Buderus Logano plus GB402 Installation And Maintenance Instructions Manual
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Buderus Logano plus GB402 Installation And Maintenance Instructions Manual

Floor standing gas condensing boiler
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Installation and maintenance
instructions for contractors
Logano plus GB402
Floor standing gas
condensing boiler
Read carefully prior to
installation and maintenance.

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Summary of Contents for Buderus Logano plus GB402

  • Page 1 Installation and maintenance Floor standing gas condensing boiler instructions for contractors Logano plus GB402 Read carefully prior to installation and maintenance.

  • Page 2: Table Of Contents

    7.8.3 Accessing the service level on the RC35 and 2.7.1 Logano plus GB402 dimensions ....8 displaying monitoring data ..... . 24 2.7.2 Technical data .
  • Page 3 Keyword index ........57 Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 4: Key To Symbols And Safety Instructions

    ▶ Never operate the boiler in rooms that are permanently occupied. ▶ Do not cover or reduce the size of ventilation apertures in doors, windows and walls. If draught-proof windows are fitted, ensure there is an adequate supply of combustion air. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 5: About The Appliance

    Determined use Instructing the customer The Logano plus GB402 is designed for conventional use as a gas ▶ Explain to the customer how the boiler works and how to operate it. condensing boiler for DHW and central heating.

  • Page 6: Product Description

    About the appliance Product description The Logano plus GB402 is a gas condensing boiler with an aluminium heat exchanger. Fig. 1 Logano plus GB402 - main components Boiler front panel The main components of the Logano plus GB402 ( Fig. 1) are: Gas train •...

  • Page 7: Scope Of Supply

    * available as an optional accessory Scope of supply The Logano plus GB402 is supplied as standard with a Logamatic BC10 Accessories basic controller and the MC10 control unit in 3 separate packages.

  • Page 8: Dimensions And Specification

    About the appliance Dimensions and specification 2.7.1 Logano plus GB402 dimensions Fig. 3 Dimensions and connections for the Logano plus GB402 (dimensions in mm) [AA] = Flue gas outlet [AKO] = Condensate outlet [EV] = Combustion air pipe inlet (balanced flue operation only)

  • Page 9: Technical Data

    Residual draught, fan (flue gas and combustion air system) Exhaust system Open flue operation: B Type (according to DVGW regulations) Balanced flue operation: C Tab. 3 Technical data Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 10 If the boiler is to be replaced in existing systems: ▶ Consult gas suppliers to ensure that the nominal gas pressure according to Tab. 5 (country-specific gas category and supply pressures) is adhered to. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 11: Regulations

    Where possible, transport the boiler to the installation location in its shipping packaging to protect it from % Load in Summer Low level High level contamination. Tab. 6 Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 12: Lifting The Boiler Off The Pallet

    Protect boiler from contamination if the boiler is not to be taken into use immediately. Dispose of packaging in an environmentally responsible manner. Fig. 5 Separating the boiler from the pallet Locking screws Fixing bar Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 13: Recommended Wall Clearances

    Fig. 8 Levelling the boiler Fitting Making the flue gas connection Observe all country-specific requirements when installing the flue system. Fig. 7 Wall clearances in the installation room Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 14: Installing The Condensate Hose

    • Country-specific requirements • The flue pipe cross-section must comply with all current regulations • Select the shortest possible route for the flue pipe and install it with a slope towards the boiler. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 15: Fitting The Boiler Cover

    ▶ Fit adaptor [2] (accessory) on the cross-brace and seal with sealant (accessory). ▶ Insert and seal in a ventilation air bend in the adaptor. ▶ In cascade arrangements, ensure that each boiler is equipped with a separate ventilation air line. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 16: Making The Heating Circuit Connection

    ▶ Fit union with gasket to connector of fitting manifold [4] and secure to Boiler return (RK) the cap valve on the distributor. DN80 PN6 standard flange EN1092 Tab. 9 Water connection dimensions Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 17: Connecting The Return

    ▶ Insert a gasket between the flange on the boiler and the threaded flange on the return. ▶ Secure the flange connection with 4 screws, washers and nuts. Fig. 15 Safety valve (up to 3 bar) Safety valve Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 18: Installing A Dhw Cylinder

    ▶ Prior to all electrical installation work, isolate all poles of the mains power supply and secure against unintentional reconnection. When connecting electrical components, also observe the connection diagram and instructions of the relevant product. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 19: Installing The Control Unit

    Fig. 20 Fitting the control unit (Logamatic MC10) 6.7.2 Making the power supply connection Create a permanent power connection in accordance with local regulations. ▶ Release two screws on the control unit cover and remove it. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 20: Providing The Fuel Supply

    ▶ Secure the gas line with pipe clips so that the gas connection is free from any stresses. ▶ Close the gas isolator. Fig. 23 Inserting the function module Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 21: Commissioning

    ▶ Never spray or let leak detection agent drip onto cable ventilation ( Chapter 6.1, page 13). entries, plugs or electrical cables/leads. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 22: Recording Gas Parameters

    • Applicable for 10.85 to 12.4 kWh/m Upper Wobbe index for 0 °C, 1013 mbar: • Adjusted to 12.2 kWh/m • Applicable for 10.6 to 13.8 kWh/m Tab. 10 Factory settings Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 23: Purging The Gas Line

    ▶ Press until the decimal point in the status display illuminates (at least 2 seconds). ▶ Carrying out a flue gas test. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 24: Accessing The Service Level On The Rc35 And Displaying Monitoring Data

    The current burner output (set/actual) and the flame current can be checked in these menus. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 25: Checking And Adjusting The Gas:air Ratio

    7.10.2 Setting and checking the CO values under partial load ▶ Press until the decimal point in the status display illuminates (at least 2 seconds). This turns on the flue gas test. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 26: Switching The Status Display On The Bc 10 To Show The Boiler Temperature Status

    ( Chapter 7.18, page 28): – Flue dynamic pressure – Flue gas temperature – Air temperature t – Net flue gas temperature t – Carbon dioxide content (CO or oxygen content (O – CO value Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 27: Function Tests

    ▶ Never spray leak detection agent onto cable entries, plugs or electrical cables. Do not allow it to drip onto them either. ▶ To prevent corrosion, carefully wipe off the leak detection agent afterwards. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 28: Commissioning Report

    – Checking the ionisation current ____________ μA Fitting sections of the casing Inform operator; hand over technical documentation Correct commissioning by the installing contractor Signature:______________________ User signature Signature:______________________ Tab. 12 Commissioning report Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 29: Shutting Down The Heating System

    The results of the services must be ▶ Check the concentration of any antifreeze/additives that may be used recorded in the inspection and maintenance report. in the system fill/top-up water annually. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 30: Internal Leak Test

    15 x 1 18 x 1 22 x 1 28 x 1.5 35 x 1.5 45 x 1.5 Tab. 15 Pipework volume (V ) subject to pipe length and diameter pipe Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 31: Carrying Out A Leak Test

    ▶ Check all sealed points in the tested pipework section using a foaming leak detection agent. ▶ If required, seal any leaks and repeat the test. ▶ If no leaks are found, replace gas train. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 32: Checking The Heating System Operating Pressure

    ▶ Observe all country-specific regulations and standards regarding the prevention of drinking water contamination. ▶ Vent the heating system via the radiator air vent valves. ▶ Check the operating pressure again. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 33: Burner Removing And Cleaning

    ▶ Undo the 4 screws from gas valve flange [1] and undo the gas ▶ Carefully pull out the burner towards you. connection. Fig. 47 Undoing the nuts at the mixture manifold Fig. 45 Undoing the gas connection Fixing nuts with washer Screws Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 34: Cleaning The Heat Exchanger

    ▶ Re-install the burner rod with a new gasket. cover. ▶ Removing the cover. CAUTION: Risk of injury from sharp edges on the cleaning blades. ▶ To avoid injury, wear gloves when cleaning the boiler using cleaning blades (accessories). Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 35 ▶ Re-install the siphon ( Chapter 6.2, page 14). ▶ Check the condensate hose between the boiler flue connection and the siphon for free flow. 6720646293-01.1BU Fig. 53 View of cleaning cover 320 kW 395-620 kW Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 36: Inspection Of Burner Electrodes

    We recommend the replacement of the electrode block as part of the annual service. Fig. 57 Undoing the gas valve Gas train Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 37: Changing The Gas Filter

    Fig. 61 Dissembling the components of the ventilation air collector Assembly plate Carriage Rear screw Front screw Fig. 59 Dissembling the components of the ventilation air collector Fan inlet nozzle Impeller Clamp Front semi-shell Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 38: Refitting Detached Parts

    ▶ Push the ventilation air hose together with the connector onto the ventilation air collector and secure with a hose clip at the upper adaptor. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 39: Checking For Leaks During Operation

    ▶ Always replace the electrode block gasket when replacing electrodes. ▶ During every service, replace the gasket at the gas connection flange of the gas valve. ▶ Generally, replace damaged gaskets or ones that appear aged. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 40: Inspection And Maintenance Reports

    13. Check that the control unit is set correctly for the – prevailing conditions (see control unit documentation). 14. Final checking of inspection work. – Confirm professional inspection Company stamp/date/signature Tab. 17 Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 41 ________ °C ________ °C ________ °C _________% _________% _________% _______% _________% _________% _________% _________% _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm ________μA ________μA ________μA ________μA ________μA ________μA ________μA ________μA Tab. 18 Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 42 Confirm professional service. Company stamp/signature Tab. 19 Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Company stamp/ signature Company stamp/ signature Company stamp/ signature Company stamp/ signature Company stamp/signature Tab. 20 Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 43: Troubleshooting

    If the display then reverts to a normal operating message, the fault has been cleared. Should the fault recur, repeat the reset two or three times. Fig. 64 Clearing a fault with the "Reset" key Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 44: Operating And Fault Displays

    (high Check whether a cast section is limit safety cut-out (STB)) blocked with dirt. and compare with the curve. Tab. 21 Operating codes Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 45: Fault Displays

    Unfavourable hydraulics in two- boiler systems: boilers influence each other, e.g. via the return or flow. Tab. 22 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 46 SAFe and the MC10. connections are OK. with the SAFe. required data is supplied by the SAFe. Tab. 22 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 47 Replace ionisation electrode. > 0.9 μA. the electrodes. Replace gas train. Check gas train function. Tab. 22 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 48 Check the continuity of the If required, replace faulty has opened. external components components. components. tied into the MC10 safety chain has been interrupted. Tab. 22 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 49 Remedy any short circuit. sensor fault short circuit (voltage sensor. (short circuit). < 0.5 V). Check water pressure sensor. Replace water pressure sensor. Tab. 22 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 50 Please note: this fault can only be reset via The SAFe has developed a fault. Replace the SAFe. the button on the SAFe. Tab. 22 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 51 Replace flow temperature sensor reading measurements of the temperature sensor. sensor in case of deviations. flow temperature deviate severely from each other. Tab. 22 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 52: Appendix

    Resistance in  Temperature in °C Two identical sensors (dual sensors) installed in one sensor casing are used as boiler sensors. All temperature sensors on the GB402 have the same sensor curve. Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 53: Hydraulic Resistance

    NOTICE: Operating faults through power failure! ▶ When connecting external components to the MC10 control unit, ensure that the total power consumption of these components does not exceed 5 A. Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 54 Appendix Fig. 67 MC10 connection diagram 1) The total current of all externally connected components must not exceed 5 A. Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 55 Fuse inside the MC10 Fuse inside the BC10 basic controller Logamatic MC10 Function modules xM10 Spare fuse 10 AT RC35 programming unit or dummy cover Basic controller BC10 Appliance fuse 10 AT Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 56: Safe Connection Diagram

    Fan (PWM signal) Ignition transformer Ionisation Gas solenoid valve (MV1/MV2) Gas pressure switch Mains entry Water pressure sensor Flue gas pressure limiter Flow temperature sensor [10] Return sensor [11] Boiler Sensor Logano plus GB402 – 6 720 804 428 (2012/09)

  • Page 57: Keyword Index

    Providing the fuel supply ............Regulations ..........Removing the burner ....... Reports, inspection and maintenance ............ Safety regulations ............Standards ............. Three-way valve ............Transport ..............Type ............. Wall clearances ............Wet cleaning Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 58 Notes Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 59 Notes Logano plus GB402 – 6 720 804 428 (2012/09)
  • Page 60 Buderus Cotswold Way, Warndon, Worcester WR4 9SW All Enquiries: 0844 892 3004 www.buderus.co.uk In the UK and IE, Buderus is a brand name of Bosch Thermotechnology Ltd.

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