Buderus Logano plus GB402 Installation And Maintenance Instructions Manual
  1. Manuals
  2. Brands
  3. Buderus Manuals
  4. Boiler
  5. Logano plus GB402
  6. Installation and maintenance instructions manual

Buderus Logano plus GB402 Installation And Maintenance Instructions Manual

Hide thumbs Also See for Logano plus GB402:
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Logano plus GB402 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Buderus Logano plus GB402

Summary of Contents for Buderus Logano plus GB402

  • Page 1 Installation and Gas condensing boiler maintenance instructions Logano plus GB402 For contractors Read carefully prior to installation and maintenance.

  • Page 2: Table Of Contents

    Dimensions and specification ..10 Checking the ventilation and extract air 2.7.1 Logano plus GB402 dimensions ..10 apertures and the flue connection ..31 2.7.2 Specification .
  • Page 3 Index ........72 Logano plus GB402 - Subject to technical modifications!

  • Page 4: Explanation Of Symbols And Safety Information

    Danger posed by explosive and easily flammable materials B Never use or store combustible materials (paper, curtains, clothing, thinners, paints, etc.) in the vicinity of the boiler. Logano plus GB402 - Subject to technical modifications!
  • Page 5 Operator errors can result in injury and damage to property. B Ensure that children never operate this appliance unsupervised or play with it. B Ensure that only personnel who can operate this appliance correctly have access to it. Logano plus GB402 - Subject to technical modifications!

  • Page 6: Information About The Appliance

    Intended use A PC with Buderus Logamatic The Logano plus GB402 is designed for conventional use ECO-Soft4000/EMS and a service key can as a gas condensing boiler for DHW and central heating. also be used as a monitoring device.

  • Page 7: Product Description

    Information 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 Gas valve Fig.
  • Page 8 Fig. 2 provides an overview of the controls of the Logamatic BC10 base controller. Programming units (such as the RC35*) offer many additional functions for the convenient control of your heating system. * available separately Logano plus GB402 - Subject to technical modifications!

  • Page 9: Standard Delivery

    Information about the appliance Standard delivery The Logano plus GB402 is supplied as standard with a Logamatic BC10 base controller and the MC10 control unit in 3 separate packages. B Upon receipt, check that all packaging is in perfect condition.

  • Page 10: Dimensions And Specification

    Information 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) = Flue gas outlet = Boiler return AKO = Condensate outlet = Safety valve or safety assembly connection...

  • Page 11: Specification

    Protection against electrocution Safety category 1 Maximum permissible appliance fuse rating Appliance dimensions and weight Handling dimensions width × depth × height 781 x 1740 x 1542 Weight (excl. casing) Tab. 3 Specification Logano plus GB402 - Subject to technical modifications!
  • Page 12 20/50 2H3P RU, UA Tab. 5 Country-specific gas categories and supply pressures 1) The gas supply utility must guarantee the minimum and maximum pressures (acc. to national regulations for public gas supply). Logano plus GB402 - Subject to technical modifications!

  • Page 13: Regulations

    B Prior to commencing installation, inform the local flue gas inspector [where appropriate] and water authority. B All heating system components that have to be replaced should be disposed of in an environmentally responsible manner at an authorised disposal site. Logano plus GB402 - Subject to technical modifications!

  • Page 14: Transporting The Boiler

    Where possible, transport the boiler to the installation location in its shipping packaging to protect it from contamination. Fig. 4 Transporting the boiler on its pallet by crane/ hoist Logano plus GB402 - Subject to technical modifications!

  • Page 15: Lifting The Boiler Off The Pallet

    Fig. 6 Transporting the boiler on rollers (measurements in mm) Protect boiler from contamination if the boiler is not to be taken into use immediately. Dispose of packaging in an environmentally responsible manner. Logano plus GB402 - Subject to technical modifications!

  • Page 16: Installing The Boiler

    Tab. 7 Recommended and minimum wall clearances the manufacturer (flue gas silencers, compensators). (dimensions in mm). Maintain minimum clearance, dimension E. 1) This clearance dimension applies independently of the installed flue system. Logano plus GB402 - Subject to technical modifications!

  • Page 17: Levelling The Boiler

    B Ensure that the installation area offers sufficient load-bearing capacity. B Bring the boiler into its final position. B Level the boiler horizontally by means of its adjustable feet and a spirit level. Fig. 8 Levelling the boiler Logano plus GB402 - Subject to technical modifications!

  • Page 18: Installation

    DANGER: Risk to life from toxic flue gases escaping. B Check the entire flue gas system for correctly made and sealed joints. Logano plus GB402 - Subject to technical modifications!

  • Page 19: Installing The Condensate Hose

    Where the neutralising system is installed system and locally applicable regulations. outside the boiler, there is the option of guiding the condensate hose through the aperture in the back panel. Logano plus GB402 - Subject to technical modifications!

  • Page 20: Fitting The Boiler Cover

    Fig. 11 Front and rear boiler covers Front boiler cover Rear boiler cover Fig. 12 Ventilation air connection for balanced flue operation (accessory) Cover panel Adaptor Logano plus GB402 - Subject to technical modifications!

  • Page 21: Making The Heating Circuit Connection

    B Level the fitting manifold and fit maximum pressure limiter [5]. Fig. 13 Fitting the flow (VK) Fig. 14 Installing the fitting manifold Flow connector Distributor Cap valve Fitting manifold complete with cap valve ¾ Inch Maximum pressure limiter Logano plus GB402 - Subject to technical modifications!
  • Page 22 Fig. 15 Safety valve (up to 3 bar) Safety valve Fig. 16 Safety assembly (3 to 6 bar) Safety valve Gasket Threaded flange Fem. connection Logano plus GB402 - Subject to technical modifications!

  • Page 23: Connecting The Return

    Installing a DHW cylinder 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 - Subject to technical modifications!

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

    B Open safety caps on all automatic air vent valves. B Connect hose to the water tap. Push the water-filled hose onto the hose ferrule of the drain & fill valve, secure it with a hose clip and fill with water. Logano plus GB402 - Subject to technical modifications!

  • Page 25: Making The Electrical Connection

    B Push the control unit towards the outside edge of the boiler. B Let the resilient hooks of the control unit click into the openings by pushing the control unit. Fig. 20 Fitting the control unit (Logamatic MC10) Logano plus GB402 - Subject to technical modifications!

  • Page 26: Making The Power Supply Connection

    NOTICE: System damage through incorrect control. B Route high and low voltage cables/leads separately inside the cable trunking. B Route all cables that run towards the back through the cable trunking. Logano plus GB402 - Subject to technical modifications!

  • Page 27: Fuel Connection

    Gas tap (here with thermally activated shut-off equipment) Pipe clip 7 747 010 720-35.1RS For higher gas supply pressures than shown Fig. 24 Fitting the cover in Tab. 10, page 33, Buderus offers additional gas pressure regulators as accessories. Logano plus GB402 - Subject to technical modifications!

  • Page 28: Commissioning The Heating System

    B Top up heating water or drain off water via the on-site drain & fill valve until the required operating pressure has been reached. B During filling, vent the heating system via the radiator bleed valves. Logano plus GB402 - Subject to technical modifications!

  • Page 29: Checking For Leaks

    Recording gas characteristics Ask your gas supply utility to advise you of the gas parameters (Wobbe index and calorific value) and record these in the commissioning report ( Chapter 7.18, page 38). Logano plus GB402 - Subject to technical modifications!

  • Page 30: Check The System Equipment Level

    • 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. 9 Factory settings Logano plus GB402 - Subject to technical modifications!

  • Page 31: Purging The Gas Line

    B Switch on the heating system emergency stop switch (if installed) and/or insert/set the corresponding Fig. 28 Purging the gas line domestic fuse/circuit breaker. Test nipple for measuring the gas supply pressure and for venting Logano plus GB402 - Subject to technical modifications!

  • Page 32: Commissioning The Control Unit And Burner

    DHW heating configuration (heating circuit pump and cylinder primary pump) must be set appropriately to ensure the heating system works correctly. For this, observe the installation and service instructions of the RC35 programming unit. Logano plus GB402 - Subject to technical modifications!

  • Page 33: Accessing The Service Level On The Rc35 And Displaying Monitoring Data

    ( Chapter 7.18). pressure regulators as accessories. B If the gas supply pressure falls outside the values in Tab. 10, shut down the boiler and notify the gas supply utility. Logano plus GB402 - Subject to technical modifications!

  • Page 34: Checking And Adjusting The Gas:air Ratio

    Chapter 7.18, page 38. Fig. 32 Checking the CO setting at full load High load adjusting screw Fig. 34 Checking the setting under partial load Logano plus GB402 - Subject to technical modifications!

  • Page 35: 3Checking The Co2 Setting Under Full Load

    CO values in an air-free state must be below 400 ppm or 0.04 % vol. Values above 100 ppm indicate and incorrect burner adjustment, incorrect appliance setup, burner and/or heat exchanger contamination or burner faults. B Identify and eliminate the cause. Logano plus GB402 - Subject to technical modifications!

  • Page 36: Function Checks

    To ensure fault-free operation, the ionisation current at partial and full load (and with burning flame) should be at least 15 μA. B Return to operating mode on the RC35. B Close the flap on the RC35. Logano plus GB402 - Subject to technical modifications!

  • Page 37: Installing Casing Parts

    B Affix the clear pocket containing the technical documentation in a clearly visible spot on the side of the boiler. Fig. 37 Installing casing parts Front Front side panels (incl. thermal insulation) Rear side panels (excl. thermal insulation) Logano plus GB402 - Subject to technical modifications!

  • Page 38: Commissioning Report

    – Check ionisation current ____________ μA 14. Install casing parts 15. Inform operator; hand over technical documentation 16. Correct commissioning by the installing contractor Signature:______________________ 17. Operator signature Signature:______________________ Tab. 11 Commissioning report Logano plus GB402 - Subject to technical modifications!

  • Page 39: Shutting Down The Heating System

    BC10, see Chapter 7. B Switch the heating system OFF at the ON/OFF switch on the BC10. B Close the main fuel shut-off valve. Fig. 38 Logamatic BC10 base controller Logano plus GB402 - Subject to technical modifications!

  • Page 40: Inspection And Maintenance

    B Check the concentration of any anti-freeze/additives B Only registered gas fitters are permitted to that may be used in the system fill/top-up water carry out work on gas lines (observe local annually. regulations). Logano plus GB402 - Subject to technical modifications!

  • Page 41: 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. 14 Pipework volume (V ) subject to pipe length and diameter pipe Logano plus GB402 - Subject to technical modifications!

  • Page 42: Carrying Out The Leak Test

    B Check the test nipple for leaks. If the read-off point for test volume (V ) and pressure test drop per minute lies within the range “Valve leaks” (see read-off example), carry out the test described below. Logano plus GB402 - Subject to technical modifications!

  • Page 43: Checking The Heating System Operating

    B Record the flue gas values. If the CO content differs by more than 0.5 % from its set value ( Tab. 3, page 11), adjust the burner as described from Chapter 7.10 to 7.10.2. Logano plus GB402 - Subject to technical modifications!

  • Page 44: Cleaning The Burner And Heat Exchanger

    Ventilation air hose Condensate tray outlet Ventilation air collector Siphon B Undo the 4 screws from gas valve flange [1] and undo the gas connection. Fig. 45 Undoing the gas connection Screws Logano plus GB402 - Subject to technical modifications!
  • Page 45 Fig. 49 Removing the burner B Blow off the burner rods and mixture manifold from the inside and outside using compressed air. Fig. 47 Undoing the nuts at the mixture manifold Fixing nuts with washer Logano plus GB402 - Subject to technical modifications!

  • Page 46: Cleaning The Heat Exchanger

    CAUTION: Risk of injury from sharp edges on the cleaning blades. 6720646293-01.1BU B To avoid injury, wear gloves when cleaning Fig. 53 View of cleaning cover the boiler using cleaning blades 320 kW (accessories). 395-620 kW Logano plus GB402 - Subject to technical modifications!

  • Page 47: Inspecting The Burner Electrodes

    B If deposits have formed on the electrodes, replace the electrode block together with a new gasket, or sand down the electrodes. We recommend the replacement of the electrode block as part of the annual service. Logano plus GB402 - Subject to technical modifications!

  • Page 48: Replacing Components

    B Insert new gasket [2] at the filter cover and refit using both screws. Fig. 56 Undoing the gas valve connections Compensation hose Screws Cables Fig. 58 Changing the gas filter Filter cassette Gasket Filter cover Screw Logano plus GB402 - Subject to technical modifications!

  • Page 49: Removing The Fan

    B Remove rear semi-shell [1]. B Check all gaskets for wear and damage. Observe the specified replacement interval for gaskets ( Chapter 9.13). B Replace gaskets if required. Fig. 60 Removing the rear semi-shell Semi-shell Logano plus GB402 - Subject to technical modifications!

  • Page 50: Fitting The Fan

    B Insert a new O-ring into the gas valve flange. B Secure the gas valve to the fan using 4 screws. B Secure the flange of the gas connection again to the gas valve using 4 screws. Logano plus GB402 - Subject to technical modifications!

  • Page 51: Fitting The Ventilation Air Unit

    9.12.2 Installing casing parts B Fit the casing parts ( Fig. 37, page 37). 9.12.3 Confirming inspection and service B Sign the inspection and maintenance report in this manual ( Chapter 9.14). Logano plus GB402 - Subject to technical modifications!

  • Page 52: 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. 16 Logano plus GB402 - Subject to technical modifications!
  • Page 53 ________ °C ________ °C ________ °C _________% _________% _________% _________% _________% _________% _________% _________% _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm ________μA ________μA ________μA ________μA ________μA ________μA ________μA ________μA Tab. 17 Logano plus GB402 - Subject to technical modifications!
  • Page 54 8. Carry out a function check. Confirm professional service. Company stamp/signature Tab. 18 Date:______ Date:______ Date:______ Date:______ Date:______ Company stamp/ Company stamp/ Company stamp/ Company stamp/ Company stamp/ signature signature signature signature signature Tab. 19 Logano plus GB402 - Subject to technical modifications!

  • Page 55: Troubleshooting

    If the display then reverts to a standard operating message, the fault has been eliminated. Should the fault recur, repeat the reset two or three times. Fig. 64 Clearing a fault with the “Reset” button Logano plus GB402 - Subject to technical modifications!

  • Page 56: Operating And Fault Displays

    Start of the program sequence to start the burner. Burner start begins. Tab. 20 Operating codes Logano plus GB402 - Subject to technical modifications!

  • Page 57: 2Fault Displays

    Replace ignition/ for the flow of monitoring electrode. 140 °C, and a flame current is detected or the solenoid valves are open. Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!
  • Page 58 Unfavourable hydraulics in two-boiler systems: boilers influence each other, e.g. via the return or flow. Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!
  • Page 59 Check the voltage at the Replace the SAFe in temperature sensor case of deviations. according to table. Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!
  • Page 60 SAFe and the MC10. connections are OK. with the SAFe. if not all required data is supplied by the SAFe. Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!
  • Page 61 > 0.9 μA. of the burner gauze have no electrode. contact with the electrodes. Replace gas valve. Check gas valve function. Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!
  • Page 62 (power off 5 times during Remedy problem with interruption the burner start. the power supply. during burner start). Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!
  • Page 63 Replace gas valve. 2 leaking. system has contamination. detected an Gas filter fitted. unacceptably high leakage rate on solenoid valve 2. Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!
  • Page 64 (voltage < 0.5 V). Check water pressure Replace water pressure (short circuit). sensor. sensor. Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!
  • Page 65 The SAFe has developed a Replace the SAFe. reset via the button fault. on the SAFe. Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!
  • Page 66 Tab. 21 Fault displays 1) V = interlocking; B = blocking Logano plus GB402 - Subject to technical modifications!

  • Page 67: Appendix

    Resistance in Ω All temperature sensors on the GB402 have Temperature in °C the same sensor curve. Two identical sensors (dual sensors) installed in one sensor casing are used as boiler sensors. Logano plus GB402 - Subject to technical modifications!

  • Page 68: Hydraulic Resistance

    5 A. Fig. 66 Flow pressure drop on the heating water side Flow rate ( m³/h) Pressure drop on the heating water side (mbar) Logano plus GB402 - Subject to technical modifications!
  • Page 69 Appendix Fig. 67 MC10 connection diagram 1) The total current of all externally connected components must not exceed 5 A. Logano plus GB402 - Subject to technical modifications!
  • Page 70 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 GB402 - Subject to technical modifications!

  • Page 71: Safe Connection Diagram

    Fig. 69 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 Return sensor Boiler sensor Logano plus GB402 - Subject to technical modifications!

  • Page 72: Index

    Leak testing, gas ..............Levelling ........Operating pressure, maximum ..............Packaging ............Product description ..........RC35 programming unit ..............Regulations ..........Removing the burner ......Reports, inspection and maintenance ............Safety precautions ..............Standards Logano plus GB402 - Subject to technical modifications!
  • Page 73 Notes Logano plus GB402 - Subject to technical modifications!
  • Page 74 Notes Logano plus GB402 - Subject to technical modifications!
  • Page 75 Notes Logano plus GB402 - Subject to technical modifications!
  • Page 76 Buderus Cotswold Way, Warndon, Worcester WR4 9SW Customer service: 0844 892 3004 Technical support: 0844 892 4224 Fax: 01905 753130 www.buderus-commercial.co.uk In the UK and IE, Buderus is a brand name of Bosch Thermotechnology Ltd.

Table of Contents