Buderus SB735 Series Manual

6302 2320 – 10/2003 US/CA For installers
Please read these instructions carefully!
Boiler Installation and
Maintenance Manual
Condensing Gas Boiler SB735
Series

2
Introduction
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Technical Changes!
Buderus Hydronic Systems, Inc. reserves the right to
this make changes due to continued technological and
engineering improvments.
Updating Technical Informations
Please contact us if you have suggestions for improving
this manual or when you have noticed incorrect
information.
Manufacturers Address:
Buderus Hydronic Systems, Inc.
50 Wentworth Ave
Londonderry, New Hampshire 03053
www.buderus.net
Document number: 6302 2320
Issue: 10/2003
FThis equipment conforms to the following
European and US requirements:
– 90/396/EWG European gas fired
guidelines
Standards: EN 677, EN 303-1,
EN 303-3, DIN 4702-6
– 92/42/EWG European efficiency
guidelines
– 73/23/EWG European low voltage
guidelines
– 89/336/EWG EMV- European
electromechanical code
guidelines
– 97/23/EG European pressure
vessel guidelines
Standard: TRD 702
– ASME Boiler and Vessel Pressure
Code
Confirmation regarding confirmity with
respect to these guidelines can be obtained
upon request from Buderus Hydronic
Systems, Inc.

TABLE OF CONTENTS
3
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735• Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Regulations and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Hydrostatic test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Packaging and Components . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical Data, Dimensions and Water Connections . . . . . . . . . 6
4 Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Anti-Vibration Supports . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Boiler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 Installation of the Thermal Insulation
and Jacket Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2 Boiler Jacket - Pack A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Boiler Jacket - Pack B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4 Installation of the Control Panel
and Sensor Well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.5 Burner Door and Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.6 Boiler Jacket - Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.7 Rating Tag Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.8 Boiler Jacket - Pack C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.9 Venting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.10 Neutralization Equipment and Water Controls Installation. . . . . . . . . . 23
7 Placing the Boiler in Operation . . . . . . . . . . . . . . . . . . . . 24
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2 Cleaning of the Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

General Information1
4
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
1 General Information
1.1 General Information
This Boiler Installation and Maintenance Manual
contains important information regarding proper and
safe assembly, start-up and operating and maintenance
procedures for the SB735 series boilers!
The assembly and maintenance instructions are
designed for the installing contractor, who, due to
vocational training, is familiar, knowledgeable and
experienced in heating system and gas piping
installations.
1.2 Regulations and Guidelines
This document also makes reference to additional
accessories that may be used in conjunction with the
SB735 boilers. Observe the proper installation
instructions when installing these accessories.
The installation must conform to the requirements of the
authority having jurisdiction or, in absence of such
requirements, to the latest edition of the National Fuel
Code, ANSI Z223.1.
ADANGER!
due to combustion products.
Route flue gases via venting system to the
atmosphere. Use only approved venting
materials.
Have the system inspected by an authorized
person prior to start-up. Only start-up the
system after approval.
Check system for leaks.
The Buderus SB735 boiler is a condensing boiler
suitable for firing with natural gas or propane only.
The installation of a low water cut-off and pressure relief
valve must be based on local code requirements. Please
install these components per manufacturer’s
instructions and per detail on page 23.
JNOTICE
To avoid build-up of debris inside the heat
exchanger of the boiler, it is recommended to
install a filter on the boiler return connection(s).
1.3 Hydrostatic test
Perform a hydrostatic test. The test pressure should be
1.5 times the actual operating pressure in the heating
system, however a minimum of 14 psi.
JNOTICE!
Observe the listed boiler output ratings as
shown on the boiler rating plate.
Maximum Temperature and Pressure Ratings:
Permissible Fuels:
Logano SB735: Fuel Natural Gas or L.P
Please observe the guidelines of the gas supply
company!
Maximum Temperature and Pressure Ratings
Maximum Supply Temperature: 210 °F
Allowed System Pressure
(Models)
790 43.5 psi
970 43.5 psi
1200 43.5 psi
Maximum Time constant:
- Manual Reset High Limit 40 sec
- Adjustable High Limit 40 sec
Table. 1 Maximum Temperature and Pressure Ratings

Packaging and Components 2
5
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
2 Packaging and Components
The complete product is shipped in the following
components:
– Boiler vessel, bolted on transport woods
– Supply manifold, packaged with hydronic control
package
– Technical documentation, secured to the boiler
– VE insulation rings for burner and PVC condensate
drain (Siphon) secured to the boiler
– Boiler jacket panels and installation components,
packaged in a wooden crate and cardboard. The
assembly components are located in Pack A.
– The insulation blankets are packaged in 2 plastic
bags.
– A sound attenuating boiler base is supplied standard
with the SB735/1200 model.
– Electronic control panel, in cardboard box (optional).
– A condensate neutralization package can be ordered
separately.
– Hydronic control package, consisting of aquastat,
low water cut-off, relief valve and temperature
pressure gauge (when ordered from Buderus).
– Gas burner and gas train components, if ordered
from Buderus.
– Pre-cut burner mounting plate, if ordered from
Buderus.
Above mentioned components may differ slightly based
on the particular boiler model.

Technical Data, Dimensions and Water Connections3
6
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
3 Technical Data, Dimensions and Water Connections
Fig. 1 Technical Data, Dimensions and Water Connections
VK = Boiler Supply Connection
RK1 = Low Temperature Return Connection
RK2 = High Temperature Return Connection
H* = Boiler Height with Logamatic 2107/2109=H+6 inch
AKO = Condensate Drain
EK = Water Feed
EL = Boiler Drain
M = Sensing Port for Temperature Sensor
Ø AA = Vent Pipe Diameter
L
LK
H
B
HAA
Ø AA
M
VK
RK2
AKO
RK1
EK/EL
Boiler Model 790 970 1200
Max. Input [MBH] 2751 3378 4179
Max. Output [MBH] 2605 3251 4079
IBR Net [MBH] 2265 2827 3547
Thermal Efficiency [%] 96.9 96.3 97.6
Combustion Efficiency [%] 94.7 95.6 96.5
Length L Inch 91 ½108 ¼108 ¼
Length LKInch 75 ½92 92
Hight HInch 81 ¼ 81 ¼ 81 ¼
Width BInch545454
Boiler Widthless Jacket Inch 44 ¼ 44 ¼ 46 ¼
Vent Connection-Ø inside Ø AA Inch 14 14 14
Vent Height HAA Inch 19 19 19
Weight Lbs. 4330 5441 5534
Boiler supply
1. First Return Connection
VK
RK1
Inch
Inch
4
4
5
5
5
5
2. Second Return Connection RK2Inch 3 4 4
Boiler Drain/Water Feed EK/EL Inch 1½ 1½ 1½
Table. 2 Technical Data, Dimensions and Water Connections

Boiler Installation 4
7
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
4 Boiler Installation
It is required to have a floor drain available near the
boiler.
It is recommended to place the boiler on solid foundation
of 2" to 4 " height. Use dimension B and L (Table 3) to
size this foundation.
The supporting floor must be level and of sufficient
strength.
Observe the indicated side clearances when placing the
boiler (Fig. 2). Dimensions shown indicate minimum
clearances to combustibles or space needed to swing
open burner door.
Place the boiler horizontally on the supporting
foundation.
JNOTICE!
Make sure to install the base supplied with the
SB735/1200.
Fig. 2 Clearance dimensions for SB735 boilers
Boiler
Model
L
[Inch]
BK
[Inch]
A
[Inch]
790 91 43 ¾98“(43“)*
970 107 ½43 ¾98“(43“)*
1200 107 ½46 98“(43“)*
Table. 3 Minimum Boiler Pad
Please observe the burner length LBr with respect to the front
clearance.
AL
8“
32“1)
LBr
(0)
Bk
(4“)
(40“)

Anti-Vibration Supports5
8
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
5 Anti-Vibration Supports
zAnti-vibration supports are standard equipment on
the SB735/1200 model; they can be ordered
separately for the other models.
zInsert the longer part of the longitudinal anti-vibration
bracket (Fig. 3, Item. 4) from the front and the
shorter part (Fig. 3, Item. 3) from the rear into the
channel sections (Fig. 3, Item. 2).
zPosition both rails of the anti-vibration boiler support,
in accordance with dimensions shown in Table 4, on
the floor where the boiler is to be installed.
JNOTICE!
Prepare the foundation, where the anti-vibration
supports are to be located, with a smooth trowel
of ±1/8“ per linear foot and with a slight rise to
the back. This ensures an even load distribution
over the longitudinal anti-vibration brackets,
and adequate boiler ventilation.
zPosition, align and place the boiler on the supports.
The boiler support should be flush with the boiler
back wall. The end-stop plates (Fig. 3, Item. 1)
should contact the channel section of the boiler.
Fig. 3 Anti-vibration support
Item. 1: End-stop plates
Item. 2: Channel section
Item. 3: Short anti-vibration bracket
Item. 4: Long anti-vibration bracket
Table. 4 Support dimensions
1) Standard delivery
2) Accessories
Boiler
Type
Boiler-
Model
Length
F
[Inch]
Distance
C
[Inch]
1200 1) 90 46
SB735 970 2) 90 43 ¾
790 2) 73 ½44
F
C
2
4
3
1

Boiler Assembly 6
9
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
6 Boiler Assembly
JNOTICE!
Make sure, that when fitting the front thermal
insulation, the burner door of the combustion
chamber is closed, to prevent damage to the
stainless steel combustion chamber from
welding or grinding activities.
Order of installation:
1. Thermal insulation/Pack A
2. Pack B
3. Pack C
6.1 Installation of the Thermal Insulation
and Jacket Panels
JNOTICE!
Ensure that the fabric is on the outside when
fitting the insulation blankets.
zPosition the insulation blankets for the boiler body so
that the cut-outs are located over the cross brackets
plates (Fig. 5, Item. 1).
JNOTICE!
Position the narrow insulation blanket for boiler
model 790 at the rear, and note the drain cut-
outs.
JNOTICE!
Note the cut-outs for the low water indicator and
the cross bracket holder
(Fig. 7, Item. 1 + 5)!
zPosition the front insulation blanket with its cut-out,
over the cross bracket holder.
zTuck the insulation blanket in underneath the boiler
(Fig. 5).
Fig. 4 Connections
M = Sensing port for temperature sensor
VK = Boiler supply and relief valve connection
RK2 = High temperature boiler return
RK1 = Low temperature boiler return
AA = Vent connection
AKO = Condensate drain
EK/EL = Water feed/boiler drain
Fig. 5 Insulation blanket
M
VK
RK2
RK1
AA
AKO
EK/EL
1

Boiler Assembly6
10
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
zOverlap the insulation blankets on the side and wrap
around the boiler body, then fasten with 8 clips.
zUnscrew four hexagon bolts (Fig. 6, Item. 1) from the
right side of the boiler door (Fig. 7, Item. 1) and four
from the left side.
ADANGER OF INJURY!
through falling parts.
Ensure that the hinge bolts (Fig. 21, Item. 1)
are in the boiler door before opening it.
JNOTICE!
The recesses (Fig. 6, Item. 2) in the boiler door
(2 on the left and 2 on the right side) have been
provided for lifting with a crane or hoist, for
example for the complete removal of the door.
zOpen the burner door (Fig. 7, Item. 1)
zPlace the insulation blanket with round cut-out
(Fig. 7, Item. 2), with its wide edge facing upwards,
on the left front of the boiler body (wide edge up) and
secure with four clips (2 left, 2 right) on the
surrounding thermal insulation.
ACAUTION!
Ensure that the wide edge is at the top at the
hinge bolts!
zClose the burner door and re-secure with eight
hexagon bolts.
zPosition the thermal insulation strip (Fig. 7, Item. 3)
laminated on the front of the reversing door.
zPosition the thermal insulation strips (Fig. 7, Item. 4)
for the reversing door from below around the side of
the reversing door and secure with two clips.
JNOTICE!
Observe the hinge bolt cut-outs!
zLocate the rear side thermal insulation (Fig. 8,
Item. 2) in accordance with the cut-outs on the rear
side of the boiler and secure with six clips (Fig. 8,
Item. 1, 3 left and 3 right) on the surrounding thermal
insulation (Fig. 8, Item. 3).
Fig. 6 Screws for opening the burner door
Fig. 7 Burner door insulation blanket
Fig. 8 Rear side insulation blanket
1
1
2
2
1
2
3
4
5
1
23

Boiler Assembly 6
11
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
6.2 Boiler Jacket - Pack A
zLocate the front cross bracket (trapezoidal cut-out
down) with its two top holes on the threaded studs
and secure with nuts (Fig. 9).
zLocate the rear cross bracket (V-shaped cut-out
down) with its two top holes on the threaded studs
and secure with nuts (Fig. 9).
JNOTICE!
The edge of the cross bracket must point
outwards (Fig. 9).
zInsert the insulation blanket from the burner door
(Fig. 7, Item. 2) and the rear side (Fig. 8, Item. 2) into
the upper edge and the front and rear cross bracket.
zLightly insert two screws M8 x 80 (Fig. 10, Item. 3)
from the top into the central cross bracket (Fig. 10,
Item.1).
zSecure the central gross bracket (Fig. 10, Item. 1) at
the top to the fixing bracket using two bolts, washers
and nuts (Fig. 10, Item. 2).
JNOTICE!
Ensure that the edge of the central cross
bracket (Fig. 10, Item. 1) points forward.
zLightly secure the central cross bracket front (Fig. 9,
Item.1) on the left and the right side using two bolts
and washers.
JNOTICE!
Initially secure the central cross bracket (Fig. 9,
Item. 1) only lightly. Tighten the cross brackets
after they have been aligned and secured to the
side wall closest to the front.
zPush the strain relief (Fig. 10, Item. 4) on the hinge
side of the burner door into the cross bracket.
zSecure the strain relief with two bolts (Fig. 10).
Fig. 9 Cross brackets
Fig. 10 Strain relief
Item. 1: Central cross bracket
Item. 2: Fixing bracket
Item. 3: M8 x 80 bolts
Item. 4: Strain relief
Item. 5: Bolt location central cross bracket for boiler models
790 and 970
Item. 6: Bolt location central cross bracket for boiler model
1200
1
1
1 2
3
4
5
6
3

Boiler Assembly6
12
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
zThe horizontal brackets (L-brackets) comprise of two
components, which must be pre-assembled.
Join both bracket components with two bolts and two
nuts (Fig. 11).
zHook the first bracket (Fig. 12, Item. 1) with the
U-shaped edge into the respective recess of the
front, center and rear cross brackets.
zThe bracket is secured at the front hole and the rear
slot using one self-tapping screw each (Fig. 12).
zHook the second bracket (Fig. 12, Item. 3) with the
U-shaped edge into the respective recess of the
front, centre and rear cross brackets.
zThe bracket is secured at the front hole and the rear
slot using one self-tapping screw each (Fig. 12).
zAlign the central cross bracket horizontally.
Fig. 11 Longitudinal (L-)bracket
Fig. 12 Secure the longitudinal bracket with bolts suppplied
Item. 1: Horizontal bracket
Item. 2: Central cross bracket
Item. 3: Horizontal bracket
123

Boiler Assembly 6
13
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Fig. 13 Bottom cross brackets (top view)
zSecure the lower front cross brackets (Fig. 13, Item.
3) to the boiler body using two bolts.
zSecure the lower rear cross bracket (Fig. 13, Item. 1)
to the boiler body using two bolts.
zSecure the left and right spacer plates (Fig. 13,
Item. 5) to the lower cross bracket using three bolts
and washers each (Fig. 13, Item. 6).
Use the holes Item. a for boiler models 790 and 970.
Use the holes Item. b for boiler model 1200.
zThe lateral blue covers (Fig. 13, Item. 2) comprise
two components, which must be pre.assembled
(Fig. 13, Item. c: screw position for model 790 and
Item. d: screw position for models 970 and 1200).
Hook-in both covers centrally behind the bracket and
align horizontally, then join both pieces with two bolts.
zSecure the left and right side of the cover (Fig. 13,
Item. 2) to the front and rear using one bolt each.
zSecure the blue cover (Fig. 13, Item. 4) at the left and
right front of the cover (Fig. 13, Item. 2) using two
bolts respectively.
Item. 1: Rear cross bracket
Item. 2: Lateral covers
Item. 3: Front cross bracket
Item. 4: Front cross bracket cover
Item. 5: Spacer plate
Item. 6: Position of bolts on the spacer plate for boiler
models 790 and 970 and 1200 (top view)
Pos. a: Position of bolts on the spacer plate for boiler
models 790 and 970 (top view)
Pos. b: Position of bolts on the spacer plate for boiler model
1200 (top view)
Pos. c: Position of the bolts on the lateral blue covers for
boiler models 790 and 970 (side view)
Pos. d: Position of the bolts on the lateral blue covers for
boiler model 1200 (side view)
1
2
3
4
2
4
5
5
6
6
6
c
b
2
5
a
d

Boiler Assembly6
14
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
zHook the rear and central side walls at the bottom
into the edge between the cover and the spacer plate
(Fig. 14).
JNOTICE!
Note the recesses (Fig. 14, Item. 1) in the side
walls:
- Rear side wall 1 recess
(towards the central side wall).
- Central side wall 2 recesses.
- Side wall nearest the front 1 recess (towards
the central side wall).
zLift the side walls and hook the top into edge of the
horizontal brackets (Fig. 15).
zPush the side walls back.
zPush the ends of the insulation blankets behind the
side wall edge.
zInsert the small side sections (Fig. 15, Item. 3) into
the side and at the bottom.
zSecure the side wall nearest the front to the central
cross brackets using one self-tapping screw (Fig. 15,
Item. 2) and secure the central cross bracket.
zSecure the small side sections (Fig. 15, Item. 3) at
the front using two self-tapping screws each (Fig. 15,
Item.1).
zAlign the side wall position with bolts Fig. 12.
JNOTICE!
Remove the smaller side sections before
opening the lower reversing door.
Fig. 14 Hooking in the side walls at the bottom
Fig. 15 Hooking in the side walls at the top
Item. 1: Self-tapping screw for the small side section
Item. 2: Self-tapping screw for the side wall nearest the front
Item. 3: Smaller side section
1
1
2
4

Boiler Assembly 6
15
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
6.3 Boiler Jacket - Pack B
zPosition the front boiler cover (Fig. 16, Item. 1) on
top of the side wall edge and pull forward, until the left
and right hooks lock into the slots.
zSecure the front boiler cover by means of two self-
tapping screws (Fig. 16, Item. 2), which should be
inserted through the boiler cover brackets and the
side wall edge into the horizontal bracket.
Fig. 16 Install the boiler front cover
1
2

Boiler Assembly6
16
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
6.4 Installation of the Control Panel
and Sensor Well
The optional Buderus control panel „Logamatic“ is
secured by fixing two hooks into the two holes in the
front top cover.
Control panel „Logamatic“ 2000 series
zUnscrew both self-tapping screws from the top out of
the terminal cover and remove the cover (Fig. 17).
zRoute the capillary tubes through the cable raceway
and unroll to the required length.
zLocate the control panel so that the insert hooks are
inserted at the front into the oval holes, pull the
control panel forward and then tilt it back, until both
resilient hooks snap into place on the right and left
side (arrows Fig. 17).
zSecure the control panel to the front top cover on left
and right inside in the cable raceway using two self-
tapping screws.
JNOTICE!
If necessary, break or cut out the knock-out
from the rear wall of the control panel (Fig. 18).
Make all electrical connections in accordance with the
wiring diagram and local code requirements.
zInsert cable clips into the clip frame and secure by
pivoting the lever (Fig. 18).
zInsert both lower hooks on the right and the left side
of the rear wall section into the clip frame, keeping
the slot in the upper edge (Fig. 18).
zPress both upper resilient sliding hooks slightly
inwards (arrows on Fig. 18) and insert the rear wall
section so that both hooks lock into place.
zLocate the terminal cover and re-fit using the self-
tapping screws (Fig. 17).
JNOTICE!
Pay particular attention to the cable and
capillary runs! Do not kink the capillaries.
Connect the appliance with a permanent main
electrical disconnect!
Observe the local code requirements!
Fig. 17 Install the control panel
Fig. 18 Installation of the cable clips

Boiler Assembly 6
17
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
zInstall the well provided with the Logamatic control
into the Mtapping.
zRoute the capillary tubes with sensor to the sensor
well (Fig. 19).
zInsert the sensor into the sensor well, until it bottoms
out (sensor well M, see page 6 in Fig. 1) (Fig. 19).
zDuring the insertion, the plastic spiral (Fig. 20,
Item. 2) holding the sensor together slides back
automatically. To ensure a perfect contact between
the sensor well (Fig. 20, Item. 3) and the sensor
surfaces - thereby guaranteeing the safe
temperature transfer - push the compensating spring
(Fig. 20, Item. 1).
zPush the sensor holder (Fig. 20, Item. 4) from the
side or from above over the sensor well head.
Fig. 19 Sensor to the sensor well
Fig. 20 Capillary tubes with sensor and sensor well
Item. 1: Compensating spring
Item. 2: Plastic spiral
Item. 3: Sensor well
Item. 4: Sensor holder
M
1
2
3
4

Boiler Assembly6
18
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Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
6.5 Burner Door and Burner
The burner door can be installed to swing to the left or
right.
ADANGER!
through falling parts.
Change the door opening only when the door is
closed and bolted.
JNOTICE!
The recesses (Fig. 21, Item. 2) in the boiler
door (2 left and 2 right) have been provided for
lifting with a crane or hoist, for example for the
complete removal of the door.
zPush the hinge bolts (Fig. 21, Item. 1) out from the
bottom through the top.
zInsert both hinge bolts with washers on the opposite
side (Fig. 21).
Do not forget to use the washers!
Observe the burner manufacturer’s installation
instructions!
Use or modify (drilled burner plate - accessory) the
appropriate burner plate subject to burner make and
type.
JNOTIVCE!
Seal the gap between the blast tube (Fig. 22,
Item. 2) and the thermal insulation (Fig. 22,
Item. 1) on site using the insulation rings
supplied (Fig. 22, Item. 3)! Cut insulation rings
to required dimensions.
Fig. 21 Burner door
Fig. 22 Burner installation
Item. 1: Thermal insualtion
Item. 2: Blast tube
Item. 3: Insulation rings
1
1
2
2
8 ¼
1
2
3

Boiler Assembly 6
19
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
6.6 Boiler Jacket - Top Covers
zLocate the boiler top cover sections Fig. 23 with the
edges facing forward loosely onto the left and right
side walls.
zPush the boiler top cover sections forward.
JNOTICE!
The third top cover section provides a cut-out
(Fig. 23, Item. 3) for the low water indicator.
Cover the cut-out with a cover plate.
Table. 5 Dimensions of boiler top cover sections from Fig. 23,
Item. 1 to 5 (all dimensions in inches)
zAlign and tightly secure the cross bracket.
zInsert the thermal insulation into the lower front wall
(Fig. 24, Item. 1).
zHook the lower front wall with four offset hooks onto
the slots of the side wall edge (Fig. 24).
zHook the offset brackets of the top front wall (Fig. 24,
Item. 2) into the slots of the lower front wall edge and
at the top into edge of the front top cover.
JNOTICE!
If the front wall can only be located with some
difficulties, re-align the central cross bracket.
zHook the upper (Fig. 25, Item. 3) and the lower cover
part (Fig. 25, Item. 2) into the front wall sections
using the hook provided.
zSecure the rating tag plate to the side panel (Fig. 25).
6.7 Rating Tag Plate
zAffix the rating tag plate (Fig. 25, Item. 1) according
to the boiler location on the left or right side wall.
Fig. 23 Top cover sections
Fig. 24 Front cover panels
Fig. 25 Inserting front cover panels
Boiler
model
Item
1
Item
2
Item
3
Item
4
Item
5
790 17¾17¾17¾11¼11¼
970 17¾17¾17¾19½19½
1200 17¾17¾17¾19½19½
1
2
345
1
22
hakghah
hakghah
hakg
1
3
2

Boiler Assembly6
20
We reserve the right to make any changes due to technical modifications!
Boiler Installation and Maintenance Manual SB735 • Issue 10/2003
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
6.8 Boiler Jacket - Pack C
JNOTICE!
The rear wall consists of seven parts (Fig. 26).
zSecure the rear wall section (Fig. 26, Item. 1) with
two self-tapping screws per side (left and right) on the
side wall edges.
zSecure the small central rear wall section (Fig. 26,
Item. 6) on the lower rear wall section (edge pointing
inwards) using two self-tapping screws (Fig. 26,
Item. 1).
zLocate the central rear wall section (Fig. 26, Item. 2)
with the Z-profile behind the lower rear wall section
on the edge of the side wall and secure on the left
and right side with two self-tapping screws each.
zInsert the upper rear wall section (Fig. 26, Item. 3)
with Z-profile behind the central rear wall section on
the edge of the side wall, and secure on the left and
right side with two self-tapping screws each.
zHook the upper small rear wall section (Fig. 26,
Item. 4) with the bracket into the upper rear wall
section, and secure with a self-tapping screw.
zSecure one or two cable clips (Fig. 26, Item. 5) or a
cable duct on the upper rear wall section.
zSecure the left and right locking plate (Fig. 26,
Item. 7) on the side wall using two self-tapping
screws respectively.
Fig. 26 installation of the rear wall section
Item. 1: Lower rear wall section
Item. 2: Central rear wall section
Item. 3: Upper rear wall section
Item. 4: Upper small rear wall section
Item. 5: Cable clip
Item. 6: Central small rear wall section
Item. 7: Left and right locking plate
7
1
2
3
4
6
5