Buderus Logano plus GB312 User manual

Please read thoroughly before use
6304 3563 – 06/2005 GB For the user
Operating instructions
Gas fired condensing boiler
Logano plus GB312

Contents
2Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
We reserve the right to make any changes due to technical modifications.
1 For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Notes regarding these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Please observe these notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4.1 If you smell gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4.2 Tips on the boiler room. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Components on the Logano plus GB312 boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 BC10 controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Operation of the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Switching on the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1.1 Starting the heating system via the control panel and programming unit . . . . . . . . . . . . 6
3.2 Switching off the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Emergency measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Checking the operating pressure, topping up with heating water and bleeding the system . . . 7
3.4.1 When should you check the operating pressure? . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.2 Checking the operating pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4.3 Filling the heating system and checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Why is regular maintenance important? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Recognising and resetting faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operating pressure
Use the following fuel only:
__________________________________
Design operating pressure
(optimum value): ______________ bar
Maximum heating system
operating pressure:
(standard = 3 bar) ______________ bar
Company stamp/date/signature

For your safety 1
3
We reserve the right to make any changes due to technical modifications.
Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
1 For your safety
1.1 Notes regarding these instructions
These installation and maintenance instructions contain
important information for the safe and correct
installation, initial start-up and maintenance of this
boiler.
In the following, the Logano plus GB312 gas-fired
condensing boiler will generally be referred to as the
boiler.
1.2 Correct use
The boiler is designed for generating heating water and
DHW, for example, in homes or apartment buildings.
1.3 Key to symbols
The following symbols are used in this manual:
ÎCross-references
Cross-references to a specific point or another
document are identified by an arrow Î.
1.4 Please observe these notes
You will learn how to use your heating system by
–letting your installer instruct you when the system is
handed over and
–reading these operating instructions carefully.
Do not carry out any work on the boiler that is not
described in these operating instructions.
1.4.1 If you smell gas
WARNING!
RISK TO LIFE
Identifies possible risks, which may lead to
serious injury or death if appropriate care is
not taken.
CAUTION!
RISK OF INJURY/
SYSTEM DAMAGE
Identifies hazardous situations, which
could lead to medium or slight injuries or to
material losses.
USER NOTE
Tip for the optimum utilisation and setting
of the control(s) plus other useful
information.
WARNING!
RISK TO LIFE
by employing unqualified personnel.
zInstallation, commissioning and
maintenance must only be carried out
by a specialist installer. Work on
electrical and fuel-bearing components
in particular must only be carried out by
suitably qualified personnel.
WARNING!
RISK TO LIFE
through the explosion of volatile gases.
If you can smell gas, there is a risk of
explosion.
zExtinguish all naked flames. Do not
smoke. Do not use lighters.
zPrevent sparks.
Do not operate electrical switches,
including telephones, plugs or door-
bells.
zClose the main gas shut-off valve.
zOpen windows and doors.
zWarn all occupants, but do not use
doorbells or mobiles or other electrical
devices.
zLeave the building.
zCall your gas supplier and your installer
from outside the building.
zIf necessary, notify police or fire
services.
zIf you hear gas escaping, evacuate the
affected area immediately.

For your safety1
4Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
We reserve the right to make any changes due to technical modifications.
1.4.2 Tips on the boiler room
WARNING!
RISK TO LIFE
from poisoning.
In open-flue operation, insufficient
ventilation can lead to dangerous flue gas
leaks.
zNever block off or obstruct air ducts and
vents or reduce their size.
zKeep the boiler room doors closed.
zProtect the boiler room and particularly
the combustion air inlet against ingress
of small animals, e.g. by the use of
grilles.
zIf an obstruction cannot be removed
immediately, the boiler must not be
operated.
WARNING!
RISK OF FIRE
from flammable materials or liquids.
zNever store flammable materials or
liquids in the boiler room.

Product description 2
5
We reserve the right to make any changes due to technical modifications.
Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
2 Product description
2.1 Components on the Logano plus GB312 boiler
The boiler is a gas-fired condensing boiler with an
aluminium heat exchanger.
The boiler comprises:
–Control panel
–Frame and casing
–Boiler block with insulation
–Gas burner
The control panel monitors and controls all electrical
boiler components.
The boiler block transfers the heat generated by the
burner to the heating water. The insulation prevents
energy losses.
2.2 BC10 controls
Fig. 1 Logano plus GB312 boiler
1Control panel
2Gas burner
3Boiler front panel
4Siphon
5Boiler block with insulation
6Burner control unit
7Gas train
8Boiler casing
3
2
4
1
5
6
7
8
This product meets all the essential
requirements of the relevant
standards and directives.
USER NOTE
zFurther information about the controls
can be found in the ÎBC10 base
controller documentation.
Fig. 2 Controls on the BC10 base controller
Item 1: ON/OFF switch
Item 2: Dial for setting DHW temperature
Item 3: "DHW heating" LED
Item 4: Status display
Item 5: Dial for maximum boiler temperature when in heating
mode
Item 6: "DHW demand" LED
Item 7: Base plate with slot for a programming unit,
e.g. RC30 (behind fascia)
Item 8: "Burner" (ON/OFF) LED
Item 9: Diagnostic plug
Item 10: "Status display" button
Item 11: "Chimney sweep" button for flue gas test and
manual mode
Item 12: "Reset" button
4
7
2
1
5
8
12 1011
3 6
9

6Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
We reserve the right to make any changes due to technical modifications.
Operation of the heating system3
3 Operation of the heating system
3.1 Switching on the heating system
Before switching the system on, check
–that the operating pressure is high enough,
–that the fuel supply at the main shut-off valve is open
and
–that the heating system emergency stop switch is
switched on.
3.1.1 Starting the heating system via the control
panel and programming unit
zSet both dials on the control panel to "AUT"
(automatic mode). In this setting, the programming
unit takes over control.
zSwitch the ON/OFF switch ON (position "1"). The
control panel checks the current system status and
the burner starts if required.
If the boiler detects a heat demand, the start program
commences and approx. 30 seconds later the burner
fires up. A heat demand is triggered if the heating or
DHW temperature falls below its set value. The LED
below the relevant dial illuminates.
zCheck and make sure the following settings on the
programming unit are set:
–Automatic operating mode
–Required room temperature
–Required DHW temperature
–Required heating program
Fig. 3 Setting the control panel
Fig. 4 Switching on the heating system
Fig. 5 Programming unit (e.g. RC30, with open flap)
USER NOTE
zOperating instructions, for example
how to set temperatures, can be found
in the Îprogramming unit
documentation.

Operation of the heating system 3
7
We reserve the right to make any changes due to technical modifications.
Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
3.2 Switching off the heating system
zSwitch the ON/OFF switch on the control panel OFF
(position "0"). This switches the boiler and all its
components OFF (for example the burner).
zClose the main fuel shut-off valve.
3.3 Emergency measures
In the event of an emergency, e.g. a fire, proceed as
follows:
zClose the main fuel shut-off valve.
zIsolate the heating system from the mains power
supply using the heating system emergency stop
switch or the corresponding domestic fuse.
3.4 Checking the operating pressure, topping up with heating water and bleeding the
system
3.4.1 When should you check the operating
pressure?
Recently topped-up heating water loses much of its
volume in the first few days because it releases gases.
This causes air pockets, and the heating system will
start to rumble.
zAfter installing a new heating system, check the
operating pressure daily for the first few days. If
necessary top up with heating water and bleed the
radiators.
zAfter a while the operating pressure will only need to
be checked monthly. If necessary top up with heating
water and bleed the radiators.
CAUTION!
SYSTEM DAMAGE
through frost.
The heating system can freeze up in cold
weather if it has been switched off.
zLeave the heating system switched ON
for as long as possible.
zProtect your heating system against
freezing by draining the heating system
and DHW pipework at the lowest
possible point.

8Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
We reserve the right to make any changes due to technical modifications.
Operation of the heating system3
3.4.2 Checking the operating pressure
The heating contractor will have set the red needle on
the pressure gauge to the required operating pressure
(at least 1 bar overpressure).
You can check the design operating pressure for this
heating system on Îpage 2.
zCheck that the pressure gauge needle is within the
green field.
zTop up with heating water if the pressure gauge
needle is below the green field.
3.4.3 Filling the heating system and checking for
leaks
Before commissioning the heating system, check for
leaks to prevent problems during operation. Pressurise
the heating system to 1.3x bar permissible operating
pressure (observe the safety pressure of the safety
valve).
On sealed systems the pressure gauge needle (Fig. 6,
item 2) must be within the green range (Fig. 6, item 3).
Set the red needle (Fig. 6, item 1) on the pressure
gauge to the required system pressure.
zCheck the system water pressure
zShut off the pressure expansion vessel from the
system by closing the cap valve.
zCheck the connections and pipework for leaks.
zOpen the mixing and shut-off valves on the hot water
(primary) side.
zFill the system via an approved filling link.
Filling the heating system
Filling and refilling of the heating circuit must been
carried out by a method that has been approved by the
Water Regulation Advisory Scheme (WRAS), for the
type of heating appliances, i.e. Domestic (in-house)
Fluid Category 3. Non-Domestic (other than in-house)
Fluid Category 4. Depending on the Fluid Category the
approved method should comprise of the following:
Fig. 6 Pressure gauge for sealed systems
1Red needle
2Pressure gauge needle
3Green field
3
1
2
CAUTION!
SYSTEM DAMAGE
through over pressure during leak testing.
Pressure, control and safety equipment
may be damaged through excessive
pressure.
zWhen you carry out a leak test, make
sure that no pressure, control or safety
equipment is fitted which cannot be
isolated from the boiler water chamber.

Operation of the heating system 3
9
We reserve the right to make any changes due to technical modifications.
Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
1. Requirements Fluid Category 3 systems (fig see
right)
zControl valve (stop valve) including a double check
valve on the mains cold water supply pipe
zTemporary connection to e removed after filling
(filling loop)
zControl valve (stop valve) on the heating system
pipework
2. Requirements Fluid Category 4 systems (fig see
right)
zControl valve (stop valve) on the mains cold water
supply pipe
zStrainer
zVerifiable Backflow Prevention Device with reduced
pressure Zone(RPZ valve assembly) incorporating a
Type BA air gap
zTundish
zControl valve (stop valve) on the heating system
pipework
zOpen the cap of the automatic air vent by one full turn
to allow air to escape.
zSlowly fill the heating system. Observe the pressure
gauge whilst filling.
zClose the water tap and the boiler drain valve once
the required operating pressure has been reached.
zBleed the system via the radiator bleed valves.
zTop up with water if the pressure drops as a result of
bleeding the system.
zTake the hose off the boiler drain valve.
Fig. 7 Requirements Fluid Category 3 systems
Fig. 8 Requirements Fluid Category 4 systems
CAUTION!
SYSTEM DAMAGE
through frequent topping up.
The heating system may be damaged,
depending on water quality, by corrosion
or scaling if you frequently need to top-up
the heating water.
zEnquire from your installer, whether
you can use your public water
untreated or whether you need to treat
it before filling your system.
zNotify your installer, if you need to
regularly add top-up water to your
system.

10 Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
We reserve the right to make any changes due to technical modifications.
Operation of the heating system3
Correct fuel
This heating system requires fuel of the correct type and
grade to ensure its proper operation.
Follow the advice of your installer if you want to convert
your heating system to another type of fuel or use fuel
with a different specification.
Boiler room
CAUTION!
SYSTEM DAMAGE
through incorrect fuel.
zOnly use the fuel specified.
CAUTION!
BOILER DAMAGE
through contaminated combustion air.
zNever use chlorinated cleaning agents
or halogenated hydrocarbons (as, for
example, contained in spray cans,
solvents or cleaning agents, paints and
adhesives).
zAvoid very dusty atmospheres.
CAUTION!
SYSTEM DAMAGE
through water.
zIn case of an acute risk of flooding,
disconnect the boiler from its power
supply and shut off the fuel supply
before water enters the boiler room
(ÎChapter 3.2, page 7).
zAfter the flood has subsided, ask your
local installer to check the heating
system before starting it up again.
zAsk your installer to replace any valves
and control/regulating equipment that
have come into contact with water.

Operation of the heating system 3
11
We reserve the right to make any changes due to technical modifications.
Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
3.5 Why is regular maintenance important?
Heating systems should be regularly maintained for the
following reasons:
–to achieve a high level of efficiency and to operate
the system economically (low fuel consumption),
–to achieve a high level of operational reliability,
–to maintain the cleanest possible combustion.
CAUTION!
SYSTEM DAMAGE
through a lack of, or unsatisfactory,
cleaning and maintenance.
zHave your system inspected, cleaned
and maintained annually by a heating
contractor.
zWe recommend you enter into a
contract covering an annual inspection
and maintenance.

12 Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
We reserve the right to make any changes due to technical modifications.
Troubleshooting4
4 Troubleshooting
4.1 Recognising and resetting faults
In the event of a fault, the relevant fault code will flash on
the control panel display. The programming unit shows
faults as plain text messages.
A fault exists if the display flashes and indicates
something other than the current boiler water
temperature or an operating message.
Example: "6A" = burner does not start
zPress and hold down the "Reset" button for
approx. 5 seconds to clear the fault.
The display shows "rE" whilst the reset is implemented.
A reset is only possible if a fault message is flashing.
The fault is cleared when the display shows the standard
operating message again. Should the fault recur, repeat
the reset two or three times.
If a fault cannot be reset:
zNote down the fault message and notify your installer
accordingly.
More information about possible faults can be found in
the Îcontrol panel documentation.
Fig. 9 Clear the fault by pressing the "Reset" button
CAUTION!
SYSTEM DAMAGE
through frost.
The heating system can freeze up in cold
weather if it has been switched OFF
through a fault shutdown.
zImmediately rectify the fault and restart
the heating system.
zIf this is not possible, protect your
heating system against freezing by
draining the central heating and DHW
pipework at the lowest possible point.

13
We reserve the right to make any changes due to technical modifications.
Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005

14 Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005
We reserve the right to make any changes due to technical modifications.

15
We reserve the right to make any changes due to technical modifications.
Operating instructions Logano plus GB312 gas-fired condensing boiler • Issue 06/2005

Your installer:
Buderus
Cotswold Way, Warndon, Worcester WR4 9SW
Tel.: [phone], Fax: [phone]
www.buderus-commercial.co.uk
In the UK, Buderus is a trading name of
BBT Thermotechnology Ltd.
BBT Thermotechnik GmbH
D-35573 Wetzlar
www.heiztechnik.buderus.de
[email protected]rus.de