reached within ten minutes of the burner starting and has to be maintained whilst the burner is firing.
This operating condition can be easily achieved by the controls monitoring the boiler temperature and reducing the flow
rate through the boiler until the required temperature is reached. This is then maintained by continuing to control flow
based on the boiler temperature. The controls can reduce the flow rate by closing the valves on the mixed heating
circuits or by modulating the boiler primary pumps or by closing the motorised butterfly valves or by having a motorised
valve in the boiler return on a single boiler installation. The Buderus 4000 series controls can manage this process or
it can be done by the BMS.
If it is not possible for the controls to regulate the flow sufficiently to meet this operating condition then a shunt pump
circuit must be fitted to avoid the type of thermal stress that all boilers would experience in these conditions. This shunt
pump circuit can be controlled either with a Buderus 4000 control or with a Buderus 4212 fitted with a ZM427 module.
Failure to ensure that the operating condition is maintained may lead to thermal stress in the boiler and eventual failure
of the sections which would be outside the scope of the warranty.
Boiler controls Minimum flow
rate through the
boiler
Minimum return
water
temperature
Minimum boiler
operating
temperature for
oil
Minimum boiler
operating
temperature for
gas
Other conditions
Buderus 4000 with
control over all
heating circuits
none none 50 degrees1) 50 degrees1) none
Where the
Buderus control is
not controlling the
heating circuits ie
External control
(BMS) or
Constant
temperature
control with
Buderus 4212 with
ZM427
none none 50 degrees1) 60 degrees1) none

Specification
4
Logano GE515 - We reserve the right to make any changes due to technical modifications.10
4 Specification
The specification provides information about the Logano
GE515 output profile.
Fig. 3 Logano GE515 specification (dimensions in mm)
1 Connection flange reduced in accordance with order to DN 100, DN 80 or DN 65.
2 Fill the boiler and the system via a separate connector in the return pipe.
3 The drain cock (EL) is only suitable for draining the system, not for filling.
EL
LK
L
RK
VK
=
=
=
=
=
Drain connection (Rp ¾")
Length of boiler block
Overall boiler length
Boiler return connection
Boiler flow connection
Logano GE515
Boiler size 240 295 350 400 455 510
Boiler sections Number 78910 11 12
Rated output kW 201–240 241–295 296–350 351–400 401–455 456–510
Combustion output kW 215.6–259.7 257.8–319.0 316.6–377.1 374.6–429.6 428.4–489.2 488.2–547.8
Overall boiler length (L) mm 1580 1750 1920 2090 2260 2430
Length of boiler block
(LK)mm 1360 1530 1700 1870 2040 2210
Boiler section transport
dimension mm width 835 / height 1315 / depth 170
Boiler block handling mm width 835 / height 1315 / length LK
Length of combustion
chamber mm 1165 1335 1505 1675 1845 2015
Diameter of combustion
chamber mm 515
Depth of burner door mm 142
Net weight1kg 1270 1430 1590 1753 1900 2060
Boiler water content l258 294 330 366 402 438
Gas capacity l421 487 551 616 681 745
1 Weight incl. packaging approx. 6–8% higher.

Specification 4
Logano GE515 - We reserve the right to make any changes due to technical modifications. 11
Logano GE515
Boiler size 240 295 350 400 455 510
Flue gas temperature2,
part load (60 %) °C 138 138 140 129 130 140
Flue gas temperature2,
full load °C 164–183 161–183 161–177 157–171 159–172 164–174
Flue gas volume flow,
oil, part load (60 %) kg/s 0.0647 0.080 0.094 0.108 0.123 0.137
Flue gas volume flow,
oil, full load3kg/s 0.092–0.110 0.109–0.135 0,134–0,160 0.159–0.182 0.182–0.208 0.207–0.233
Flue gas volume flow,
gas, part load (60 %) kg/s 0.065 0.080 0.095 0.108 0.123 0.138
Flue gas volume flow,
gas, full load3kg/s 0.092–0.111 0.110–0.136 0.135–0.161 0.160–0.183 0.183–0.208 0.208–0.233
CO2 content, oil %13
CO2 content, gas %10
Required pressure
(draught) Pa 0
Flue gas resistance mbar 0.5–0.6 1.0–1.4 1.1–1.6 2.1–2.9 2.5–3.3 2.4–3.1
Maximum permissible
flow temperature4°C 100–1205
Maximum permissible
operating pressure bar 6
Type approval number, boiler 06-226-640
CE designation, boiler CE - 0461 AR 6154
2 Acc. to DIN 303. The minimum flue gas temperature for the chimney calculation is approx. 12 K lower.
3 Full load details relate to the upper and lower rated output range.
4 High limit safety cut-out (safety limit thermostat). Max. possible flow temperature = safety limit (STB) –18 K. Example: Safety limit (STB)= 100 C;
max. possible flow temperature = 100 – 18 = 82 °C.
5 In accordance with national standards and guidelines.

Standard delivery
5
Logano GE515 - We reserve the right to make any changes due to technical modifications.12
5 Standard delivery
The Logano GE515 boiler can be supplied as ready
assembled block or in individual boiler sections.
zUpon receipt, check the boiler is in perfect condition.
zCheck the delivery for completeness.
5.1 Logano GE515 – delivery as ready
assembled unit
5.2 Logano GE515 – delivery in sections
Component Piece Packaging
Boiler block with burner door and
flue gas collector 1 Pallet
Assembly components
(longitudinal rails and feed pipe) 1Carton
Casing pack A, B, C
(depending on boiler size) 1–3 Cartons
Thermal insulation 1PU sack
Component Piece Packaging
Front and rear section plus burner
door 1Pallet
Central sections – depending on
boiler size 1–2 Pallet
Furniture 1Carton
Flue gas collector 1Carton
Anchor rods 1Bundle
Assembly components
(longitudinal rails and feed pipe) 1Carton
Casing pack A, B, C
(depending on boiler size) 1–3 Cartons
Thermal insulation 1PU sack

Boiler handling 6
Logano GE515 - We reserve the right to make any changes due to technical modifications. 13
6 Boiler handling
Handle the individual boiler sections (loose delivery)
plus other individual components with suitable means of
transportation.
CAUTION!
DANGER OF INJURY
through inadequately secured boiler
sections.
zFor your own safety, use only suitable
means of transportation when handling
individual boiler sections, e.g. a sack
truck with strap or a stair truck, etc.
zWhen handling, secure the boiler
sections to the means of transport to
prevent them slipping.
CAUTION!
SYSTEM DAMAGE
through impact.
The standard delivery of the Logano
GE515 oil- and gas-fired special boiler
comprises components which are
sensitive to impact.
zWhen handling the boiler (sections),
protect electronic and other
components against impact.
zPlease note the handling references on
the packaging.
CAUTION!
SYSTEM DAMAGE
through contamination.
Note the following if the boiler is to be
stored in its assembled condition:
zProtect boiler connections by closing or
sealing them off.
USER NOTE
Dispose of packaging in an
environmentally responsible manner.

Boiler positioning
7
Logano GE515 - We reserve the right to make any changes due to technical modifications.14
7 Boiler positioning
In this chapter you will learn how to correctly position the
Logano GE515.
7.1 Tools and accessories
The following tools and auxiliary materials are required
for the boiler assembly (the listed items must be
provided by the installer):
–Boiler compression tool 2.2 (Fig. 4, page 15)
or 2.3 (Fig. 5, page 15)
–Boiler installation template for fitting the boiler
sections together
–Steel hammer and wooden or rubber mallet
–Half-round bastard file
–Screwdrivers (Philips and flat bladed)
–Flat chisel
–Spanner SW 13, 19, 24, 36 and Allen key SW 19
–Support wedge, flat iron
–Cleaning rags and cloth
–Fine emery cloth
–Wire brush
–3-in-1 oil
–Solvent (petrol or solution)
–Spirit level, ruler, chalk, straight edge
–Blanking flange with vent facility (for pressure test)
CAUTION!
SYSTEM DAMAGE
through frost.
zInstall the system in a room which has
been protected from frost.

Boiler positioning 7
Logano GE515 - We reserve the right to make any changes due to technical modifications. 15
7.1.1 Boiler compression tool size 2.2
7.1.2 Boiler compression tool 2.3
(complete in the toolbox)
Fig. 4 Boiler compression tool size 2.2 (dimensions in mm)
1Mating flange
2Additional flange
3Compression unit
4Pull rod
5Extension
6Cylindrical pin (size 2.2)
1
23
45
6
Boiler
sections
Compression
tool per
boiler hub
Extension
piece per
boiler hub
Dimensions
(overall) in
mm
7–10 1 0 2160
11–12 1 1 2760
Fig. 5 Boiler compression tool size 2.3 (dimensions in mm)
1Mating flange
2Additional flange
3Compression unit
4Pull rod
5Extension
6Wedge (size 2.3)
6123
45
Boiler
sections
Compression
tool per
boiler hub
Extension
piece per
boiler hub
Dimensions
(overall) in
mm
7–12 1 3 3080

Boiler positioning
7
Logano GE515 - We reserve the right to make any changes due to technical modifications.16
7.2 Recommended wall clearances
You may hang the burner door for l.h. or r.h. opening (in
the "as delivered condition" the door will be hinged on
the r.h. side).
When installing your boiler, please maintain the
recommended minimum dimensions (shown in
brackets). Select the recommended clearances
between wall and boiler to enable easy access during
installation, maintenance and service work.
The distance from the wall on the hinge side must at
least permit the burner withdrawal (AB). We recommend
a distance between wall and boiler of AB + 100 mm.
If a front clearance less than the recommended
dimension A (Fig. 6) is chosen, you will not be able to
clean the boiler with the optional cleaning kit. As an
alternative we would recommend the use of shorter
(length approx. 1 m) cleaning devices or wet cleaning.
Fig. 6 Boiler room with boiler (dimensions in mm)
USER NOTE
zWe recommend you maintain the
indicated clearance between boiler and
walls, which is required in order to be
able to install the boiler and for opening
the burner door, as well as for cleaning
and maintaining your system (ÆFig. 6
and table below).
Boiler size Clearance A in mm
kW Boiler
sections
Recommen
-dation
There
follows
240–350 7–9 1700 1000
400–510 10–12 2200 1000

Boiler positioning 7
Logano GE515 - We reserve the right to make any changes due to technical modifications. 17
7.3 Positioning the boiler on a sub-
structure or on foundations
You can cast a concrete plinth if the optional boiler plinth
is not used. When casting the plinth, you must
incorporate a steel angle with the dimensions
100 x 50 x 8 mm or a steel strip with the dimensions
100 x 5 mm (ÆFig. 7 and the following table), to ensure
the boiler sections will slide into position during
installation.
It is advantageous to position the boiler on a plinth
50 - 80 cm high (Fig. 7, [1]). The support surface must
be perfectly flat and level. The front edge of the boiler
should be flush with the edge of the foundation.
Fig. 7 Foundation dimensions in mm
1
USER NOTE
As accessory Buderus offers a boiler plinth
designed to reduce body resonance.
USER NOTE
zWhen casting the foundation, note the
side to which the burner will be pivoted
(burner door hinged on the r.h. or l.h.
side, Fig. 6, page 16).
Number of
boiler sections
L1(foundation)
in mm
L2 (length of
steel section)
in mm
7 1360 1190
8 1530 1360
9 1700 1530
10 1870 1700
11 2040 1870
12 2210 2040

Boiler block assembly
8
Logano GE515 - We reserve the right to make any changes due to technical modifications.18
8 Boiler block assembly
Depending on the type of delivery, we distinguish
between delivery in loose sections and as ready
assembled block. For a delivery as block, the boiler
sections are pre-assembled and checked for leaks prior
to despatch. If, because of physical limitations, a boiler
block cannot be assembled as a complete unit, the on
site installation is carried out using loose components.
For the further installation of pre-assembled boiler
sections, Æchapter 8.3 "Positioning the boiler block –
for pre-assembled deliveries", page 26.
Fig. 8 Boiler block
1Plinth or vibration absorbing boiler plinth
2Flue gas collector
3Rear section
4Return connection
5Flow connection
6Centre section
7Anchor rod
8Arrow – assembly direction
9Front section
10 Burner door with burner plate
1
2
3
67
8
10
7
9
4
5
CAUTION!
DANGER OF INJURY
through inadequately secured boiler
sections.
zUse only suitable means of
transportation when handling individual
boiler sections, e.g. a sack truck with
strap or a stair truck, etc.
zWhen handling, secure the boiler
sections to the means of transport to
prevent them slipping.

Boiler block assembly 8
Logano GE515 - We reserve the right to make any changes due to technical modifications. 19
8.1 Arrangement of boiler sections within
the boiler block
The boiler block is assembled from the rear to the front,
commencing with the rear section (Fig. 8, [3],page 18).
Always assemble the front section (Fig. 8, [9], page 18)
last.
During assembly please observe the arrows denoting
the direction of installation (Fig. 8, [8]) and proceed
according to the following instructions and illustrations.
8.2 Joining the boiler block assembly
Prior to fitting the front and rear sections, remove the
nuts and washers from the bolts on the boiler section
hubs.
zRemove the clean-out covers on the rear section
(Fig. 10, [1] and [2]).
Fig. 9 Rear section with mounted installation template
CAUTION!
DANGER OF INJURY
through inadequately secured boiler
sections.
zWith the installation template, secure
the rear/end section against tipping.
Buderus supplies the installation
template (accessory) on request.
USER NOTE
zRemove the clean-out cover from the
rear section, if you are using the
installation template, to secure the
template.
Fig. 10 Remove the clean-out covers
2
1

Boiler block assembly
8
Logano GE515 - We reserve the right to make any changes due to technical modifications.20
zPosition the rear section and secure against tipping
over with the installation template (Fig. 11 and Fig. 9
as well as the separate installation instructions for
the installation template).
zRemove possible burrs from the hub using a file
(Fig. 12).
zClean the packing groove (Fig. 13, [3]) where
necessary using a wire brush and cloth.
zClean the hub sealing faces (Fig. 13, [1] and [2]) with
a cloth soaked in white spirit.
zCoat the hub sealing faces evenly with jointing
compound.
Fig. 11 Secure the installation template
Fig. 12 Remove burr
CAUTION!
DANGER OF BURNING
through flammable solvents.
zWhen using solvents, avoid naked
flames, incandescence and sparks.
zPlease observe the safety instructions
regarding any solvents used.
Fig. 13 Prepare packing grooves and hubs
2
1
3