Buderus Logano GC124 II/SP Installation And Service Instructions Manual
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Buderus Logano GC124 II/SP Installation And Service Instructions Manual

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7 747 000 512 – 07/2006 US
Installation and Service
Instructions
Gas boiler
Logano GC124 II/SP
CAUTION!
Before placing this boiler in operation
observe the safety instructions of this
installation and maintenance manual.
WARNING!
Installation, adjustment, modification,
operation or maintenance of the
heating system carried out by
unqualified personnel may result in
property damage, personal injury, and
loss of life.
The directions of this installation and
maintenance manual must be followed
precisely.
Contact a qualified service company,
service provider or the gas company if
support or additional information is
required.
CAUTION!
The operating manual is a component
of the technical documentation handed
over to the operator of the heating
system. Discuss the instructions in this
manual with the owner or operator of
the heating system and ensure that
they are familiar with all information
required for operation of the heating
system.
In the Commonwealth of
Massachusetts this boiler must be
installed by a licensed plumber or gas
fitter.
Keep this installation and maintenance manual available for future
reference.
Please read carefully prior to installation and maintenance.
For installers

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Summary of Contents for Buderus Logano GC124 II/SP

  • Page 1 7 747 000 512 – 07/2006 US For installers Installation and Service Instructions Gas boiler Logano GC124 II/SP CAUTION! Before placing this boiler in operation observe the safety instructions of this installation and maintenance manual. WARNING! Installation, adjustment, modification, operation or maintenance of the...

  • Page 2: Table Of Contents

    ....... 42 We reserve the right to make any changes due to technical modifications. Installation and Service Instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 3 ........80 We reserve the right to make any changes due to technical modifications. Installation and Service Instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 4: Safety Considerations

    National Fuel Gas Code, ANSI people from entering, notify police and Z 223.1. fire departments from outside the building. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 5 Observe the local installation regulations. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 6: Tools, Materials And Accessories

    Dispose of any components of the heating system that require replacement in an environmentally prudent fashion. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 7: Product Description

    3 Ignition module (GC124 II only) 4 Boiler block with insulation 5 Burner 6 Boiler jacket We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 8: Dimensions And Connections

    For the size and dimensions of the main gas orifices, refer to Chapter 18, page 79. Fig. 3 Pressure drop/boiler We reserve the right to make any changes due to technical modifications Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 9: Scope Of Delivery

    1 plastic pack- Tab. 2 Scope of delivery On Palette Accessory Cleaning Brush Tab. 3 Scope of delivery We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 10: Moving The Boiler

    Fig. 4 Moving the boiler with rollers We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 11: Lifting And Carrying The Boiler

    7 747 000 511-04.0K Fig. 6 Lifting and carrying the boiler We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 12: Placing The Boiler

    3 Burner tray access door with combustion air opening as required per ANSI Z.223.1 (not supplied) for leveling purposes. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 13: Boiler Installation

    USER NOTE For better access remove the front door. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 14: Connecting The Heating System

    4 Heating system without low-water cut-off venting the boiler water from circulating by gravity during the cooling cycle. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 15 USER NOTE Ensure compliance with all state and local regulations pertaining to the installation of boiler systems. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 16: Electrical Connections

    Install an ON/OFF switch near the boiler per local code requirements. Fig. 10 ON/OFF switch (emergency shutoff switch) We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 17 WARNING! Make sure that all cables are routed in the ducts or on the boiler insulation. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 18: Fuel Gas Supply Connection

    0.60 and a gas pressure of 0.5 psi or less and a pressure gradient corresponding to a water column of 0.3 inches. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 19 If the boiler is assembled and not in use, CAUTION! note the following: Protect the boiler connections from dirt by closing the connections. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 20: Filling Heating System And Checking For Leaks

    45 psi lief valve) 58 psi (with special relief 75 psi valve) Tab. 6 Pressure Test We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 21 Close fill valve and remove fill hose for fill valve. Fig. 15 Pressure temperature gauge 1 Pressure gauge 2 Set pressure mark We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 22: Check Openings For Combustion Air Supply And Venting

    4. If the openings are connected to ventilation ducts, the ducts must have the same cross-section area as the openings. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 23: Requirements For Connection To Chimneys Or Venting Systems

    Run all venting fans We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 24: Flue Pipe Installation

    We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 25 1 Vent damper connection plug 2 Aquastat 3 Power supply indicator light 4 Aquastat temperature control knob We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 26: Placing The Heating System In Operation

    2. Check all combustion air and all flue gas ducts and openings. ( Chapter 8 and 9, page 22 and page 23). We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 27 9. Follow the safety information on the following pages. Fig. 19 Opening front door We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 28 We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 29: Starting Up The Gc124 Ii And Gc124 Sp Boilers

    (set temperature dial at least 10°F above ambient). Fig. 21 ON/OFF switch 1 Emergency shutoff switch We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 30: Final Start-Up Procedures For Gc124 Ii Models

    1 ON/OFF knob (shown in ON position) power source and inform your customer service technician or gas company. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 31 4 Safety screw on orifice pressure measurement port 5 Safety screw on ignition gas adjustment screw We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 32 Fig. 26 GC124 II gas valve 1 ON/OFF knob (shown in ON position) We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 33 3 Vent damper 4 Damper blade position indicator 5 Vent damper motor 6 Flue gas collector 7 Boiler We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 34 25. Set aquastat to its desired setting. 26. Replace front door and close. Fig. 28 Checking aquastat 1 Adjustment knob We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 35: Final Start-Up Procedure For Gc124 Sp Models

    Contact your service technician or gas supplier immediately and have the fault repaired. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 36 4 Screw plug for gas pressure measurement port 5 Safety screw for manifold pressure setting 6 Screw plug for manifold measurement port We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 37 We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 38 3 Vent damper 4 Damper blade position indicator 5 Vent damper motor 6 Flue gas collector 7 Boiler We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 39 34. Set the aquastat to its desired setting 35. Replace front door and close Fig. 36 Checking aquastat 1 Adjustment knob We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 40: Start-Up Protocol

    Inform the customer of the correct fuel and enter it in the table (operating manual of boiler). We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 41: Informing The Owner/Operator And Handing Over Technical Documentation

    Sign the protocol on page 40 with the owner and hand over the technical documentation. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 42: Taking The Heating System Out Of Operation

    3. Shut down the heating system using the boiler emergency shutoff switch or the corresponding circuit-breaker. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 43: Boiler Inspection And Maintenance

    1. Visually check the boiler and burner for external dirt. 2. If dirt is found, clean boiler and burner. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 44: Preparing Boiler For Cleaning

    Fig. 38 Gas valve (GC124 II left, GC124 SP right) 1 ON/OFF knob (shown in ON position) We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 45: Cleaning The Boiler

    Fig. 40 Correct ignition flame setting 1 Flame rises ½" to 1-½" above sensor 2 Ignition flame We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 46 ( Fig. 44, page 47). Fig. 43 Correct flame configuration 1 Ignition flame We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 47 13. Before opening a unit: disconnect electrical power and lock to prevent accidental reactivation. 14. Close main gas shut-off. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 48 8 Gas valve cable connector 9 Pilot line 10 Igniter cable (GC124 II only) or Thermocouple cable (GC124 SP only) We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 49 21. Remove 4 screws on sides of the top cover and lift off. Fig. 47 Remove top cover We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 50 39. Continue to ventilate boiler room well. 40. Install burner. Fig. 49 Wet cleaning boiler 41. Reattach boiler jacket. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 51: Cleaning The Burner

    13. Assemble and install the burner in reverse order of removal and disassembly. ( page 47). We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 52 Sign the mainte- nance protocol and discuss it with the owner of the heat- ing system. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 53: Maintenance Protocol

    52 materials, gasoline or corrosive liquids. Confirm maintenance Confirmation of correct maintenance (company stamp, signature) We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 54 W. C inches W. C inches W. C inches W. C ––––––– ––––––– ––––––– ––––––– ––––––– We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 55: Troubleshooting The Gc124

    If the gas valve does not close, replace gas valve. End of troubleshooting Repeat procedure until heating system operates properly. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 56 Specified thermostat value (control) reached Main and ignition gas valves close, gas burners ex- tinguished, vent damper closes. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 57: Troubleshooting The Gc124 Sp

    If the gas valve does not close, replace gas valve. Repeat procedure until heating system operates properly. End of troubleshooting We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 58 Specified thermostat value (control) reached Main valve closes, gas burner switches off. Ignition flame is burning. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 59: Parts Lists

    Sheet metal screws material see mounting Mounting material material Tab. 10 Boiler jacket We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 60 Parts lists C l a 7747100028-01-Verkleidung GC124 US Fig. 52 Boiler jacket We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 61 1" NPT X5" PIPE NIPPLE 1-1/4" NPT ELBOW 1-1/4" NPT X 1" NPT REDUCING ELBOW ¾" NPT STREET ELBOW We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 62 RELIEF VALVE ¾" M x F NPT Mounting material 7747000912 Tab. 11 Boiler block mounting material We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 63 Parts lists 7747100027-01-Kesselblock Anbauteile GC124 US Fig. 53 Boiler block mounting material We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 64 07079498 Blocked vent switch kit 7747004677 Consists of: Cable protector Mounting Self tapping screw material GAW027-031 We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 65 Angle bracket Wiring harness 7747004671 Junction box 7747004455 Mounting material 63015810 Tab. 12 Controls for GC124 II We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 66 Parts lists 7747100019-01-Regelung GAW030 US Fig. 54 Controls for GC124 II We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 67 Angle bracket Wiring harness 7747004671 Junction box 7747004455 Mounting material 63015810 Tab. 13 Controls for GC124 SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 68 Parts lists 7747100020-01-Regelung GAW031 US Fig. 55 Controls for GC124 SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 69 Screw 05947712 Flame roll-out switch 63034010 Holder for match 7747001230 Tab. 14 Burner for GC124 II/SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 70 Parts lists 7747100077-01-Brennrost AE124GC II/SP US Fig. 56 Burner for GC124 II/SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 71 Propane conversion kit 0-8500ft GC124 II 7747001- Propane conversion kit 0-8500ft GC124 SP 7747001- Tab. 15 LP conversion kits We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 72 Parts lists 7747100076-01-Brennervarianten, Gasartumstellteile AE124GC II/SP US Fig. 57 Gas conversion kits We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 73 Gas valve VR8200H1004 GC124 SP 05181446 Gasket 05483082 Screw for gas valve 63025928 Tab. 16 Gas valve GC124 II/SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 74 Parts lists 7747100078-02-Gasarmatur VR8204H 1006 GC124 II US Fig. 58 Gas valve GC124 II/SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 75 Screw Torx 63010217 Screw set 7747001217 Ignition gas line 7747001228 Tab. 17 Ignition burner GC124 II We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 76 Parts lists 7747100080-00-Zündbrenner GC124 Classic II US Fig. 59 Ignition burner GC124 II We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 77 63010217 Screw set 7747001217 Ignition gas line 7747001229 Thermocouple 05176988 Tab. 18 Ignition burner GC124 SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 78 Parts lists 7747100081-00-Zündbrenner GC124 Classic SP US Fig. 60 Ignition burner GC124 SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 79: Technical Specifications

    8500 feet operation. Do not attempt to alter this boiler without consulting Buderus. We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...

  • Page 80: Electrical Circuit Diagrams

    Electrical circuit diagrams 19 Electrical circuit diagrams Fig. 61 Wiring Diagram– GC124 II We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 81 Electrical circuit diagrams Fig. 62 Wiring Diagram– GC124 SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 82 Electrical circuit diagrams Fig. 63 Wiring Diagram– GC124 II Fig. 64 Wiring Diagram– GC124 SP We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 83 Notes We reserve the right to make any changes due to technical modifications. Installation and maintenance instructions Gas Boiler Logano GC124 II/SP • Issue 07/2006...
  • Page 84 Your installer: BBT North America Corporation - Bosch Group 50 Wentworth Ave Londonderry, New Hampshire 03053 USA Tel: (603) 552-1100/800-Buderus Fax: (603) 421-2719 www.buderus.net BBT Thermotechnik GmbH, D-35573 Wetzlar www.heiztechnik.buderus.de info@heiztechnik.buderus.de...

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