Buderus G315 Assembly, Maintenance And Operating Instruction
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Buderus G315 Assembly, Maintenance And Operating Instruction

Buderus G315 Assembly, Maintenance And Operating Instruction

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5647 853-5/98 USA
A s s e m b l y, Maintenance and
Operating Instructions
Buderus G315 Boiler
Save These Instructions!
G315
This assembly, maintenance and operating
manual must be kept near the boiler !

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Summary of Contents for Buderus G315

  • Page 1 5647 853-5/98 USA A s s e m b l y, Maintenance and Operating Instructions Buderus G315 Boiler G315 This assembly, maintenance and operating Save These Instructions! manual must be kept near the boiler !

  • Page 2: Table Of Contents

    TABLE OF CONTENTS General Guidelines Boiler Operating Data Technical Data Boiler Foundation and Minimum Boiler Clearances Assembly Tools/Tools Req’d for Boiler Assembly Boiler Assembly 8-11 Hydrostatic Test Installation of Boiler Components 13-15 Installation of Insulation & Boiler Jacket Panels 16-19 Installation of Hydronic Control Components Maintenance Instructions 21-23...

  • Page 4: General Guidelines

    General Guidelines General guidelines Installation, maintenance and service of this boiler must only be carried out by a qualified contractor. The assembly sequence is essential to reliable operation of the boiler and associated heating system. The boiler can be assembled, hydrostatically tested and operated without boiler insulation and jacket panels. These items can be installed at a later date without disrupting boiler operation.

  • Page 5: Boiler Operating Data

    Any approved (based on application testing at burner manufacturer’s facilities) oil or power gas burner can fire into G315 boilers. Burners with low fire start or two stage firing are recommended. The high fire setting on the burner should match the rated output of the boiler to prevent condensation in the heat exchanger.

  • Page 6: Technical Data

    Technical Data ” Supply ” Return ” 37” ” ” 1” ” 7” max. ” 9” 3/4” Drain Front View Side View Top View Rear View Fig. 1 Table 1: Boiler Dimensions Gross Output (Btu/hr.) 358,000 478,000 580,000 682,000 785,000 No.

  • Page 7: Boiler Foundation And Minimum Boiler Clearances

    4 Boiler Foundation and Minimum Boiler Clearances Boiler foundation preparations ” 1 / 2 10” It is required that the boiler is placed on a level, smooth concrete base, of sufficient strength. The width of the platform must be 33 1/2”. Length L 1 is the platform length.

  • Page 8: Assembly Tools/Tools Req'd For Boiler Assembly 5

    Assembly Tools/Tools Req’d for Boiler Assembly 5 Assembly tools and auxiliary assembly materials Boiler assembly tool rods size 2.2 (2 pieces) Wooden or rubber mallet Half-round rough file Flat head and Phillips screwdrivers Flat chisel, steel strips for boiler support Metric wrenches sizes 13, 19, 24, 36 and socket size 19 (US equivalent sizes may also be used) Cleaning rags, machine oil, gasoline or paint...
  • Page 9 6 Boiler Assembly Boiler block sectional arrangement The boiler is always assembled starting with the rear section Rear Front section and finishing with the front section. section Middle sections Flue gas collector The arrow markings on the sections must point to the rear (Fig.

  • Page 10: Boiler Assembly

    Make sure surfaces are dry, clean and free of any oily residues. • Apply the Buderus Haftgrund Primer 181 to all sealing grooves using a small paint brush (Fig. 10). • The sealing of the flueway of each section is achieved with the sealing cord.
  • Page 11 6 Boiler Assembly Sealing groove Coat with orange • Insert the elastic sealing cord (“Dichtschnur”) into the sealing compound sealing groove only on the front side of the rear section. Start at the top and press lightly to adhere to the Primer 181 (Fig.
  • Page 12 Boiler Assembly Pull sections together with boiler assembly tool Pressure flange Assembly rod • Place assembly rods through upper and lower ports as shown (Fig. 14). • Slide small pressure flange on each end of the lower assembly rod. • Thread the pressure flanges on the rods.

  • Page 13: Hydrostatic Test

    7 Hydrostatic Test Hydrostatic Test Preparing for the hydrostatic test 3/4” tapping • A pop-off relief valve is recommended on cold water Supply feed line to prevent over pressurization. header Return header • Install return header pipe per instructions on page 13. •...
  • Page 14 Installation of Boiler Components Flue gas collector installation Studs • Install the pliable sealing rope in the groove of the rear section. • Place the flue gas collector on the studs and tighten with washers and nuts provided to ensure a gas tight seal (Fig.
  • Page 15 8 Installation of Boiler Components Flue gas baffle plates Flue gas baffle plates • Flue gas baffle plates are factory installed in an assembled boiler. Remove corrugated card board from baffle plates and insert plates as shown in Figure 21. NOTE: Install the baffle plates per schedule below.

  • Page 16: Installation Of Boiler Components

    Cut and drill the burner mounting plate according to burner specifications. (The burner plate can be M 12 x 45 cut by Buderus Hydronic Systems per specifications submitted with the boiler order). • Mount burner mounting plate to burner door. Seal with 1/2”...
  • Page 17 9 Installation of Insulation & Boiler Jacket Panels Location of support brackets for jacket panels • Loosen the first nut from the upper front tie bar. • Position the upper front support bracket between the first and second nut. Point the folded edge of the bracket forward (Fig.
  • Page 18 Installation of Insulation & Boiler Jacket Panels • Arrange the insulation blanket according to Insulation blanket Figure 28. Rear insulation piece • Push the insulation between the boiler feet. Cut-out provisions are made in the blanket for this purpose. • Install the rear insulation piece with the return connection cut-out upward on the vent connection (Fig.
  • Page 19 Place the rear top cover between the side panels Knock-out with its knock-outs aligned with the support bracket (Fig. 31). NOTE: In case a Buderus Ecomatic control is used, install the sensors and capillaries in the appropriate wells before all top jacket panels are in place. Side panel Fig.

  • Page 20: Installation Of Insulation & Boiler Jacket Panels

    Installation of Insulation & Boiler Jacket Panels • Secure the lower rear panel with the knock-out for the drain on the bottom with screws to the side panels (Fig. 34). Screw Lower rear panel Fig. 34 Front panel Folded edge •...

  • Page 21: Installation Of Hydronic Control Components

    10 Installation of Hydronic Control Components Installation of supply header and controls NOTE: The G315 boiler can be equipped with 2” or 3” supply/return connections depending on items ordered. The 3” supply manifold is suitable for commercial installations. • Refer to Figure 37 for details on the 3” supply header for use in commercial installations requiring multiple aquastats.
  • Page 22 Check burner operation on a regular basis. Verify efficiency of boiler and ensure soot free operation. Inspect flue way passages. Clean boiler annually. Cleaning brushes are available from Buderus Hydronic Systems. Burner door Boiler cleaning with brushes • Disconnect electricity. (Disconnect main system switch and padlock open to prevent the burner from being energized during service).
  • Page 23 11 Maintenance Instructions Baffle plates • Remove flue gas baffle plates from secondary heat exchanger from the front (Fig. 39). Fig. 39 • Remove the screws from the lower rear panel at the lower back of the boiler. Remove this panel (Fig.

  • Page 24: Maintenance Instructions

    Replace sealing ropes if damaged or #3 for combustion chamber walls hardened by contacting Buderus Hydronic Systems. Fig. 42 • Insert flue gas baffles. See page 14 for details. • Reinstall clean-out covers and secure burner door.

  • Page 25: Optional Noise Reduction Equipment

    12 Optional Noise Reduction Equipment Vent connection Sealing rope locking collar Vent connection locking collar ” 8” 6” 2” ” 2” ” Fig. 44 Muffler Assembly Components not in stock. Allow 4-6 weeks for delivery.

  • Page 26: Shipping Component Listing

    Shipping Component Listing Table 6. Shipping Component Reference Table Boiler Sections G315/5 G315/6 G315/7 G315/8 G315/9 part no. 5029530 5029540 5029550 5029560 5029570 Front and rear section, 3 intermediate sections, burner door part no. 5621512 Additional intermediate section/s part no. 5479400...

  • Page 27: Supply Temperature Control

    Refer to Figure 45 for a typical control schematic for a single boiler with supply temperature control. Control components can be furnished by Buderus Hydronic Systems, Inc.; relay, burner and circulator operating controls can not be provided.
  • Page 28 Notes...
  • Page 29 Notes...
  • Page 30 (date of installation) Buderus Hydronic Systems 50 Wentworth Avenue Londonderry, NH 03053 USA Tel: (603) 552-1100 • Fax: (603) 421-2719 www.buderus.net Buderus Hydronic Systems, Inc. reserves the right to make changes without notice due to continuing engineering and technological advances.

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