Buderus Logalux SM300/1 Manual

Documentation for the con-
tractor
Please read carefully prior
to installation and mainte-
nance
When the anode rod is not profes-
sionally and annually maintained, the
tank will lose its warranty. Annual
service records must be maintained
and shown in case of a warranty
claim along with an original proof of
purchase. Refer to page 23 to 27 for
annual maintenance instructions to
maintain tank warranty.
In the Commonwealth of Massachu-
setts this tank must be installed by a
licensed plumber.
Installation and
Maintenance Manual
Solar and High Capacity -
Domestic Hot Water
Logalux SM300/1
Logalux SM400/1
6 720 615 190 - 02/2008 US

Index
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
2
Index
1 Safety Precautions and symbol clarification 3
1.1 Placement, remodeling 3
1.2 Symbol Clarification 3
2 Product Description 4
2.1 Applications 4
2.2 Intended Use 4
2.3 Guidelines for Installations 4
2.4 Product Disposal 4
2.5 Product Packaging 5
2.6 Dimensions and Connections 7
2.7 Technical Specifications 9
3 Transportation 10
3.1 Transportation Means 10
3.1.1 Transportation with dolly 10
3.1.2 Transportation with overhead crane 11
3.2 Product Placement 11
4 Tank Assembly 12
4.1 SM300/1 Placement and Installation 12
4.1.1 Installation of tank feet 12
4.1.2 Installation of tank aquastat or temperature
sensor 12
4.2 SM400/1 Placement and Installation 15
4.2.1 Installation of M2 - M5 temperature sensors 15
4.2.2 Installation of Tank Insulation
for SM400/1 Tank 16
4.3 Water side Piping Connections for both
Tank Models 17
4.4 Connections for Solar station KS 19
4.5 Connections for High Output Indirect Fired
Tank Piping 20
4.5.1 Serial Connections of the bottom and
top coils 20
4.5.2 Parallel Connections of bottom and top coils 20
5 Start-up and Shut-down of Tank 21
5.1 Start-up Operations 21
5.1.1 Operational information from contractor 21
5.1.2 System start-up 22
5.2 Decommissioning of the system 22
5.2.1 Shutdown of solar hot water tank 22
5.2.2 Shutdown of heating system in cold
weather conditions 22
5.2.3 Environmental protection 22
6 Maintenance 23
6.1 Preparation of cleaning of solar water tank 23
6.2 Cleaning of solar hot water tank 24
6.3 Checking of magnesium anode rod 25
6.4 Placing solar tank back in operation after
cleaning 27
7 Replacement Parts 28
7.1 Replacement parts for SM300/1 - 300/1W 28
7.2 Access cover and anode rod assembly
for SM300/1 - 300/1W 30
7.3 Replacement parts for SM400/1 31
7.4 Tank access cover and anode rod assembly
for SM400/1 33
7.5 Tank Jacket System for SM400/1 Tank 35

1
Safety Precautions and symbol clarification
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice. 3
1 Safety Precautions and symbol clarification
1.1 Placement, remodeling
Placement, remodeling
VFire danger!
Solder and welding operations can result in fire, as the
insulation is combustible.
VThe solar tank can only be installed or renovated by
technical specialists.
Installation and Start-up Procedure
VIn the Commonwealth of Massachusetts this tank must
be installed by a licensed plumber.
VAny electrical wiring must be installed by a licensed
electrician.
VDo not assemble the equipment in a damp environ-
ment.
Function
VFollow these directions for trouble free operation for
installation and maintenance.
VDanger of Scalding!
(> 140 °F) during operation of the tank as part of a
solar system. Please install tempering valve on domes-
tic hot outlet connection of tank, which is supplied with
solar pumping station
Maintenance
VRecommendation for end customer: Please sign
up for an annual service and maintenance contract with
your installer. Make sure to have annual maintenance
performed on your boiler and solar system.
VUse only original replacement parts.
1.2 Symbol Clarification
Signal words are describing the gravity of each danger
when safety precautions are not followed.
–Careful indicates possibility of light property damage.
–Warning indicates light personal injury or severe prop-
erty damage.
–Danger indicates possible severe personal injury with
potential loss of life.
Guidelines contain important information in these cases
to avoid or reduce danger to people and equipment.
In case the solar storage tank will be installed in Massa-
chusetts, it must be installed by an installer or dealer who
is registered in that state.
We reserve the right to change and improve technical
information without notice.
It is expected that the installer is a licensed heating con-
tractor with the knowledge of accepted industry practices
for the installation and maintenance of the equipment and
various applications of the equipment involved.
Safety warnings are designated in the text
with a triangular warning label and grey color-
ing.
Guidelines in the text are designated with
shown symbol. The text is bracketed between
two horizontal lines.

2Product Description
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
4
2 Product Description
2.1 Applications
The solar tanks SM300/1 and SM400/1 are designed for
the heating and storage of domestic hot water. Applicable
guidelines for domestic hot water must be followed.
2.2 Intended Use
The domestic hot water can be heating by a solar system
with a boiler as a back-up system, or by a boiler in general
for high output hot water heating. (Operate the 2 coils
either in series or in parallel). In case of solar heating, the
solar system must be filled with a solar fluid to prevent
accidental freezing. The tank can only be used in a closed
system.
Any other application voids the warranty of the tank.
2.3 Guidelines for Installations
2.4 Product Disposal
VDispose of packaging of the solar tank in an environ-
mental friendly fashion.
VA solar hot water heater that is being replaced must be
disposed of in a suitable fashion.
Follow all specific state and local codes re-
garding the installation and operation of the
equipment.
All electrical components must be approved
for the US.

2
Product Description
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice. 5
2.5 Product Packaging
Solar hot water tank consists of:
– Tank shell [6] with corrosion protection and magne-
sium anode rodes.
– Tank insulation [1] made from non FCKW insulation
material.
– SM300/1: direct attached to tank shell.
– SM400/1: Insulation must separately be installed.
– 2 Smooth high output heat transfer coils [11]
– The smooth surface coil transfers the energy from
the solar and/or heating system to the domestic
water inside the tank shell. The water volume is
evenly heated with the coil areas.
– Dry well M1 [12] for installation of DHW tank tempera-
ture sensor or aquastat.
–
Dry well [14] for installation of tank temperature sensor.
– The solar control is controlled by the tank tempera-
ture sensor (lower port) which operates the solar
system based on collector sensor.
– Hand hole [3] cover for service and maintenance
access
– Dual magnesium anodes [5; 10]
– Jacket cover [8]
–B-Kit(US)(ÆFig. 2, page 6)
Fig. 1 A: SM300/1
B: SM400/1
1Insulation
2Clean-out cover insulation
3Inspection opening
4Inspection opening cover
5Magnesium anode rod
6Tank shell
7Thermoglaze Duo Clean
8Top tank cover
9Insulation disc for SM300/1 tank
10 Magnesium anode rod
11 Smooth coil heat exchangers
12 Dry well sensing port for heating system control
13 DHW recirculation connection
14 Dry well sensing port for solar
15 Tank feet

2Product Description
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
6
B-Kit Komponenten
Fig. 2 Tank kit fittings
1Tee piece with P & T relief valve
2Bracket for mounting of aquastat
3Spacer set for securing DHW tank sensor
4Cover cap for DHW recirc connection (EZ)
5Tee piece with tank drain valve

2
Product Description
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice. 7
2.6 Dimensions and Connections
Fig. 3 SM300/1 Dimensions and connections
AW DHW outlet
VS1 Solar coil supply
VS2 Boiler coil supply
RS1 Solar coil return
RS2 Boiler coil return
M1 Temperature measuring point for DHW temperature sensor (FB) or aquastat
M2 Temperature measuring point for solar DHW sensor (FSS)
EK Cold water feed
EL Tank drain
EZ DHW recirc tapping

2Product Description
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
8
Fig. 4 SM400/1 Dimensions and connections
AW DHW outlet
VS1 Solar coil supply
VS2 Boiler coil supply
RS1 Solar coil return
RS2 Boiler coil return
MTemperature measuring point for DHW temperature sensor (FB) or aquastat
M1 Temperature measuring point #1 for solar DHW sensor (FSS) or temperature sensor solid fuel boiler (FPM)
M2 Alternative location for DHW temperature sensor (FB) or shut-off sensor for loading by solid fuel boiler (FPU)
M3 Solid fuel boiler on temperature
M4 Temperature measuring point #2 for solar DHW sensor (FSS)
EK Cold water feed
EL Tank drain
EZ DHW recirc tapping
4
0.8

2
Product Description
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice. 9
2.7 Technical Specifications
Tank Model SM300/1 SM400/1
Tank volume gal 77 103
Liter 290 390
Volume of solar heat exchanger gal 2 2.5
Liter 8 9.5
Diameter inch 27 34
mm 670 850
Height H1) inch 59 62
mm 1465 1550
Height H (Installation site)2) inch 86 74
mm 2150 1880
AW - Domestic outlet connection NPT 1 NPT 1
VS - Coil supply connection NPT 1 NPT 1
RS - Coil return connection NPT 1 NPT 1
EK/EL - tank drain/cold feed NPT 1¼ NPT 1¼
EZ - DHW recirculation connection NPT ¾ NPT ¾
Dry weight 3) lb. 342 445
kg 155 202
Maximum Operating Values
Solar system fluid temperature °F 320 320
°C 160 160
DHW temperature °F 203 203
°C 95 95
Operating pressure solar fluid system4) psi 232 232
bar 16 16
Operating pressure DHW5) psi 145 145
bar 10 10
Tab. 1 Technical Specifications
1) Included top cover, without tank feet.
2) Minimum height required for removal of anode rod.
3) Without water, includes packaging.
4) Every installation requires the use of a thermal expansion tank and pressure/temperature relief valve in the heating system and solar system.
5) In the Commonwealth of Massachusetts the operating pressure is limited to 100 psi. Install a 100 psi relief valve.

3Transportation
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
10
3 Transportation
3.1 Transportation Means
One can move the solar water heater tank SM300/1 with
a hand dolly and the SM400/1 also with a lifting crane or
device.
3.1.1 Transportation with dolly
VPlace the hand dolly at the backside of the packaged
tank.
VStrap the tank to the hand dolly.
VMove the tank to its final location.
VRemove only the tank packaging at the final installation
site.
Fig. 5 Transportation with kuli cart
Danger: Potential danger due to falling over
of tank.
VUse only transport devices that are in safe
operating condition
VPlace the lifting hook only in the designat-
ed location.
Danger: Potential for injury due to carrying
of heavy loads.
VAlso move and lift the tank with at least
two people.
Caution: Potential damage due to improper
securing of tank for transport.
VUse suitable tools and strapping materials
when securing and moving the tank with a
transport aid.
Bring in the entire tank in its original packag-
ing to the final installation location. This will
protect the tank better during transport.
A Buderus dolly (kuli cart) can be purchased
through your local wholesaler.

3
Transportation
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice. 11
3.1.2 Transportation with overhead crane
VPlace the two lifting hooks of the chain into the desig-
nated lifting rings on top of the tank [1].
VHook the crane chain into the lifting chain.
VProtect the tank from falling and lift the tank to its final
installation location.
VLower the tank carefully to the floor; do not drop down
onto the floor!
One can move the tank inside the building also in a hori-
zontal manner due to possible height restrictions.
VRemove only the tank packaging at the final installation
site.
Fig. 6 Transportation with lifting crane (SM400/1)
1Lifting eyes
3.2 Product Placement
VMaintain suggested service access dimensions
(ÆFig. 7).
VMaintain 2" clearance from heated pipes to
combustible surfaces.
VPlace tank on a level and sufficiently strong floor.
VRemove plastic and packaging materials.
Clearance to wall
Fig. 7 Recommended minimum clearances
(in inch/mm)
1Solar hot water heater
2Boiler
Caution: Damage due to internal stresses
and corrosion!
VPlace the tank in a frost free room.
VUse the solar water heater ONLY in
closed loop applications.
VOpen expansion tanks can NOT be used
with these solar water heater tanks.
Minimum 12" overhead space is required for
the removal of the magnesium anode rod as
well as some side clearance.
VVerify for suitable clearance dimensions by
referencing (ÆTab. 1, page 9 und Fig. 7).

4Tank Assembly
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
12
4 Tank Assembly
4.1 SM300/1 Placement and Installation
4.1.1 Installation of tank feet
VPlace top foam material on the floor [1].
VCarefully place the solar tank on its side on top of the
foam material.
VRemove the tank support bolts M10x30 from the Styro-
foam packaging and screw into the bottom of the tank
[2].
VPut solar tank straight-up and level by adjusting the
tank bolts [2].
Fig. 8 Installation of tank bolts
1Foam packaging material
2Tank bolts
4.1.2 Installation of tank aquastat or temperature
sensor
VTo measure and secure the DHW water temperature
an installed temperature sensor or aquastat on the
DHW tank is reqiured.
Danger: Risk of fatal injury from electric
shock.
VElectrically disconnect the system.
For DHW temperature control, one can
use an aquastat or tank sensor depending
on the selected control strategy.
Follow the directions supplied by the manu-
facturer of the aquastat or tank sensor re-
garding electrical wiring connections and
temperature adjustments.

4
Tank Assembly
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice. 13
Installation of tank temperature sensor
(Supplied with R2107, 4000 series control or Stecca
control)
VIdentify and remove the DHW tank sensor from the
control package.
VSlide the sensor assembly (R2107 or 4000 controls)
into the dry well [5] (item 12, page 5) along with quarter
pie pieces and tension spring. The plastic wrap [3] will
automatically slide from the assembly.
The tension spring [4] ensures good contact between the
dry well and sensor surface for excellent temperature
sensing.
Fig. 9 Installation of DHW tank sensor
1Quarter pie piece
2Quarter pie sensor
3Plastic wrap
4Tension spring
5Dry well
VOnce fully inserted, slide locking tab [1] over dry well
[2].
VGuide sensor wire to suitable control panel and use
strain relief. The wiring cannot be in contact with hot
boiler parts.
Fig. 10 Installation of locking tab.
1Locking tab
2Dry well
Make sure to have the entire sensor surface
come in good contact with the dry tank well.
56
5
4
123
56
2
1

4Tank Assembly
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
14
Installation of aquastat
VRemove cover from aquastat [2] ). Loosen hex head
screw from cover.
VSecure aquastat [2] with 2 screws [1] to the mounting
bracket.
Fig. 11 Installation of aquastat bracket
1Sheet metal screws
2Aquastat
3Mounting bracket
VSlide capillary and tension spring together into the dry
well.
VSecure mounting bracket [3] with 4 sheet metal
screws [1] to tank jacket.
VInstall aquastat cover in its place.
Fig. 12 Installation of aquastat
1Sheet metal screws
2Aquastat
3Dry well
4Capillary
5Tension spring

4
Tank Assembly
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice. 15
4.2 SM400/1 Placement and Installation
VPlace tank shell in desired location.
VSlide insulation disc under tank between the tank sup-
ports.
4.2.1 Installation of M2 - M5 temperature sensors
Alternatively to the sensor dry wells the M2 - M5 sensor
tension brackets can be used to install temperature sen-
sor on the outside of the DHW tank shell.
VUse heat conducting paste to improve contact.
VSlide sensor surface behind tension bracket to ensure
that the entire sensor surface is in contact with the tank
shell.
VCarefully route the sensor wiring.
VIn order to install a well, remove the ½" cap (M) and
install a ½" dry well.
Fig. 13 Installation of temperature sensor
1Temperature sensor
2Tension bracket
MDry well, for temperature sensor (FB) or Aquastat
M2 Alternative location for DHW temperature sensor (FB) or
shut-off sensor for loading by solid fuel boiler (FPU)
M3 Solid fuel boiler on temperature
M4 Temperature measuring point #2 for solar DHW sensor
(FSS)
M5 Temperature sensor location, to switch operation between
a solid fuel boiler and gas/oil boiler
Make sure to sensing elements are fully in-
serted into the wells and that they make good
surface contact.

4Tank Assembly
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
16
4.2.2 Installation of Tank Insulation for SM400/1
Tank
VRoute sensor wiring carefully along tank shell.
VConnect both pieces of insulation [6] on the front of the
tank shell.
VSlide front cover pieces [4] in place.
VConnect both insulation pieces at the back side of the
tank.
VSlide small locking pieces [5] in place.
VFully engage the front cover pieces.
VFurther tighten the insulation in the back of the tank.
VPut top foam piece [2] and top cover [1] in place.
Review entire insulation for proper fit.
Fig. 14 Insulation installation for SM400/1 tank
1Tank top cover
2Top insulation piece
3Cover of top of locking piece
4Front locking piece
5Short locking piece
6Insulation
7Bottom insulation disc
We recommend to only installing the insula-
tion after all piping and a water test has been
successfully completed.
The insulation is best installed at a room tem-
perature of 59 °F/15 °C. Slight tapping on
the insulation in the direction of the connec-
tion eases the installation of the insulation.

4
Tank Assembly
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice. 17
4.3 Water side Piping Connections for
both Tank Models
VConsider the volume of the solar heating coil of the
Solar tank when sizing the thermal expansion tank.
VInstall sensor wires on rear side of tank through insula-
tion to control or alternate heat source.
VConnect tank piping in such a manner that internal
recirculation is not possible.
VInstall piping connections without undue stress.
VInstall furnished tank fittings to their proper connec-
tions.
VCheck all connections for leaks.
Fig. 15 Piping Connections (Basic diagram)
1DHW tank
2Isolation valve
3P & T valve (combined with DHW outlet connection)
4Flow check valve
5Tank coil charging pump
6Bronze DHW recirculation pump (optional)
7Vacuum breaker
8Tank drain valve
9Thermal expansion tank
10 Thermostatic mixing valve
AW DHW outlet
EZ DHW recirculation connection
VS2 Tank coil supply connection
RS2 Tank coil return connection
EK Cold feed connection
EL Tank drain connection (combined with EK connection)
Danger: Fire danger due to soldering and
welding!
VTake proper precautionary measures dur-
ing soldering and welding, as the insula-
tion material is combustible.
VCheck the insulation following work for ir-
regularities.
Warning:
Scalding due to excessively hot water!
During solar operation, the domestic hot
water can reach 194 °F/90 °C temperature.
A thermostatic mixing valve must be placed
on the DHW tank outlet to avoid scalding
through improper adjustment.
VInstall a thermostatic mixing valve
between the hot water outlet and
cold water inlet connections when
using the SM300/1 or SM400/1 tank
for solar applications. Buderus
supplies a thermostatic mixing valve
as part of the solar pump station.
It is not a part of the solar hot water
heater.
Caution: Water damage
VInstall tank drain and other accessories
prior to filling the tank.
VClose off all non using tank tappings.
Caution: Be careful not to damage non heat
resistant materials (e.g. PEX tubing).
VUse installation materials that can handle
temperatures in excess of 176 °F/80 °C.

4Tank Assembly
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
18
Installation of tank kit components
VAttach a note to discharge piping saying: "Do not close
off discharge. Water can discharge from piping during
operation".
VSize discharge piping to conform with relief valve dis-
charge dimension (Tab. 2).
VPeriodically verify proper relief valve operation.
Fig. 16 Tank kit connections on solar water heater
1T piece with P & T valve
2Cap for DHW recirc connection
3Bracket for aquastat
4Tee piece with drain valve
Danger: Personal and system damage due
to incorrectly installed relief valve discharge
line!
VPipe relief valve discharge piping full port
to nearest floor drain. (Maximum length:
6 ft and maximum 290° elbows).
Minimum pipe
size
Water volume Max. coil input
liter Gal kW BTU/hr
¾" 200-400 53-103 58 198,000
Tab. 2 Sizing of the P & T valve discharge line

4
Tank Assembly
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice. 19
4.4 Connections for Solar station KS
VConnect solar pump station KS [4]to the lower coil
connections of the solar tanks SM300/SM400 to the
connections VS1 (supply solar) and RS1 (return solar).
VConnect the alternative back-up heat source to the
upper tank coil connections at the VS2 (supply boiler)
and RS2 (return boiler).
VUse piping connections made from copper, red brass
pipe or non-galvanized steel material for connections
between solar pump station KS [4]and solar hot water
heater [5].
Fig. 17 Connections for solar pump station KS
1Supply piping to solar panels
2Return piping from solar panels
3Boiler or alternate heat source for back-up heating of
DHW
4Solar pump station KS
5Solar hot water heater
Grounding of water piping
VPlace a grounding strap on both the supply and return
piping to the tank. (Suitable location).
VConnect both grounding lines (AWG9) with a suitably
heavy line to the main ground of the electrical system.
Piping will receive an automatic air vent during
roof installation (accessory)
VRoute the piping with a steady slope down from the air
vent. Install an air vent where necessary at every air
high point in the piping system. (Temperature range up
to 302 °F/ 150 °C).
Warning: Potential system damage due to
very high temperatures and pressures!
VUse pressure and temperature resistant
piping connections.
VUse not any galvanized piping, connec-
tions and graphite or plastic gasket mate-
rials or PEX or plastic piping or
connections of any such type.
VWhen soldering piping connections, make
sure to use high temperature rated lead
free solder.
(Melt temperature > 455 °F/ 235 °C).
For proper, trouble free and efficient opera-
tion of the entire system make sure to proper-
ly vent the system. Directions for proper
system venting can be found in the Installa-
tion Instructions of the KS solar station.
Make sure to have all piping connections
done by a licensed contractor.

4Tank Assembly
Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
20
4.5 Connections for High Output Indi-
rect Fired Tank Piping
The SM300/1 and SM400/1 tanks can also be used for
high capacity indirect fired hot water tanks. Two scenarios
exist.
4.5.1 Serial Connections of the bottom and top
coils
VConnect SM300/1 or SM400/1 coils in series by con-
necting the upper connection of the lower coil to the
lower connection of the upper coil.
VConnect tank charging pump to the upper connection
of the top coil.
VConnect lower connection of the lower coil to the
boiler return piping.
VInstall aquastat or temperature sensor into M1 dry well
for the SM300/1 tank (Fig. 3, page 7) or use the M dry
well connection for the SM400/1 tank. (Fig. 4, page 8).
4.5.2 Parallel Connections of bottom and top
coils
The SM300/1 and SM400/1 internal coils can also indi-
vidually connected to dedicated tank charging pumps.
VConnect one tank charging pump to pump into the top
connection of the top coil.
VInstall its aquastat or temperature sensor into dry well
M1 for the SM300/1 (Fig. 3, page 7)or dry well M for
the SM400/1 tank (Fig. 4, page 8).
VConnect the second pump to pump into the top con-
nection of the lower coil.
VInstall its aquastat into dry well M2 for the SM300/1
(Fig. 3, page 7) or dry well M1 for the SM400/1
(Fig. 4, page 8).
In case of using a 2000 or 4000 series control, the indi-
vidual tank charging pumps must be electrically combined
as the controls do not have 2 separate wiring terminals
available.
VUse terminal PS.
VPlease note that the maximum combined amp draw can
NOT exceed 5 Amp.
VWhen using pumps with high amp draws, use isolation
relays.