Buderus Logano plus GB312 Installation And Maintenance Instructions Manual
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Buderus Logano plus GB312 Installation And Maintenance Instructions Manual

Gas condensing boiler
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Installation and
maintenance instructions
Logano plus GB312
Gas condensing boiler
For contractors
Read carefully prior
to installation and
maintenance.

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Summary of Contents for Buderus Logano plus GB312

  • Page 1 Installation and Gas condensing boiler maintenance instructions Logano plus GB312 For contractors Read carefully prior to installation and maintenance.

  • Page 2: Table Of Contents

    6.17.2CO value ......37 5.5.2 Connecting the heating return ..22 Logano plus GB312 - Subject to technical modifications.
  • Page 3 10.2.1Operating messages ....58 10.2.2Fault displays ......59 Logano plus GB312 - Subject to technical modifications.

  • Page 4: Key To Symbols And Safety Instructions

    Danger through failure to consider your own safety in an emergency such as a fire B Never put yourself at risk of fatal injury. Your own safety is paramount. Logano plus GB312 - Subject to technical modifications.
  • Page 5 B Maintenance and repairs may only be carried out by an authorised contractor. B Use only original spare parts. B Only use alternative combinations, accessories and wearing parts if these are designed for this application. Logano plus GB312 - Subject to technical modifications.

  • Page 6: Product Information

    R1¼ " (for 160 to 280 kW) Boiler connection elbow Boiler flue connection Tab. 4 Required accessories 1) Safety valve or safety assembly are required to ensure the function and safety. Logano plus GB312 - Subject to technical modifications.

  • Page 7: Product Overview

    • Gas burner The control unit monitors and controls all electrical boiler components. The boiler block transfers the heat generated by the burner to the heating water. The thermal insulation reduces energy losses. Logano plus GB312 - Subject to technical modifications.

  • Page 8: Dimensions And Connections

    = Combustion air pipe connection = Gas connection (balanced flue operation only) = Boiler flow = Connection for safety valve or safety assembly = Connection for diaphragm expansion = Boiler return vessel Tab. 5 Connections Logano plus GB312 - Subject to technical modifications.
  • Page 9 VK and RK connection Rp 2" PN6 standard flange (DN 50) (DN 65) ST connection R 1" R 1¼ " Ø GAS R ¾ " R 1½ " Tab. 6 Dimensions and connection measurements Logano plus GB312 - Subject to technical modifications.

  • Page 10: Specification

    Wobbe index 12.2 kWh/m Type (acc. to DVGW regulations) , (C 63(x) open flue and balanced flue operation Type (Belgium) , (C 33 (x) 53(x) open flue and balanced flue operation Tab. 7 Specification Logano plus GB312 - Subject to technical modifications.

  • Page 11: Gas Throughput

    Wobbe index 12.2 kWh/m 10.6 12.3 13.2 14.3 16.4 17.6 19.1 20.4 21.9 23.8 24.6 26.3 28.6 28.7 30.7 33.4 Tab. 8 Gas throughput (relative to 15 °C gas temperature and 1013 mbar air pressure) Logano plus GB312 - Subject to technical modifications.

  • Page 12: Country-Specific Gas Categories And Supply Pressures

    • Natural gas H or E (G20, 20 mbar) • Natural gas L (DE) (20 mbar) • Natural gas L (NL) (G25, 25 mbar) • Natural gas H (BE) (G20, 20 mbar) Logano plus GB312 - Subject to technical modifications.

  • Page 13: Regulations

    B Prior to commencing the installation, notify the responsible flue gas inspector and the waste water authority. Logano plus GB312 - Subject to technical modifications.

  • Page 14: Ventilation Requirements

    4729. Ensure system separation by means of a heat exchanger if the plastic pipes do not conform with these standards. NOTICE: Boiler damage through corrosion! B Never operate this boiler as a gravity-fed or as open vented heating system. Logano plus GB312 - Subject to technical modifications.

  • Page 15: Inspection/Maintenance

    5 pipes (approx. R 1¼ , 0.7 m long) as supports for rolling the boiler. 3.10 Validity of regulations Modified regulations or supplements are also valid at the time of installation and must be observed. Logano plus GB312 - Subject to technical modifications.

  • Page 16: Transporting The Boiler

    B Slightly lift front panel [1] and remove towards the front. B Remove locking screws [3] from the side panels at the front and back of the boiler. Fig. 4 Lifting the boiler from its pallet Locking screws Pallet Logano plus GB312 - Subject to technical modifications.

  • Page 17: Transporting The Boiler On Rollers

    ~ 7 0 0 ~ 4 0 0 Fig. 5 Transporting the boiler using pipes Fig. 6 Transporting the boiler on rollers Points to secure the boiler against slippage (measurements in mm) Pipe Logano plus GB312 - Subject to technical modifications.

  • Page 18: Installation

    B Where the boiler surroundings are sensitive to noise (e.g. residential units), use the silencer options offered by the manufacturer (flue gas silencers, compensators). Fig. 7 Wall clearances in the installation room (boiler placed on the left or right) Logano plus GB312 - Subject to technical modifications.

  • Page 19: Levelling The Boiler

    B Make the flue connection in accordance with the requirements applicable in your country. Fig. 8 Levelling the boiler Adjustable feet Spirit level Fig. 9 Fitting the flue connection Boiler connection elbow (accessory) Boiler connector (accessory) Logano plus GB312 - Subject to technical modifications.

  • Page 20: Making The Ventilation Air Connection (Room Sealed Operation)

    Fig. 10 Making the ventilation air connection for balanced flue operation Screw Cover Ventilation air connection elbow RLU (accessory) Fig. 11 Adaptor (accessory) Return Flow Logano plus GB312 - Subject to technical modifications.

  • Page 21: Connecting The Heating Flow

    Check valve not included in the standard delivery: Check valves are not required in single boiler systems. The software of the burner control unit will recognise incorrect flow. This would result in a fault shutdown. Logano plus GB312 - Subject to technical modifications.

  • Page 22: Connecting The Heating Return

    B Ensure that the sealing washer with gasket is seated in the locking cap. B Remove the siphon [5]. B Undo locking cap [4] and fill siphon with approx. 2 litres of water. Logano plus GB312 - Subject to technical modifications.

  • Page 23: Fitting The Connection For The Diaphragm

    B Installing the neutralising system (accessory) in accordance with the installation instructions B Fit the siphon provided to the drain on the condensate pan. Logano plus GB312 - Subject to technical modifications.

  • Page 24: Filling The Heating System And Checking For Leaks

    BSEN 12828. The connection of the auto fill unit into the heating system should be in the flow header, to avoid causing thermal stress to the boiler. Logano plus GB312 - Subject to technical modifications.

  • Page 25: Fuel Connection

    It is not enough to switch off the control unit. B Safeguard the heating system against unintentional reconnection. Logano plus GB312 - Subject to technical modifications.

  • Page 26: Installing The Control Unit

    B Route all cables through the cable entries to the control unit and connect in accordance with the connection diagram. Fig. 18 Fitting modules Module (accessory) Mounting plate Logano plus GB312 - Subject to technical modifications.

  • Page 27: Fitting The Cover

    B Push the control unit cover down into the guide rails. Fig. 22 Levelling the boiler vertically B Secure the control unit cover with 2 screws. Screws Nuts Spirit level 7 747 010 720-35.1RS Fig. 21 Fitting the cover Logano plus GB312 - Subject to technical modifications.

  • Page 28: Commissioning

    B Prior to commissioning, check the operating pressure of the heating system on the water side and adjust if required. NOTICE: System damage through boiler scaling! B Observe the details in the "Water quality log". Logano plus GB312 - Subject to technical modifications.

  • Page 29: Recording Gas Parameters

    • Adjusted to 11.5 kWh/m • Applicable for 10.85 to 12.4 kWh/m Wobbe index for 0 °C, 1013 mbar: • Adjusted to 12.2 kWh/m • Applicable for 10.6 to 13.8 kWh/m Tab. 14 Factory settings Logano plus GB312 - Subject to technical modifications.

  • Page 30: Checking For Leaks

    B Never allow the agent to come in contact with electrical cables. B Confirm the tightness test with an entry into the commissioning report ( Chapter 6.23). Fig. 24 Replacing the gas restrictor (boiler size 90/ 120 kW) Gas restrictor Logano plus GB312 - Subject to technical modifications.

  • Page 31: Conversion For Boiler Size 160 Kw

    Converting from gas type L to gas type H: B Decrease the value of adjusting screw V ( Fig. 26, [2]) by 0.5, e.g. from setting 1.6 to 1.1. Fig. 27 Updating the type plate Type plate Label (gas values) Logano plus GB312 - Subject to technical modifications.

  • Page 32: Purging The Gas Line

    Chapter 3.4, page 14). B Have any faults rectified immediately. Fig. 29 Purging the gas line (boiler size 160 kW) Pressure test nipple for testing the gas supply pressure and for purging Logano plus GB312 - Subject to technical modifications.

  • Page 33: Check The Ventilation Air Diaphragm

    The entire heating system is switched on. During commissioning, “-” briefly flashes on the display, then fault message “4A”-“700” is displayed. Fault display “4A”-“700” appears, as the burner is supplied in a fault state. Logano plus GB312 - Subject to technical modifications.

  • Page 34: 6.11 Carrying Out A Flue Gas Test

    Gas train boiler size 160 kW B Check the CO content. Insert the test probe through the test port into the core flow inside the flue. B Press to open the DIAGNOSIS/MON. VALUE menu. Logano plus GB312 - Subject to technical modifications.

  • Page 35: Under Partial Load

    – L25 for boiler size 120 and 160 kW – L33 for boiler size 90 kW – L30 for boiler size 200 to 280 kW These values represent the minimum modulation ranges for the different boiler sizes. Logano plus GB312 - Subject to technical modifications.
  • Page 36 (boiler size 90/120 kW) commissioning report, Chapter 6.23. Partial load adjusting screw B Recheck the CO content and enter the value in the commissioning report, Chapter 6.23. Logano plus GB312 - Subject to technical modifications.

  • Page 37: Switching The Status Display On The Bc10 To Show The Boiler Temperature Status

    B Return to the operating mode at the RC35 adjustment, incorrect appliance setup, burner and/or heat programming unit. exchanger contamination or burner faults. B Close the flap on the RC35 programming unit. B Identify and eliminate the cause. Logano plus GB312 - Subject to technical modifications.

  • Page 38: 6.18 Function Tests

    (with a burning flame) should be at least 3 μA. B Return to the operating mode at the RC35 programming unit. B Close the flap on the RC35 programming unit. Logano plus GB312 - Subject to technical modifications.

  • Page 39: 6.19 Testing The Gas Supply Pressure

    Fig. 41 Checking the gas supply pressure (boiler size Pressure test nipple for testing the gas supply pressure 90/120 kW) and for purging Pressure test nipple for testing the gas supply pressure and for purging Logano plus GB312 - Subject to technical modifications.

  • Page 40: 6.20 Checking For Leaks During Operation

    B Secure the side panels with locking screws [3] at the front and back of the boiler. B First hook in the bottom of the front panel [1], then raise slightly and hook in at the top. Logano plus GB312 - Subject to technical modifications.

  • Page 41: 6.23 Commissioning Report

    ____________ μA Check for leaks during operation Fit sections of the casing Informing the user; handing over technical documentation Correct commissioning by the installing contractor Signature:______________________ User signature Signature:______________________ Tab. 18 Commissioning report Logano plus GB312 - Subject to technical modifications.

  • Page 42: Shutting Down The Heating System

    B Close the main shut-off valve or gas tap. B Isolate the heating system from the mains power supply by means of the heating system emergency stop switch or the appropriate domestic fuse/circuit breaker. Logano plus GB312 - Subject to technical modifications.

  • Page 43: Environmental Protection/Disposal

    Old appliances contain materials that should be recycled. The relevant assemblies are easy to separate, and all plastics are identified. This allows the various assemblies to be appropriately sorted for recycling or disposal. Logano plus GB312 - Subject to technical modifications.

  • Page 44: Inspection And Maintenance

    B Work on gas components must only be B Once a year, check the concentration of any anti- carried out by authorised gas fitters freeze/additives that may be used in the system fill (observe local regulations). water. Logano plus GB312 - Subject to technical modifications.

  • Page 45: 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. 21 Pipework volume (V ) subject to pipe length and diameter pipe Logano plus GB312 - Subject to technical modifications.

  • Page 46: Carrying Out A Leak Test

    Pressure test nipple Fig. 48 Checking the internal tightness (boiler size 90/ 120 kW) Pressure test nipple Fig. 50 Checking the internal tightness (boiler sizes 200 to 280 kW) Pressure test nipple Logano plus GB312 - Subject to technical modifications.
  • Page 47 B If no leaks are found, replace gas train. Completing the leak test B Remove hose. B After completing the test, fully tighten the screw inside the pressure test nipple. B Check the pressure test nipple for tightness. Logano plus GB312 - Subject to technical modifications.

  • Page 48: Checking The Heating System Operating

    If the CO content deviates by more than 0.5 % from its set value ( Tab. 7, page 10), adjust the burner as described in Chapter 6.13 and 6.14, page 34 ff. Logano plus GB312 - Subject to technical modifications.

  • Page 49: Checking The Level Of Contamination Of Burner And Heat Exchanger

    B Cancel the flue gas test; press again. Fig. 53 Checking the level of contamination Test nipple on the burner Test point at the boiler flue connection Fig. 55 Calling up the flue gas test Logano plus GB312 - Subject to technical modifications.

  • Page 50: Cleaning The Burner And Heat Exchanger

    If the actual pressure is higher than the value in the table, clean the heat exchanger. Boiler size [kW] Fig. 57 Undoing electrical plug-in connections from the burner Ignition cable Tab. 22 Cleaning threshold - differential pressure in Pa Monitoring cable Logano plus GB312 - Subject to technical modifications.

  • Page 51: Wet Cleaning The Heat Exchanger

    During wet cleaning, protect electrical components (fan, gas train etc.) against moisture and contamination. Fig. 60 Cleaning the siphon B Check the condensate hose between the boiler flue connection and the siphon for free flow. Logano plus GB312 - Subject to technical modifications.

  • Page 52: Cleaning The Burner

    The electrode is positioned above the row of slots. Fig. 61 Burner rods Manifold Fig. 62 Check the electrode position (dimension in mm) Burner rod Ionisation electrode Ignition electrode Burnout B Inspect the ignition electrode gap (burn-off). Logano plus GB312 - Subject to technical modifications.

  • Page 53: Refitting Detached Parts

    B Start the boiler and check all gaskets for leaks under full load using a leak detection agent. B Further checks of the tightness of the entire gas path Chapter 6.20, page 40). Logano plus GB312 - Subject to technical modifications.

  • Page 54: 9.12 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. 23 Logano plus GB312 - Subject to technical modifications.
  • Page 55 ________ °C ________ °C ________ °C _________% _________% _________% _________% _________% _________% _________% _________% _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm ________μA ________μA ________μA ________μA ________μA ________μA ________μA ________μA Tab. 24 Logano plus GB312 - Subject to technical modifications.
  • Page 56 Carry out a function check. Confirm professional service. Company stamp/signature Tab. 25 Date:______ Date:______ Date:______ Date:______ Date:______ Company stamp/ Company stamp/ Company stamp/ Company stamp/ Company stamp/ signature signature signature signature signature Tab. 26 Logano plus GB312 - Subject to technical modifications.

  • Page 57: 10 Troubleshooting

    If the display then reverts to a standard 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 GB312 - Subject to technical modifications.

  • Page 58: 10.2 Operating And Fault Displays

    Start of the program sequence to start the burner. Burner start begins. Tab. 27 Operating codes Logano plus GB312 - Subject to technical modifications.

  • Page 59: 2Fault Displays

    140 °C, and a Replace ignition/ flame current is monitoring electrode. detected or the solenoid valves are open. Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.
  • Page 60 Therefore, this fault message can generally not appear. Unfavourable hydraulics in two-boiler systems: boilers influence each other, e.g. via the return or flow. Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.
  • Page 61 Check the voltage at the Replace the SAFe in temperature sensor case of deviations. according to table. Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.
  • Page 62 SAFe and the MC10. connections are OK. with the SAFe. if not all required data is supplied by the SAFe. Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.
  • Page 63 > 0.9 μA. of the burner gauze have electrode. no contact with the Replace gas train. electrodes. Check gas train function. Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.
  • Page 64 SAFe burner control unit Replace the SAFe. faulty. Ignition transformer faulty Replace the ignition (no or delayed ignition transformer. spark, "hard start"). Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.
  • Page 65 Replace gas train. 2 leaking. system has contamination. detected an Gas filter fitted. unacceptably high leakage rate on solenoid valve 2. Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.
  • Page 66 Check water pressure Replace water pressure (short circuit). (voltage < 0.5 V). sensor. sensor. Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.
  • Page 67 The SAFe has developed a Replace the SAFe. button on the fault. SAFe. Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.
  • Page 68 Tab. 28 Fault displays 1) V = locking; B = blocking Logano plus GB312 - Subject to technical modifications.

  • Page 69: Sensor Curves

    Resistance in k Ω 2 similar temperature sensors (twin sensors) fitted in a single sensor casing are used as boiler temperature sensors. All temperature sensors on the boiler have the same sensor curve. Logano plus GB312 - Subject to technical modifications.

  • Page 70: Pressure Drop On The Heating Water Side

    Pressure drop on the heating water side in mbar Fig. 67 Pressure drop on the heating water side (with check valve - cascade) Flow rate in l/h Pressure drop on the heating water side in mbar Logano plus GB312 - Subject to technical modifications.

  • Page 71: Mc10 Connection Diagram

    NOTICE: Operating faults through power failure! B 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 GB312 - Subject to technical modifications.
  • Page 72 Appendix Fig. 68 MC10 connection diagram 1) The total current of all externally connected components must not exceed 5 A. Logano plus GB312 - Subject to technical modifications.
  • Page 73 Fuse inside the MC10 Fuse inside the BC10 base controller Logamatic MC10 Function modules xM10 Spare fuse 10 AF RC35 programming unit or dummy cover BC10 base controller Appliance fuse 10 AF Logano plus GB312 - Subject to technical modifications.
  • Page 74 ..Ventilation air connection elbow RLU (accessory) ..........Heating water circuit ............Wet cleaning ............Wobbe index ..........Ignition cable ..........Ignition electrode ..........Installation location ..........Ionisation current ..........Ionisation electrode Logano plus GB312 - Subject to technical modifications.
  • Page 75 Notes Logano plus GB312 - Subject to technical modifications.
  • Page 76 Buderus Cotswold Way, Warndon, Worcester WR4 9SW Customer service: 0844 892 3004 Technical support: 0844 892 4224 www.buderus.co.uk In the UK and IE, Buderus is a brand name of Bosch Thermotechnology Ltd.

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