BUDERUS LOGANO GE315 (02) PDF Document

The BUDERUS LOGANO GE315 fan-assisted boiler is intended for generating heating water. Using the boiler for any other purpose is considered improper use. Your warranty could be invalidated if you do not comply with the installation and operating instructions.

You may use any type-tested oil or gas fired burners that conform to EN 267 or EN 676, provided their operating range meets the boiler specification.

Approved fuel types for the BUDERUS LOGANO GE315 are:

• Heating oil EL

• Natural gas, LPG

For the protection of the entire system, it is recommended to install a dirt filter as well as a de-sludge facility into the return line.

The key application specifications for the BUDERUS LOGANO GE315 are detailed in the following table:

It is crucial to observe the details on the boiler data plate.

To ensure easy access for installation, maintenance, and service work, you should maintain the recommended minimum clearances between the BUDERUS LOGANO GE315 and the walls. The burner door can be hung for left-hand or right-hand opening.

• The distance from the wall on the hinge side must at least permit the burner withdrawal (AB). It is recommended to have a distance between the wall and boiler of AB + 100 mm.

• A clearance of at least 1000 mm (recommended 1500 mm) should be maintained at the front of the boiler.

• A clearance of at least 400 mm (recommended 750 mm) should be maintained at the rear of the boiler.

• A clearance of at least 100 mm (recommended 400 mm) should be maintained on the non-hinge side of the boiler door.

If a clearance less than the recommended distance is chosen, you may not be able to clean the boiler with the optional cleaning kit. In this case, the use of shorter cleaning devices (approx. 1 m) or wet cleaning is recommended.

To assemble the BUDERUS LOGANO GE315 when delivered in loose sections, follow these steps. The boiler block is assembled from the rear to the front, starting with the rear section and finishing with the front section.

1. Prepare the Rear Section:

• Position the rear section and secure it against falling.

• Remove possible burrs from the hub using a file.

• Clean the packing groove, if required, using a wire brush and cloth.

• Clean the hub sealing faces with a cloth soaked in white spirit.

• Coat the hub sealing faces evenly with the orange sealing compound (LEINOMENNIGE).

2. Prepare and Fit the Nipples:

• Clean the nipples with a cloth soaked in white spirit and coat half their surface with the orange sealing compound.

• Fit the nipples straight into the upper and lower hubs of the rear section. Hammer them home securely with alternate heavy blows until they protrude approx. 28 mm from the hub.

• Remove any burrs from the nipples with a file and finish coating their outer surface with the orange sealing compound.

3. Prepare the Packing Grooves:

• Keep the packing grooves clean and dry.

• Coat the packing groove with primer (Buderus Haftgrund primer 181). Ensure adequate ventilation.

• Insert the elastic sealing cord (KM string) into the packing groove at the front of the rear section, starting in the hub area. Overlap the cord by 2 cm and press firmly together. Do not stretch the cord.

4. Prepare the First Middle Section:

• Remove any burrs from the hub using a file.

• Ensure sealing grooves are clean and dry.

• Clean hub sealing faces with a cloth soaked in white spirit.

• Coat the hubs with the orange sealing compound.

• Coat the sealing grooves with primer.

5. Join the Sections:

• Set the middle section with its upper and lower hubs onto the nipples in the rear section. The assembly arrow must point to the rear. It’s easier to locate the section on the upper nipple first, then align the lower hub.

• Drive the centre section onto the end section using a wooden or rubber mallet.

6. Compress the Sections:

• Use only boiler compression tools size 2.2 or 2.3.

• Push the compression units onto the pull rods.

• Insert one pull rod through the upper and one through the lower boiler hub.

• Push additional pull flanges onto both pull rods at the back of the boiler and secure each with a wedge or cylindrical pin.

• Lightly draw the compression tools together using the clamping nut. Never pull together more than one nipple connection (two sections) per compression step to avoid uneven pulling and leaks.

• Set both ratchet spanners onto the clamping nuts and press the boiler sections evenly together by tightening the nuts equally. Do not use force once the hubs are in contact, as this could damage the sections.

• Loosen and remove the boiler compression tool. Check the nipples for correct seating.

7. Assemble Remaining Sections:

• Assemble all other boiler sections as described above. The front section is always assembled last.

8. Install Tie Bars:

• After the front section is assembled, slacken the compression tool but do not remove it yet.

• Insert the three tie bars with their spring sets into the locations in the cast profiles. The spring sets should be at the back of the boiler.

• By hand, screw one nut onto each of the tie bar threads.

• Tighten the nuts on each tie bar by 1 to 1.5 turns.

• Align the boiler on the plinth.

• Remove the boiler compression tool.

A leak test should only be carried out on a BUDERUS LOGANO GE315 that has been delivered in loose sections and assembled on-site. Pre-assembled boilers are leak-tested in the factory.

Leak Test Preparation:

1. Close the lower boiler hub at the front and rear. Set the corresponding gasket onto the hub and seal with the corresponding drain plug. Fit the plug with the internal ¾” thread for the drain cock to the rear of the boiler.

2. Fit the drain cock (not supplied as standard).

3. Close the flow and return connections. Install the flange with a vent screw on the flow connections.

Important: When carrying out the leak test, no control or safety equipment must be connected to the water system, as they could be damaged by high pressure.

Test Procedure:

1. The test pressure depends on the design pressure for the individual heating system and should be 1.5 times the nominal pressure (typically 7.8 bar for 30 minutes). Use a pressure gauge class 1.0 for measurement.

2. Slowly fill the boiler with water through the drain cock, simultaneously venting the system at the boiler flow connection.

3. If a hub connection is leaking, first drain the water through the drain cock.

4. Remove the return header, then remove the nuts and the tie bars.

5. Separate the leaking boiler sections by hammering flat wedges or a chisel at the provided points at the top and bottom between the sections.

6. You must use new nipples and gaskets for the re-assembly. Draw the boiler sections together again and re-test for leaks.

For a BUDERUS LOGANO GE315 delivered as a pre-assembled block, the burner door and flue gas collector are already fitted. For unassembled boilers, follow these steps:

Positioning the Flue Gas Collector:

1. Use a sealing cord as a gasket between the boiler and the flue gas collector.

2. Clean the groove before packing the sealing cord.

3. Coat the packing groove with adhesive (primer 181).

4. Firmly press the sealing cord into the groove so that it lies in the lateral area of the groove.

5. Position the flue gas collector onto both bolts at the rear section and secure with washers and nuts.

Installing the Burner Door:

1. The hinges are factory-fitted for right-hand (r.h.) opening. To convert to left-hand (l.h.) hinges, fit the hinge parts to the l.h. side of the burner door.

2. Secure each hinge pin with two M12 x 50 screws on the front section.

3. Stick sealing cord (18 mm dia.) into the front section using adhesive. Position the butt ends of the gasket string on the side of the section.

4. Hook the burner door with the hinge rings onto the hinge pins.

If you received a pre-assembled BUDERUS LOGANO GE315 boiler block, the hot gas baffles are already fitted, and you only need to remove the transport packing. If you assembled the boiler from sections, you must install them.

Remove the hot gas baffles from the fitting crate and insert them into the hot gas ways according to the instructions cast into the baffle body and the table below.

To install the burner on the BUDERUS LOGANO GE315, follow these steps:

1. Close the burner door and secure it with 4 screws (M16 x 140). Tighten the screws alternately in a cross pattern.

2. Cut (using oxy-acetylene) or drill the burner plate on site according to the required burner pipe diameter (max. diameter 270 mm). Drill the burner mounting holes according to the hole pattern of the burner connection flange. As an option, pre-drilled burner plates are available from Buderus.

3. Secure the burner plate on the burner door with the screws provided. Seal with sealing cords of 10 mm diameter.

4. Screw the burner to the burner plate.

5. Cut out insulating rings according to the burner pipe diameter.

6. Fill the remaining gap between the thermal insulation on the burner door and the burner blast tube with suitably adapted insulating rings.

7. Connect the breather tube on the sight glass with the burner to keep the glass free from condensation.

8. Fit the burner according to the manufacturer’s instructions.

Follow this procedure to install the thermal insulation and casing on the BUDERUS LOGANO GE315:

1. Support Brackets:

• At the front, screw a further nut onto each tie-bar. Insert the cross support bracket on top between the first and second nut and secure on the cast lugs. Tighten the outer nuts.

• Secure the lower front cross support bracket with two screws on the boiler section feet.

• Secure the upper rear support bracket on the cast lugs with M8 x 15 screws. The edge must point to the front.

• Secure the lower rear support bracket with two screws to the feet of the rear section. The edge must point to the rear.

2. Thermal Insulation:

• Arrange the thermal insulation on the boiler block according to its size. At the lower area, push the insulation under the boiler block, setting the boiler feet into the cut-outs.

• Slide the rear section insulation onto the flue gas coupling, with the cut-out for flow/return pointing upwards.

• Hook the rear insulation into the upper cross support bracket using two spring hooks.

• Close the gap below the flue gas coupling with spring hooks.

• Slide the front insulation with its slot onto the front edge of the upper support bracket.

• Route the burner cable on top of the insulation and secure it with strain relief on the lower cross tie-rod. Always route the burner cable on the hinge side of the door.

3. Side and Top Casing:

• Hook the side casing with its cut-outs into the slots of the upper cross support bracket and push forward against the end stop.

• Secure the side walls at the bottom with two self-tapping screws each.

• Position the front top piece between the side walls so the cut-out engages above the cross support bracket. Secure with one self-tapping screw on each side wall.

• Position the rear hood between the side walls, engaging the cut-out above the cross support bracket.

4. Plinth Rails and Walls:

• Push the plinth rails (front and back) on the lower side wall edge and secure with one self-tapping screw each.

• Secure the rear upper boiler wall on the back of the rear hood and on the side walls.

• Secure the lower rear boiler wall (with the cut-out for the fill/drain cock) on the side walls.

• Hook the front wall at the bottom centre into the front plinth, then hook the top of the front wall into the edge of the front hood.

• Hook the burner door cover into the front wall recesses and place the data plate on the appropriate side wall.

To install the control unit for the BUDERUS LOGANO GE315, follow these steps:

1. Mount the Control Unit:

• Loosen the two screws securing the terminal cover and remove it by pulling upwards.

• Insert the control unit at the front of the boiler with the locating tabs into the oval apertures of the front boiler hood. Pull the control unit forward and pivot it back, ensuring the resilient hooks engage at the rear into the rectangular apertures of the hood.

• Secure the control unit base on both sides of the cable way in the front boiler hood with two self-tapping screws.

2. Install the Temperature Sensor:

• Remove any necessary knockouts in the back of the cable gland.

• Insert the capillary tubes through the cable gland and unroll them.

• The sensor well should already be sealed into the flow connection coupling.

• Lead the sensor bundle (three sensors, one sensor blank) to the measuring point and insert it into the ¾” sensor well. Secure the assembly with a sensor securing device.

3. Electrical Connections:

• Secure the cable gland on the left and right side to the rear of the boiler.

• Make all electrical connections according to the wiring diagram, paying attention to cable and capillary pipe runs. A permanent connection according to EN 50165 is required.

• Observe all local wiring regulations and secure all cables with cable clips.

• Insert cable clips with fitted cables into the clip frame and secure by pivoting the lever.

• Fit the terminal cover with two self-tapping screws and secure it on the control unit base.

The requirements for fill and make-up water for the BUDERUS LOGANO GE315 are based on the Code of Practice K8 “Water treatment for hot water heating systems”. The pH value of the heating water should be checked 3 to 6 months after filling to ensure it has settled.

Before commissioning the BUDERUS LOGANO GE315, check the system for leaks. Pressurise the heating system to 1.3x the permissible operating pressure, observing the safety pressure of the safety valve.

Initial Checks:

• On sealed systems, the pressure gauge needle must be within the green range. Set the red needle on the pressure gauge to the required system pressure.

• Check the system water pressure.

• Shut off the pressure expansion vessel from the system by closing the cap valve.

• Check connections and pipework for leaks.

• Open the mixing and shut-off valves on the hot water (primary) side.

Filling Procedure:

1. Fill the system only via the filling connection in the pipework (return) of the heating system, using an approved filling link (e.g., meeting WRAS requirements in the UK).

2. Open the cap of the automatic air vent by one full turn to allow air to escape.

3. Slowly fill the heating system, observing the pressure gauge while filling.

4. Close the water tap and the boiler drain valve once the required operating pressure has been reached.

5. Bleed the system via the radiator bleed valves.

6. Top up with water if the pressure drops as a result of bleeding the system.

7. Take the hose off the boiler drain valve.

Frequent topping up may damage the system due to corrosion or scaling depending on water quality. If you need to regularly add top-up water, investigate the cause.

For the initial start-up (commissioning) of the BUDERUS LOGANO GE315, follow these steps:

1. Make the System Operational:

• Prior to commissioning, vent the heating system via radiators and air vents.

• Check that the hot gas baffle plates have been correctly inserted.

2. Commission the Control Device:

• Refer to the documentation for the series 4000 control device you are using to learn how to commission it.

3. Start up the Burner:

• Proceed with the commissioning of the burner in accordance with the installation and maintenance instructions included with the burner.

• Complete the commissioning report included in the burner documentation.

If you discover during commissioning that the flue gas temperature is too low for the type of chimney used (danger of condensation), you may need to raise the flue gas temperature.

Finally, complete the commissioning report for the boiler.

During the commissioning of your BUDERUS LOGANO GE315, the following tasks must be completed and signed off in the commissioning report:

1. Fill the heating system with water.

2. Vent the heating system via radiators and air vents.

3. Leak test carried out? (only for boilers supplied in sections).

4. Check the location of the hot gas baffle plates.

5. Commission the control device.

6. Start up the burner.

7. Check the flue gas temperature.

8. Inform the system user and hand over all relevant technical documentation.

9. Confirm professional commissioning.

To shut down the BUDERUS LOGANO GE315 via the control device, simply use the controls on your series 4000 control device. The burner will automatically shut down when the system is shut down via the control device.

After shutting down via the control device, you should also isolate the main fuel valve.

CAUTION: The heating system can freeze up if it is not in use, e.g., through a shut-down because of a fault. To protect your system against frost damage where temperatures below zero are expected, drain the heating water at the drain cock at the lowest point in the system. To do this, open the air vent valve at the highest point in the system.

Only in an emergency should you switch off the BUDERUS LOGANO GE315 system via the boiler room fuse or the heating system emergency stop switch.

In other dangerous circumstances, isolate the main fuel shut-off valve and the electrical power supply of the system via the boiler room main fuse or the emergency stop switch for the boiler room.

After performing an emergency shutdown, you should also isolate the main fuel valve.

The BUDERUS LOGANO GE315 should be checked and maintained annually by a heating engineer. The following is the standard procedure for cleaning with brushes:

1. Preparation:

• Disconnect the heating system from the mains electricity supply (e.g., activate the emergency stop switch).

• Switch the On/Off switch on the control unit to “0” (OFF).

• Isolate the main fuel valve.

• Slightly raise the front wall and remove it forward.

• Loosen the four screws securing the burner door and open the door.

2. Disassembly for Cleaning:

• Remove the hot gas baffles by pulling them forward out of the hot gas flues.

• Loosen the four self-tapping screws on the lower boiler back and remove the boiler back panel.

• Loosen the hook springs below the flue gas coupling.

• Pivot both ends of the thermal insulation upwards and fix with the hook spring.

• Remove the cleaning cover on the rear section and the flue gas collector.

3. Cleaning:

• Use special cleaning brushes available from your Buderus dealer.

• Clean the hot gas flues from the front to the back.

• Clean the combustion chamber.

• Clean the lower hot gas flues from the front.

• Remove all loose combustion residues from the combustion chamber, hot gas flues, and flue gas collector.

• Check all sealing cords in cleaning openings and on the burner door. Replace any damaged or hardened seals.

• Clean the hot gas baffle plates with cleaning brushes.

4. Reassembly:

• Insert the clean hot gas baffles back into the hot gas flues.

• Close the cleaning cover and the burner door. Tighten all screws equally.

• Pivot the thermal insulation on the rear section back down and draw it together below the flue gas coupling using a spring hook.

• Re-attach the lower boiler wall sections.

When wet-cleaning (chemical cleaning) the BUDERUS LOGANO GE315, use a cleaning agent appropriate for the level of contamination (soot or encrustation). Always observe the operating instructions of the cleaning equipment and the cleaning solution.

The process may need to be varied from what is described here. The general steps are:

1. Select a cleaning agent in accordance with the level of contamination.

2. Cover the control device with foil; spray must not enter the control device.

3. Disassemble the boiler for cleaning access as you would for brush cleaning.

4. Spray the cleaning agent evenly from the top into the hot gas flues.

5. Heat up the boiler water temperature to at least 70 °C.

6. Brush out the hot gas flues.

7. Reassemble the boiler.

How you check the water pressure depends on whether you have a sealed or open system.

Open Systems:

On open systems, the pressure gauge needle must be within the red range. Note that kettling noise may occur within the boiler in open systems, which does not cause damage but can be a nuisance.

Sealed Systems:

On sealed systems, the pressure gauge needle must be within the green range. You should set the red needle on the pressure gauge to the required system pressure for easy reference.

When checking, always:

• Set the pressure gauge needle accordingly (red needle on sealed systems).

• Check the system water pressure reading.

• Ensure your heating system is adequately vented.

• Check the heating system for leaks and the function of the expansion vessel.

Frequent re-filling can damage the system through corrosion or scaling, depending on water quality.

If the pressure gauge needle on your BUDERUS LOGANO GE315 falls below the green range (on a sealed system), the water pressure in the system is too low. You need to re-fill the heating system with make-up water.

1. Top up with water as required. The boiler must only be filled via a filling tap installed in the return pipe, using an approved method (e.g., W.R.A.S. approved method in the UK).

2. Vent the heating system.

3. Check the water pressure once more.

Avoid temperature stresses by filling slowly.

The annual inspection for the BUDERUS LOGANO GE315 should be completed by a qualified engineer. The following checks should be performed and documented:

1. Check the general system condition.

2. Check the system visually and for function.

3. Check the fuel and water components of the system for: leaks, visible signs of corrosion, and signs of ageing.

4. Check the combustion chamber and the heating surface for contamination; shut-down the system for this step.

5. Check the burner function (see burner documentation).

6. Check the flue gas routing for function and safety (see burner documentation).

7. Check the water pressure and inlet pressure of the diaphragm expansion vessel in sealed systems.

8. Check the water pressure and the inlet pressure in open systems.

9. Check the function of the DHW cylinder and that of the corrosion protection anode (see DHW cylinder documentation).

10. Check the control device settings (see control device documentation).

11. Final check of the inspection work; document the measurement and test results.

Demand-dependent maintenance for the BUDERUS LOGANO GE315 includes cleaning and functional checks. These tasks should be performed by a qualified engineer and documented:

1. System shutdown.

2. Remove and clean the hot gas baffle plates.

3. Clean the hot gas flues (heating surfaces).

4. Clean the combustion chamber.

5. Clean the flue gas collector.

6. Install the hot gas baffle plates.

7. Check and, if required, replace gaskets/packing cord on the burner and burner door (see burner documentation).

8. System start-up.

9. Final check of the maintenance work; document the measurement and test results (see burner documentation).

10. Check the function and safety in operation (see burner documentation).

Heating system faults on the BUDERUS LOGANO GE315 are indicated on the control device display. Any burner fault is also indicated by a fault lamp on the burner itself.

To reset a fault, press the burner reset button (refer to the burner operating instructions).

CAUTION: SYSTEM DAMAGE

The burner ignition transformer may be damaged if you press the reset button more than three times in succession after the burner refuses to start. Do not attempt to clear a fault more than three times in succession by using the reset button.

If the burner will not start after three attempts, refer to the technical burner documentation for further information regarding resetting the burner.

The technical specifications for the various sizes of the BUDERUS LOGANO GE315 are as follows: