Buderus Logano G315 Guida rapida

Assembly, Maintenance and

Operating Instructions

Buderus G315 Boiler

Save These Instructions!

5647 853-5/98 USA

This assembly, maintenance and operating

manual must be kept near the boiler!

Buderus Hydronic Systems, Inc.

16 Industrial Way

Salem, New Hampshire 03079

Tel: (603) 898-0505 • Fax: (603) 898-1055

Boiler installed by:

(contractor’s address)

Boiler installed on:

(date of installation)

Buderus Hydronic Systems, Inc. reserves the right to make changes without notice due to continuing engineering and technological improvements.

G315

TABLE OF CONTENTS

1General Guidelines 3

2Boiler Operating Data 4

3Technical Data 5

4Boiler Foundation and Minimum Boiler Clearances 6

5Assembly Tools/Tools Req’d for Boiler Assembly 7

6Boiler Assembly 8-11

7Hydrostatic Test 12

8Installation of Boiler Components 13-15

9Installation of Insulation & Boiler Jacket Panels 16-19

10 Installation of Hydronic Control Components 20

11 Maintenance Instructions 21-23

12 Optional Noise Reduction Equipment 24

13 Shipping Component Listing 25

14 Supply Temperature Control 26

General Guidelines 1

General guidelines

Installation, maintenance and service of this boiler must only be carried out by a qualified contractor.

The assembly sequence is essential to reliable operation of the boiler and associated heating system. The

boiler can be assembled, hydrostatically tested and operated without boiler insulation and jacket panels.

These items can be installed at a later date without disrupting boiler operation.

NOTE:A minimum supply temperature of 122° F must be maintained during burner operation. Controls

must be provided that will shut off circulation through the boiler when the supply temperature

drops below 122° F.This requirement applies only during burner operation. There is no

minimum return water temperature requirement.

All work shall be performed in strict accordance with the requirements of state and local regulating agencies

and codes dealing with boiler installations. Initial start-up must be performed by qualified personnel.

After start-up the owner or its representative should be instructed about the boiler operation and be given

the assembly and maintenance manual.

Boiler cleaning and maintenance must be carried out once annually. This includes an overall check of the

heating system. Any discrepancies must be corrected immediately.

NOTE: To perform the hydrostatic pressure test after the boiler is assembled, 2-2” or 3” caps, 3/4”, 1”

and 2” plugs and a 3/4” air vent may be needed. These items arenot furnished with the boiler.

NOTE: This manual is for reference only.The manual does NOT purport to address all design,

installation and safety considerations. It is the responsibility of the user of this manual to

determine the applicability and safety of each individual application and ensure its compliance

with local building codes.

It is expected that the user/installer is a licensed heating contractor with knowledge of accepted

industry practices for the installation and maintenance of the equipment and various applications

of the equipment involved.

General Guidelines 1

General guidelines

Installation, maintenance and service of this boiler must only be carried out by a qualified contractor.

The assembly sequence is essential to reliable operation of the boiler and associated heating system. The

boiler can be assembled, hydrostatically tested and operated without boiler insulation and jacket panels.

These items can be installed at a later date without disrupting boiler operation.

NOTE:A minimum supply temperature of 122° F must be maintained during burner operation. Controls

must be provided that will shut off circulation through the boiler when the supply temperature

drops below 122° F.This requirement applies only during burner operation. There is no

minimum return water temperature requirement.

All work shall be performed in strict accordance with the requirements of state and local regulating agencies

and codes dealing with boiler installations. Initial start-up must be performed by qualified personnel.

After start-up the owner or its representative should be instructed about the boiler operation and be given

the assembly and maintenance manual.

Boiler cleaning and maintenance must be carried out once annually. This includes an overall check of the

heating system. Any discrepancies must be corrected immediately.

NOTE: To perform the hydrostatic pressure test after the boiler is assembled, 2-2” or 3” caps, 3/4”, 1”

and 2” plugs and a 3/4” air vent may be needed. These items arenot furnished with the boiler.

NOTE: This manual is for reference only.The manual does NOT purport to address all design,

installation and safety considerations. It is the responsibility of the user of this manual to

determine the applicability and safety of each individual application and ensure its compliance

with local building codes.

It is expected that the user/installer is a licensed heating contractor with knowledge of accepted

industry practices for the installation and maintenance of the equipment and various applications

of the equipment involved.

Technical Data 3

Table 1: Boiler Dimensions

Table 2: Technical Specifications

Gross Output (Btu/hr.) 358,000 478,000 580,000 682,000 785,000

No. of Sections 5 6 7 8 9

Overall Boiler Length LG(In.) 441/4 501/2 563/4 631/4 691/2

Boiler Block Length LK(In.) 381/4 441/2 503/4 57 631/2

Minimum Boiler Width BE(In.) 28 28 28 28 28

Fire Box Depth LF(In.) 31 371/2 43 3/4 50 561/4

Fire Box Diameter (In.) 153/4 153/4 15 3/4 153/4 153/4

Fire Box Volume (Cu.Ft.) 5.19 6.39 7.59 8.79 9.99

Dry Weight (Lbs.) 1197 1391 1585 1779 1973

Water Content (Gals.) 37.8 45.2 52.6 60.0 67.4

Operating Weight (Lbs.) 1512 1768 2024 2280 2535

Vent Connection Size (In.) 7 7 7 7 7

Door Thickness T (In.) 5 5 5 5 5

Fig. 1

Gross Output (Btu/hr.) 358,000 478,000 580,000 682,000 785,000

No. of Sections 5 6 7 8 9

Boiler HP 10.7 14.3 17.4 20.4 23.5

Net IBR Rating (Btu/hr.) 311,000 416,000 504,000 593,000 683,000

Max Input Oil (GPH) 3.0 3.85 4.7 5.5 6.4

Max Input Gas (Btu/hr.) 420,000 540,000 660,000 770,000 896,000

Fire side heating surface (Sq.ft.) 50.6 62.4 74.3 86.1 96.9

Firebox Pressure (In. W.C.) .18 .32 .50 .71 .75

34 3/4”

40 3/4”

173/4”

max.

9” 7”

LK111/4”

37”

32 1/4”

251/2”

3/4”

Drain

1”

Top View

Rear View

Side ViewFront View

Supply

Return

2 Boiler Operating Data

Boiler operating ratings

Maximum supply temperature: 248°F (120°C)

Maximum operating pressure: 58 psi (4 bar)

Water quality requirements

Fill water requirement: water with alkalinity < 200 mg/li for initial system filling.

Make-up water requirement: water with alkalinity < 30 mg/li

System water requirements:

pH value (@ 77°F): 9.0 - 10.0

Acid capacity: 3.0 - 50 mg/li

Oxygen (O2): .01%

Phosphate (P205): 2.5 %

Sodium sulfate (Na2SO3): 1 - 4%

For overall system protection, it is recommended to install a filter and sludge removal system

in the boiler return piping.

Any approved (based on application testing at burner manufacturer’s facilities) oil or power gas

burner can fire into G315 boilers. Burners with low fire start or two stage firing are recommended.

The high fire setting on the burner should match the rated output of the boiler to prevent

condensation in the heat exchanger. The CO volume percent in undiluted, dry flue gas should

not exceed .04% (400 ppm).

Technical Data 3

Table 1: Boiler Dimensions

Table 2: Technical Specifications

Gross Output (Btu/hr.) 358,000 478,000 580,000 682,000 785,000

No. of Sections 5 6 7 8 9

Overall Boiler Length LG(In.) 441/4 501/2 563/4 631/4 691/2

Boiler Block Length LK(In.) 381/4 441/2 503/4 57 631/2

Minimum Boiler Width BE(In.) 28 28 28 28 28

Fire Box Depth LF(In.) 31 371/2 43 3/4 50 561/4

Fire Box Diameter (In.) 153/4 153/4 15 3/4 153/4 153/4

Fire Box Volume (Cu.Ft.) 5.19 6.39 7.59 8.79 9.99

Dry Weight (Lbs.) 1197 1391 1585 1779 1973

Water Content (Gals.) 37.8 45.2 52.6 60.0 67.4

Operating Weight (Lbs.) 1512 1768 2024 2280 2535

Vent Connection Size (In.) 7 7 7 7 7

Door Thickness T (In.) 5 5 5 5 5

Fig. 1

Gross Output (Btu/hr.) 358,000 478,000 580,000 682,000 785,000

No. of Sections 5 6 7 8 9

Boiler HP 10.7 14.3 17.4 20.4 23.5

Net IBR Rating (Btu/hr.) 311,000 416,000 504,000 593,000 683,000

Max Input Oil (GPH) 3.0 3.85 4.7 5.5 6.4

Max Input Gas (Btu/hr.) 420,000 540,000 660,000 770,000 896,000

Fire side heating surface (Sq.ft.) 50.6 62.4 74.3 86.1 96.9

Firebox Pressure (In. W.C.) .18 .32 .50 .71 .75

34 3/4”

40 3/4”

173/4”

max.

9” 7”

LK111/4”

37”

32 1/4”

251/2”

3/4”

Drain

1”

Top View

Rear View

Side ViewFront View

Supply

Return

2 Boiler Operating Data

Boiler operating ratings

Maximum supply temperature: 248°F (120°C)

Maximum operating pressure: 58 psi (4 bar)

Water quality requirements

Fill water requirement: water with alkalinity < 200 mg/li for initial system filling.

Make-up water requirement: water with alkalinity < 30 mg/li

System water requirements:

pH value (@ 77°F): 9.0 - 10.0

Acid capacity: 3.0 - 50 mg/li

Oxygen (O2): .01%

Phosphate (P205): 2.5 %

Sodium sulfate (Na2SO3): 1 - 4%

For overall system protection, it is recommended to install a filter and sludge removal system

in the boiler return piping.

Any approved (based on application testing at burner manufacturer’s facilities) oil or power gas

burner can fire into G315 boilers. Burners with low fire start or two stage firing are recommended.

The high fire setting on the burner should match the rated output of the boiler to prevent

condensation in the heat exchanger. The CO volume percent in undiluted, dry flue gas should

not exceed .04% (400 ppm).

Assembly Tools/Tools Req’d for Boiler Assembly 5

Assembly tools and auxiliary assembly materials

✔Boiler assembly tool rods size 2.2 (2 pieces)

✔Wooden or rubber mallet

✔Half-round rough file

✔Flat head and Phillips screwdrivers

✔Flat chisel, steel strips for boiler support

✔Metric wrenches sizes 13, 19, 24, 36 and socket

✔size 19 (US equivalent sizes may also be used)

✔Cleaning rags, machine oil, gasoline or paint

thinner, level, steel wire brush, tape measure,

chalk.

Boiler assembly tool components

No. of Sections Assembly Tool Extension Piece Total Tool Length (ft)

Table 4. Assembly tool requirements

Fig. 5

Tightening Nut

Assembly Tool

85”

Straight Pin

Stop

Flange

Pressure

Bearing

Pressure

Bearing

Small

Pressure

Flanges

5-9 1 0 7

Boiler foundation preparations

It is required that the boiler is placed on a level, smooth

concrete base, of sufficient strength. The width of the

platform must be 33 1/2”. Length L1is the platform

length. It is required to cement in either a 4” x 1/4” flat

steel plate or a 4” x 2” x 1/4” angle iron, as shown in

Figure 2; Table 3 shows dimensions.

Minimum wall clearances

The recommended wall clearances must be observed in

order to open the burner door, assemble the boiler and

allow sufficient access for boiler maintenance.

(See Figures 3 and 4 for details).

The burner door is field adjustable to hinge right or left.

Recommended clearances:

Wall clearance W1: minimum 12”.

Wall clearance W2: Burner length A + 4”, minimum 43”.

Wall clearance W3: Boiler length L + 40”.

Wall clearance W4: 1/2 Boiler length + 20”.

Absolute minimum clearances:

Wall clearance W1: minimum 12”.

Wall clearance W2:* minimum 12”.

Wall clearance W3: Boiler length L or minimum 86”.

Wall clearance W4: 36”.

Note: Wall clearance W3 can be reduced to 4 feet for

assembled boilers. Boiler cleaning will now require

use of segmented brushes.

*Requires burner removal during cleaning.

4 Boiler Foundation and Minimum Boiler Clearances

Fig. 2

Fig. 3

Fig. 4

16”

7 3/4”

Table 3: Foundation and support strip lengths

No. of Sections Length LI (In.) Length L2 (In.)

5 36 283/4

6 421/4 35

7 481/2 411/4

8 543/4 471/2

9 61 54

33 1/2”

4” 4”

4”

20” 3 1/2”

10”

Assembly Tools/Tools Req’d for Boiler Assembly 5

Assembly tools and auxiliary assembly materials

✔Boiler assembly tool rods size 2.2 (2 pieces)

✔Wooden or rubber mallet

✔Half-round rough file

✔Flat head and Phillips screwdrivers

✔Flat chisel, steel strips for boiler support

✔Metric wrenches sizes 13, 19, 24, 36 and socket

✔size 19 (US equivalent sizes may also be used)

✔Cleaning rags, machine oil, gasoline or paint

thinner, level, steel wire brush, tape measure,

chalk.

Boiler assembly tool components

No. of Sections Assembly Tool Extension Piece Total Tool Length (ft)

Table 4. Assembly tool requirements

Fig. 5

Tightening Nut

Assembly Tool

85”

Straight Pin

Stop

Flange

Pressure

Bearing

Pressure

Bearing

Small

Pressure

Flanges

5-9 1 0 7

Boiler foundation preparations

It is required that the boiler is placed on a level, smooth

concrete base, of sufficient strength. The width of the

platform must be 33 1/2”. Length L1is the platform

length. It is required to cement in either a 4” x 1/4” flat

steel plate or a 4” x 2” x 1/4” angle iron, as shown in

Figure 2; Table 3 shows dimensions.

Minimum wall clearances

The recommended wall clearances must be observed in

order to open the burner door, assemble the boiler and

allow sufficient access for boiler maintenance.

(See Figures 3 and 4 for details).

The burner door is field adjustable to hinge right or left.

Recommended clearances:

Wall clearance W1: minimum 12”.

Wall clearance W2: Burner length A + 4”, minimum 43”.

Wall clearance W3: Boiler length L + 40”.

Wall clearance W4: 1/2 Boiler length + 20”.

Absolute minimum clearances:

Wall clearance W1: minimum 12”.

Wall clearance W2:* minimum 12”.

Wall clearance W3: Boiler length L or minimum 86”.

Wall clearance W4: 36”.

Note: Wall clearance W3 can be reduced to 4 feet for

assembled boilers. Boiler cleaning will now require

use of segmented brushes.

*Requires burner removal during cleaning.

4 Boiler Foundation and Minimum Boiler Clearances

Fig. 2

Fig. 3

Fig. 4

16”

7 3/4”

Table 3: Foundation and support strip lengths

No. of Sections Length LI (In.) Length L2 (In.)

5 36 283/4

6 421/4 35

7 481/2 411/4

8 543/4 471/2

9 61 54

33 1/2”

4” 4”

4”

20” 3 1/2”

10”

Boiler block sectional arrangement

The boiler is always assembled starting with the rear section

and finishing with the front section.

The arrow markings on the sections must point to the rear

(Fig. 6) and use the sequence in Table 5.

Assembly of individual boiler sections

• Remove the nuts and washers from the rear and

front sections prior to boiler assembly.

• Note the arrow marking on each section. These

arrows are located on the top left and right of

each section and must point to the rear during

boiler assembly (Fig. 6).

•Assemble the boiler on a smooth hard surface

with flat steel plates underneath to permit easy

sliding of sections.

• Position and align the rear section upright in

final location and secure it from falling over

(Fig. 7).

• To reduce the risk of injuries, support the boiler

section or secure it with an overhead lifting device.

6 Boiler Assembly

315/5 1 3 1

315/6 1 4 1

315/7 1 5 1

315/8 1 6 1

315/9 1 7 1

Model No. of

Front Section No. of

Midsections No. of

Rear Section

Table 5: Boiler section arrangement

Fig. 6

Fig. 7

Flue gas

collector

Assembly

arrow marking

Rear

section Front

section

Middle sections

CAUTION: The work area must be well

ventilated during boiler assembly .

WARNING: Keep Buderus Haftgrund 181 primer

away from flam e! Do not smoke

during assembly! Do notpour

Buderus Haftgrund 181 primer down

open drains!

• File off any burrs from the nipple ports (Fig. 8).

•Clean the sealing surfaces of the nipple ports with

a rag soaked in thinner or gasoline. Wipe dry.

• Evenly coat the nipple port sealing surfaces with

the orange sealing compound (Leinolmennige)

using the brush provided (Fig. 9).

• Clean the sealing grooves for sealing the flue side

of the boiler using a steel wire brush. Make sure

surfaces are dry, clean and free of any oily residues.

• Apply the Buderus Haftgrund Primer 181 to all

sealing grooves using a small paint brush (Fig. 10).

•The sealing of the flueway of each section is

achieved with the sealing cord. The sealing

cord can be installed 5 to 15 minutes after

the application of the primer.

Fig. 8

Fig. 9

Coat with

orange sealing

compound

Fig. 10

Boiler Assembly 6

Sealing grooves

Boiler block sectional arrangement

The boiler is always assembled starting with the rear section

and finishing with the front section.

The arrow markings on the sections must point to the rear

(Fig. 6) and use the sequence in Table 5.

Assembly of individual boiler sections

• Remove the nuts and washers from the rear and

front sections prior to boiler assembly.

• Note the arrow marking on each section. These

arrows are located on the top left and right of

each section and must point to the rear during

boiler assembly (Fig. 6).

•Assemble the boiler on a smooth hard surface

with flat steel plates underneath to permit easy

sliding of sections.

• Position and align the rear section upright in

final location and secure it from falling over

(Fig. 7).

• To reduce the risk of injuries, support the boiler

section or secure it with an overhead lifting device.

6 Boiler Assembly

315/5 1 3 1

315/6 1 4 1

315/7 1 5 1

315/8 1 6 1

315/9 1 7 1

Model No. of

Front Section No. of

Midsections No. of

Rear Section

Table 5: Boiler section arrangement

Fig. 6

Fig. 7

Flue gas

collector

Assembly

arrow marking

Rear

section Front

section

Middle sections

CAUTION: The work area must be well

ventilated during boiler assembly .

WARNING: Keep Buderus Haftgrund 181 primer

away from flam e! Do not smoke

during assembly! Do notpour

Buderus Haftgrund 181 primer down

open drains!

• File off any burrs from the nipple ports (Fig. 8).

•Clean the sealing surfaces of the nipple ports with

a rag soaked in thinner or gasoline. Wipe dry.

• Evenly coat the nipple port sealing surfaces with

the orange sealing compound (Leinolmennige)

using the brush provided (Fig. 9).

• Clean the sealing grooves for sealing the flue side

of the boiler using a steel wire brush. Make sure

surfaces are dry, clean and free of any oily residues.

• Apply the Buderus Haftgrund Primer 181 to all

sealing grooves using a small paint brush (Fig. 10).

•The sealing of the flueway of each section is

achieved with the sealing cord. The sealing

cord can be installed 5 to 15 minutes after

the application of the primer.

Fig. 8

Fig. 9

Coat with

orange sealing

compound

Fig. 10

Boiler Assembly 6

Sealing grooves

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