Buderus Logano plus GB402 Installation And Maintenance Instructions For Contractors
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Buderus Logano plus GB402 Installation And Maintenance Instructions For Contractors

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Gas-fired condensing boiler
Installation and maintenance instructions for contractors
Logano plus GB402
Read carefully prior to installation and maintenance.

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Summary of Contents for Buderus Logano plus GB402

  • Page 1 Gas-fired condensing boiler Installation and maintenance 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 ..... . 27 2.7.2 Specifications .
  • Page 3 Keyword index ........61 Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 4: Key To Symbols And Safety Instructions

    ▶ Any other combinations, accessories and wearing parts may only be used if these are specifically designed for the application and impair neither the performance characteristics nor the safety requirements. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 5: Information On The Device

    CE-0085BU0332 Table 2 Approval data Determined use The Logano plus GB402 is designed for conventional use as a gas condensing boiler for DHW and central heating. Only gas supplied by the public gas supplier can be used. Observe the details on the data plate and the specification (...

  • Page 6: Product Description

    Information on the device 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 valve •...

  • Page 7: Scope Of Delivery

    * available separately Scope of delivery The Logano plus GB402 is supplied as standard with a Logamatic BC10 ACCESSORIES basic controller and the MC10 control unit in 3 separate packages. Many individual accessories are available for this boiler.

  • Page 8: Dimensions And Specifications

    +0,3 Ø 250 +0,7 6 720 618 585-16.4T Fig. 3 Dimensions and connections for the Logano plus GB402 (dimensions in mm) Flue outlet MAG Optional connection for a diaphragm expansion vessel to protect AKO Condensate outlet a single boiler Combustion air pipe inlet (balanced flue operation only,...

  • Page 9: Specifications

    EN 1443 Corrosion resistance classification to be used Min. 2 Min. 2 Min. 2 Min. 2 Min. 2 for flue system in accordance with EN 1443 Table 4 Specifications Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 10 AT, BY, CH, CZ, 320-620 2H, G20 DK, EE, ES, GB, HR, IE, IT, LT, LV, PT, RO, RS, RU, SI, SK, TR, UA Table 6 Country-specific gas categories and supply pressures Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 11: Product Data For Energy Consumption

    6 (country-specific gas category and supply pressures) is adhered to. Product data for energy consumption The product data on energy consumption can be found in the operating instructions for the user. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 12: Regulations

    NOTICE: System damage through frost! ▶ If there is the risk that pipework may freeze up when operating in room temperature-dependent mode (e.g. radiator in a garage), set the pump overrun time to 24 hours. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 13: Combustion Air Connection/Flue Connection

    Validity of regulations Modified regulations or supplements are also valid at the time of installation and must be observed. 1) In addition to this, country-specific and local regulations must be observed. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 14: Transporting The Boiler By Crane/Hoist

    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 – 6 720 820 700 (2018/01)

  • Page 15: Installing The Boiler

    Where applicable, allow extra wall clearances for additional components, for example DHW cylinder, pipe connections or other components on the flue gas side etc. Fig. 8 Levelling the boiler Fig. 7 Wall clearances in the installation room Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 16: Fitting

    The boiler must not be connected to any combined flue system with motorised combustion systems (e.g. combined heat and power unit). Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 17: Installing The Condensate Hose

    ▶ Connect the condensate hose from the siphon with a slope to the neutralising system. Where the neutralising system is installed outside the boiler, there is the option of guiding the condensate hose through the aperture in the back panel. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 18: Fitting The Boiler Cover

    6 720 618 585-46.2T Fig. 12 Ventilation air connection for balanced flue operation (accessory) Front boiler cover Ventilation panel Adaptor Rear boiler cover Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 19: Establishing The Heating Circuit Connection

    ▶ Seal in distributor [2] at flow connector [1] using a suitable sealant. ▶ Remove the union at the cap valve fitting [3]. ▶ Fit union with gasket to connector of fitting manifold [4] and secure to the cap valve on the distributor. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 20: Connecting The Return

    Make the connection of a DHW cylinder to the flow and return on site. The MC10 + BC10 control unit can switch the required external cylinder primary pump ( MC10/BC10 instructions). Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 21: Filling The Heating System And Checking For Leaks

    ▶ Prior to filling the heating system, carefully read the enclosed operator's log on water quality. ▶ Open safety caps on all automatic air vent valves. ▶ Open the fill and drain valve. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 22: Making The Electrical Connection

    NOTICE: System damage through incorrect control! ▶ Route high and low voltage cables separately inside the cable conduits. ▶ Route all cables that run towards the back through the cable trunking. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 23: Providing The Fuel Supply

    ▶ Press the front of the module downwards. stress. ▶ Secure the gas line with pipe clips so that the gas connection is free from any stresses. ▶ Close gas isolation valve. Fig. 23 Inserting the function module Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 24: Start Up The Heating System

    ( chapter 6.1, page 16). ▶ Never spray or let leak detection agent drip onto cable entries, plugs or electrical cables/leads. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 25: Recording Gas Parameters

    • Applicable for 10.9 to 12.4 kWh/m Upper Wobbe index for 0 °C, 1013 mbar: • Set to 12.2 kWh/m • Applicable for 11.5 to 13.1 kWh/m Table 11 Factory settings Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 26: Purging The Gas Line

    ▶ Press the key until the decimal point in the status display illuminates (at least 2 seconds). ▶ Carry out the flue gas test. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 27: Accessing The Service Level On The Rc35 And Displaying Monitoring Data

    The values monitored are displayed as a list; in other words, more venting values will appear if the rotary selector is turned. The current burner output (set/actual) and the flame current can be checked in these menus. Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 28 ▶ Read off load at the RC35 or via the service key. values (natural gas DK CO rat.=12.0 Vol. – %) from Chapter 12.5, ▶ Wait until 20 % of the load is reached. page 60 Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 29 ▶ Press to change to the next status display. incorrect appliance setup, burner and/or heat exchanger contamination The boiler temperature is displayed. or burner faults. ▶ Identify and eliminate the cause. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 30: Function Tests

    ▶ Explain to the customer what to do in an emergency, e.g. a fire, ▶ To prevent corrosion, carefully wipe off the leak referring to the operating instructions. detection agent afterwards. ▶ Hand over the technical documents to the user. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 31: Commissioning Report

    Function tests – Checking the ionisation current ____________ μA Installing casing parts Inform operator; hand over technical documentation Correct commissioning by the installing contractor Signature:______________________ User signature Signature:______________________ Table 13 Commissioning report Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 32: Shutting Down The Heating System

    ▶ Slightly lift the front panel and remove by pulling forwards. DANGER: Risk to life through explosion of flammable gasses! ▶ Only registered gas fitters are permitted to carry out work on gas lines (observe local regulations). Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 33: General Work

    15 x 1 18 x 1 22 x 1 28 x 1.5 35 x 1.5 45 x 1.5 Table 16 Pipework volume (V ) subject to pipe length and diameter pipe Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 34: Carrying Out A Leak Test

    ▶ Check all joints 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 – 6 720 820 700 (2018/01)

  • Page 35: Checking The Heating System Operating Pressure

    Fig. 43 Removing the siphon ▶ Observe all regulations and standards applicable in Condensate pan outlet your country regarding the prevention of drinking Siphon water contamination. ▶ In Europe, observe standard EN 1717. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 36: Removing And Cleaning Burner

    ▶ Carefully pull out the burner towards you. 6 720 618 585-37.2T Fig. 45 Undoing the gas connection Fig. 47 Undoing the nuts at the mixture manifold Screws Fixing nuts Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 37: Clean Heat-Exchangers

    ▶ Re-install the burner rod with a new gasket. CAUTION: Risk of injury from sharp edges of cleaning blade! ▶ To avoid injury, wear protective gloves when cleaning the boiler using cleaning blades (accessories). Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 38 ▶ Re-install the siphon ( Chapter 6.2, page 17). ▶ 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 – 6 720 820 700 (2018/01)

  • Page 39: Inspecting The Burner Electrodes

    ▶ For completing maintenance see  Chapter 10.9, page 41. Gas valve If spare parts replacement is necessary, see from Chapter 10.8. ▶ For completing maintenance see  Chapter 10.9, page 41. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 40: Changing The Gas Filter

    ▶ Remove mounting plate [1] from the fan. ▶ Undo both rear screws [3] (joint between carriage [2] and fan [5] (do not remove). ▶ Support the fan and remove both front screws [4]. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 41: Refitting Detached Parts

    [1] as shown in Fig. 63 (below the guide rod). Fig. 62 Replacing the fan/carriage gaskets Fig. 63 Plug-in connection at the electrode block ▶ After the fan installation, check the gasket for correct seating. Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 42: Fitting The Gas Line To The Gas Valve

    10.12.3 Checking the gas/air ratio ▶ Measuring carbon dioxide content ( Chapter 10.5,page 35). 10.12.4 Confirming inspection and maintenance ▶ Sign the inspection and maintenance report in this manual ( Chapter 10.14, page 43). Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 43: Inspection And Maintenance Reports

    14. Check that the control unit is set correctly to meet – demand (see documents for the control unit). 15. Final checking of inspection work. – Confirm correct inspection Company stamp / date / signature Table 18 Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 44 ________ °C ________ °C ________ °C _________% _________% _________% _______% _________% _________% _________% _______% _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm ________μA ________μA ________μA ________μA ________μA ________μA ________μA ________μA Table 19 Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 45 Carry out a function check. Confirm professional maintenance. Company stamp/signature Table 20 Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Company stamp/signature Company stamp/signature Company stamp/signature Company stamp/signature Company stamp/signature Table 21 Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 46: Troubleshooting

    Should the fault reoccur, repeat the reset two or three times. 6 720 801 303-02.1T Fig. 65 Clearing a fault on the burner control unit Reset button Fig. 64 Clearing a fault with the "Reset" key Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 47: Operating And Fault Displays

    > 15K. temperature sensor using a boiler sensor (high limit thermometer. safety cut-out (STB)) and Check whether a cast section is compare with the curve. blocked with dirt. Table 22 Operating codes Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 48: Control Unit Fault Displays

    Unfavourable hydraulics in two-boiler systems: the boilers influence each other reciprocally, e.g. via the return or flow. Table 23 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 49 (Does the flame extinguish cut-out responds. reached its maximum after a controlled shutdown?) permitted level. Table 23 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 50 Replace ionisation electrode. 0.9 μA. the electrodes. Replace gas train. Check gas train function. Table 23 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 51 If required, replace faulty has opened. external components, components. components. which are integrated in the MC10 safety chain has been interrupted. Table 23 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 52 Remedy any short circuit. sensor fault short circuit (voltage < sensor. (short circuit). 0.5 V). Check water pressure sensor. Replace water pressure sensor. Table 23 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 53 Please note: this fault can only be reset via The SAFe has developed a fault. Replace the SAFe. the button on the SAFe. Table 23 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 54 Table 23 Fault displays 1) V = locking; B = blocking Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 55: Status Indicator Of The Burner Control Unit

    ........................off The burner control unit is not in operation Table 24 Display of the operating condition of the burner via the lighting of the reset button. Permanently   GREEN Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 56: Appendix

    NOTICE: Operating faults through power failure! ▶ When connecting external components to the MC10 control unit, ensure that these components do not exceed a total maximum power consumption of 5 A. Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 57 Appendix Fig. 67 MC10 connection diagram 1) The total current of all externally connected components must not exceed 5 A. Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 58 Logamatic MC10 Function modules xM10 Spare fuse 10 AT RC35 programming unit or dummy cover BC10 basic controller Appliance fuse 10 AT Fuse inside the MC10 Fuse inside the BC10 basic controller Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 59: Safe Connection Diagram

    Fan (pulse width modulation 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 – 6 720 820 700 (2018/01)

  • Page 60: Burner Setting

    (with the read-off example) 2max Read-off calculation: Default value: CO = 9.1 vol. – % Nominal value: CO = 12.0 vol. – % 2max Result: O = 5.1 vol. – % Logano plus GB402 – 6 720 820 700 (2018/01)

  • Page 61: Keyword Index

    Providing the fuel supply ............Recycling ............Regulations ........Removing and cleaning burner ....... Reports, inspection and maintenance ........... Safety precautions ............Sensor curves ............Standards ............. Three-way valve ............Transport ..............Type Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 62 Notes Logano plus GB402 – 6 720 820 700 (2018/01)
  • Page 63 Notes Logano plus GB402 – 6 720 820 700 (2018/01)

This manual is also suitable for:

Gb402-320-5Gb402-395-6Gb402-470-7Gb402-545-8Gb402-620-9

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