Installation and Maintenance Gas-fired boiler

Instructions

WARNING!
Before commissioning the boiler, heed the safety
instructions for mounting and maintenance.
DANGER!
If installation, adjustment, modification, operation
or maintenance of the heating system is carried
out by an unqualified person, this may result in
danger to life and limb or property damage. The
installation and servicing instructions must be
followed precisely. If you require assistance or
further information, contact a qualified installer or
an appropriate service provider.
CAUTION!
The operating instructions are part of the techni-
cal documents that must be handed over to the
operator of the heating system. Discuss the in-
struction in this manual with the owner or opera-
tor of the heating system to ensure that they are
familiar with all information required for operation
of the heating system.

For heating contractors

Please read carefully before

Logano G234X installing and servicing.

gas-fired boiler
6 720 642 833 (12/2009) US/CA
Contents
5.7.1 Check openings for combustion air supply
1 Explanation of symbols and safety and venting . . . . . . . . . . . . . . . . . . . . . . . . . .23
information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5.7.2 Requirements for connection to chimneys
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . 3 or venting systems . . . . . . . . . . . . . . . . . . . .24
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . 3 5.7.3 Installing the flue pipe . . . . . . . . . . . . . . . . . 25
5.7.4 Connecting flue pipe . . . . . . . . . . . . . . . . . 25
2 Product description . . . . . . . . . . . . . . . . . . . . . . 5 5.7.5 Installation of vent damper . . . . . . . . . . . . . 25
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . 5 5.7.6 Installing electrical connection of vent
2.2 Standards, regulations and directives . . . . 5 damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.2.1 National regulations . . . . . . . . . . . . . . . . . . . 5
2.2.2 Boiler operating conditions . . . . . . . . . . . . . 5 6 Commissioning the heating system . . . . . . . 27
2.3 Notes on installation and operation . . . . . . 5 6.1 Test safety valve . . . . . . . . . . . . . . . . . . . . . 27
2.3.1 Other important information . . . . . . . . . . . . . 5 6.2 Making the heating system ready for
2.4 Tools, materials and equipment . . . . . . . . . . 6 operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6.3 Start-up instructions . . . . . . . . . . . . . . . . . . 29
2.6 Product description . . . . . . . . . . . . . . . . . . . 6 6.4 Making boiler ready for operation . . . . . . . 30
2.7 Package Contents . . . . . . . . . . . . . . . . . . . . 6 6.4.1 Commission the heating system with
2.8 Dimensions and specifications . . . . . . . . . . 7 aquastat control . . . . . . . . . . . . . . . . . . . . . .30
2.8.1 Logano G234X dimensions . . . . . . . . . . . . 7 6.4.2 Placing heating system with
2.8.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 8 Logamatic 2000 control unit in operation .30
2.8.3 Main gas orifice identification and rated 6.5 Then carry out start-up procedures. . . . . . 30
orifice pressure . . . . . . . . . . . . . . . . . . . . . . . 8 6.6 Shutting off gas supply to boiler . . . . . . . . 34
6.7 Inform owner/operator, hand over
3 Moving the boiler . . . . . . . . . . . . . . . . . . . . . . . . 9 technical documentation . . . . . . . . . . . . . . .34
6.8 Commissioning log . . . . . . . . . . . . . . . . . . . 35

4 Placing the boiler . . . . . . . . . . . . . . . . . . . . . . . 10

4.1 Boiler room requirements . . . . . . . . . . . . . 10 7 Shut down the heating system . . . . . . . . . . . . 36
4.2 Recommended wall clearances . . . . . . . . 10 7.1 Normal shut-down . . . . . . . . . . . . . . . . . . . . 36
4.3 Leveling the boiler . . . . . . . . . . . . . . . . . . . 11 7.2 Shutting down the boiler in an emergency 36
7.2.1 Action in an emergency . . . . . . . . . . . . . . . 36

5 Installing the boiler . . . . . . . . . . . . . . . . . . . . . 12

5.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . 12 8 Heating system inspection and
5.2 Connecting the heating system . . . . . . . . . 12 maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2.1 General safety instructions . . . . . . . . . . . . 12 8.1 Why is regular maintenance important? . . 37
5.2.2 Connect the central heating supply and 8.2 Checking the flue system including the
return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 combustion air supply, inlet and outlet air
5.3 Electrical connection . . . . . . . . . . . . . . . . . 14 openings . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.3.1 Connecting power supply . . . . . . . . . . . . . 14 8.3 Inspection of the boiler and burner . . . . . . 37
5.3.2 Mount the Logamatic 2000 control unit 8.4 Preparing boiler for cleaning . . . . . . . . . . . 38
(accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . 14 8.5 Cleaning the boiler . . . . . . . . . . . . . . . . . . . 39
5.3.3 Installing the rear boiler cover . . . . . . . . . . 17 8.5.1 Cleaning the boiler with cleaning brushes 39
5.4 Connecting the gas supply . . . . . . . . . . . . 18 8.5.2 Wet cleaning (chemical cleaning) . . . . . . . 40
5.4.1 Installing gas feed . . . . . . . . . . . . . . . . . . . . 18 8.6 Cleaning the burner . . . . . . . . . . . . . . . . . . 41
5.4.2 Converting boiler to propane . . . . . . . . . . . 20 8.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 42
5.4.3 Installation at high altitudes . . . . . . . . . . . . 20 8.8 Maintenance log book . . . . . . . . . . . . . . . . 44
5.5 Filling the heating system and checking
for water leaks . . . . . . . . . . . . . . . . . . . . . . . 21 9 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.6 Install front wall of boiler . . . . . . . . . . . . . . 22
5.7 Connecting the flue . . . . . . . . . . . . . . . . . . 23
10 Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . 61

2 Logano G234X - Technical specifications are subject to change without prior notice.
 Explanation of symbols and safety information 1

1 Explanation of symbols and safety information

1.1 Explanation of symbols 1.2 Safety instructions
Warnings If you smell gas
B Turn off the gas shut-off valve (Æ page 36).
Warnings in the text are indicated by a
warning triangle with a gray background in a B Open windows and doors.
framed box. B Do not operate any electrical switches, not even
telephones, plugs or doorbells.
B Extinguish all open flames. Do not smoke! Do not use
In case of danger due to current, the lighters.
exclamation point on the warning triangle is
B Warn all occupants of the building, but do not ring
replaced with a lightning symbol.
doorbells.
Signal words at the beginning of a warning are used to B If you can actually hear gas escaping, leave the building
indicate the type and seriousness of the ensuing risk if immediately. Prevent others from entering and notify
measures for minimizing damage are not taken. the police and fire department from outside the
building.
• NOTE indicates that damage to property may occur.
B From outside the building, call the gas utility
• CAUTION indicates possible minor to medium
company and approved heating contractor.
personal injury.
• WARNING indicates possible severe personal injury. If you smell flue gas
• DANGER indicates that severe personal injury may B Switch off the heating system (Æ page 36).
occur. B Open windows and doors.
Important Information B Inform an authorized heating contractor.

Important information that presents no risk to Danger from escape of toxic flue gases.
people or property is indicated with this B Ensure that the boiler is not equipped with a
symbol. They are separated by lines above thermostatic shut-off damper downstream of the draft
and below the text. hood.

Risk of poisoning. Intervention in the flue gas

Additional symbols
monitor can result in dangerous escape of flue gas.
Symbol Explanation B Do not attempt to repair the flue gas temperature
sensor.
B Sequence of steps
B When changing the flue gas temperature sensor, use
Æ Cross-reference to other points in this only original spare parts.
document or to other documents B When replacing the flue gas temperature sensor install
the new one in the specified position.
• Listing/list entry
Danger from escape of toxic flue gases if the flue
– Listing/list entry (2nd level)
gas monitor trips frequently.
Tab. 1 If the flue gas monitor trips frequently, there may be a
problem with the chimney or the flue gas venting. This can
cause flue gas to escape.
B Remedy faults and perform function test.

Risk of poisoning. Insufficient ventilation may

cause dangerous flue gas leaks.
B Never close off or reduce the size of air intake and
outlet openings.
B The boiler must not be operated until the obstruction
has been removed.
B Inform the system user in writing of the problem and
associated danger.

Logano G234X - Technical specifications are subject to change without prior notice. 3
 1 Explanation of symbols and safety information

Danger from escaping flue gases Set-up, installation, commissioning

B Make sure that the vent pipes and gaskets are not B Correct and proper installation and adjustment of the
damaged. burner and the control panel are the fundamental
B Use silicone as sealing compound. requirements for safe and economical operation of the
B The boiler must not be fitted with a barometric damper boiler.
or a thermally controlled flue flap downstream of the B The boiler may only be installed or converted by an
flue socket. approved heating contractor.
B Connect only one boiler to each venting system or B Never change any parts in contact with flue gas.
chimney flue. B Only qualified electricians are permitted to carry out
B Connection of another boiler may cause serious injury electrical work. Installation regulations must be
or death. complied with.
B The venting system piping must not feed into another B The hot water tank may only be used for heating
air extraction duct. domestic hot water.
B Do not route the flue system piping through or inside B Never shut off safety valves!
another air extraction duct, for example where there is Water may escape from the safety valve for the hot
a masonry or prefabricated chimney flue. water system and piping when the water is being
heated.
Danger of explosion of flammable gases.
B Work on gas components may only be carried out by Inspection/maintenance
qualified and authorized personnel. B Servicing and repairs may only be carried out by an
B Mounting, gas and flue connection, initial approved heating contractor.
commissioning, electrical connection and maintenance B Immediately correct all faults to prevent system
activities must only be carried out by a trained service damage.
provider. B The operator is responsible for the general and
environmental safety of the heating system.
Dangers posed by explosive and easily B Use only genuine spare parts! Damage caused by the
combustible materials use of parts not supplied by Buderus is not covered by
B Do not use or store easily-combustible materials the Buderus warranty.
(paper, lace curtains, clothing, thinners, paints, etc.)
B Recommendation for users: take out a maintenance
near the boiler.
and servicing contract with an approved heating
B Maintain a clearance of 16.2 inches (415 mm) from the contractor covering annual servicing and condition-
boiler. based maintenance.
Combustion air Instructing the customer
B Keep the combustion air free of corrosive substances B Explain to the customer how the boiler works and how
(e. g. halogenated hydrocarbons that contain chlorine to operate it.
or fluorine compounds). This will help prevent B Inform the customer that he/she must not carry out any
corrosion.
alterations or repairs.
Danger from electric shock when the boiler is open.
B Before opening the boiler:
Disconnect the heating system from the electrical
power supply by means of the emergency shutoff
switch or the heating system circuit breaker on the
main fuse panel.
B It is not enough to only switch off the control unit.
B Take measures to ensure that the heating system
cannot be switched on again unintentionally.

Danger due to short-circuits

To prevent short circuits, only
B use genuine Buderus wiring.

4 Logano G234X - Technical specifications are subject to change without prior notice.
 Product description 2

2 Product description
This installation and maintenance manual contains Engineers Safety Code for Controls and Safety Devices
important information for the safe and correct installation, for Automatically Fired Boilers (ASME CSD-1).
initial commissioning, and maintenance of this boiler.
Carbon monoxide detectors must be installed as
The special gas-fired boiler Logano G234X is generally specified by the local regulations. The boiler must be
referred to below as a boiler. serviced annually.
The installation and maintenance manual is provided for 2.2.2 Boiler operating conditions
technicians who have been trained and have experience Maximum boiler temperature: 220 °F (104 °C)
in working with heating systems and oil and gas fired
installations. Maximum operating pressure: 58 psi (4 bar)
Only use the boiler in the combinations and with the The hot water distribution system must comply with all
accessories and spare parts that are specified in the applicable codes and regulations. If an existing boiler is
installation and servicing instructions. replaced, the complete hot water piping system must be
inspected to ensure that it is in perfect condition to ensure
Other combinations, accessories and worn out parts safe operation.
must only be used if they are specifically designed for the
intended application and do not affect the system
performance and the safety requirements. 2.3 Notes on installation and operation
When installing and operating the heating system
2.1 Intended use observe the following:
The boiler is designed for heating central heating system • The local building codes regarding the installation
water and indirect heating of domestic hot water (e.g. in a • The local building regulations regarding air supply and
hot water cylinder), for instance in individual homes or venting systems and the chimney flue connection.
apartment buildings. • Regulations governing power connection to the power
supply
2.2 Standards, regulations and • The technical regulations of the gas utility company
directives regarding the connection of the gas burner to the local
main gas supply.
Observe all standards and guidelines
• The regulations and standards relating to the safety
applicable to the installation and operation of
systems for the water heating system
this heating system in your jurisdiction!
2.3.1 Other important information
2.2.1 National regulations • The installation of a boiler must be notified to and
The design and mode of operation of this boiler comply approved by the relevant gas utility company.
with the American National Standard ANSI Z21.13/ • Only operate the boiler with the combined air/flue
CSA4.9, latest edition for Gas Fired Low Pressure Steam system specifically designed and approved for it.
and Hot Water Boilers.
• Regional approvals with regard to the flue system may
Other confirmed approvals and certifications are be required.
indicated by stickers on the boiler.
Installation of the boiler must comply with all applicable
codes and regulations imposed by the national, Federal or
local authorities and bodies. If no specific requirements
are defined, in the USA, the latest edition of the National
Fuel Gas Code ANSI Z223.1/NFPA 54 must be complied
with. In Canada, installation must comply in all respects
with the latest edition of the Installation Code for Gas
Burning Appliances and Equipment, CAN/CSA-B.149
and the applicable local regulations and requirements for
the appliance category. The relevant authorities and
regulatory bodies must be informed before installation
starts.
Where required by local regulations, the system must
comply with the American Society of Mechanical

Logano G234X - Technical specifications are subject to change without prior notice. 5
 2 Product description

2.4 Tools, materials and equipment

For the installation and maintenance of the boiler, you will
need the standard tools used for central heating and gas
and water systems plus set of a metric wrenches and
Allen wrenches
The following may also prove useful:
• Pipes for transport
• Wood battens
• Cleaning brushes and/or chemical cleaning agent for
wet cleaning

2.5 Disposal
B Dispose of boiler packaging in an environmentally-
responsible manner.
B All heating system components that have to be
replaced should be disposed of in environmentally-
responsible manner at an authorized disposal site.
Fig. 1 G234X boiler
2.6 Product description 1 Aquastat
2 Burner control unit
The boiler is a low temperature gas-fired boiler.
3 Boiler block with thermal insulation
4 Boiler casing
The boiler is fully functional with the factory- 5 Burner
installed aquastat. A Logamatic 2000 control 6 Front wall of boiler
can be installed in addition to the aquastat. 7 Logamatic 2000 control unit
The control unit can be ordered as an
accessory from Buderus. 2.7 Package Contents
B After delivery, check all packaging for perfect
The boiler consists of:
condition.
• Automatic ignition unit and aquastat
B Check the delivery for completeness.
• Boiler casing and front wall of boiler
• Boiler block with thermal insulation The boiler is supplied in one packing unit with the
mounted boiler casing, gas burner and gas fitting, and
• Burner
technical documentation.
• Logamatic 2000 control unit (accessory)
The automatic ignition, the aquastat and, if applicable, the Component Qty Packaging
Logamatic 2000 control unit monitor and control all
electrical components of the boiler. Boiler 1 Pallets/box

The boiler casing and the front wall of the boiler prevent • 90°-elbow (¾ " NPT) 1 Box
heat loss and reduce noise. • Safety valve
The boiler block transfers the heat generated by the • Drain valve (¾ ")
burner to the boiler water. The insulation prevents energy Vent Damper 1 Box
loss.
Technical documentation 1 Foil package
Tab. 2 Package Contents
All accessories can be ordered optionally from Buderus:
• Logamatic 2000 control unit
• Heating pump
• Cleaning brush

6 Logano G234X - Technical specifications are subject to change without prior notice.
 Product description 2

2.8 Dimensions and specifications

2.8.1 Logano G234X dimensions

Fig. 2 Connections and dimensions for Logano G234X, dimensions in mm (dimensions in inches)
VK/VS Boiler supply/Storage tank supply
GAS Gas connection + main isolating valve
RK Boiler return
RSL/EL Return safety line/draining

Boiler capacity Unit 38 45 55 64

MBtu/hr 160 187 228 266

Ignition heat load
kW 46.9 54.8 66.8 78.0

MBtu/hr 130 154 188 219

Nominal output
kW 38 45 55 64

Inches 25.6 25.6 29.1 32.7

Dimension A
mm 650 650 739 831

Vent Inches 7 7 7 8

Minimum capacity of the safety relief lb/hr 130 153 188 218
valve kg/h 59 69 85 99

Number of burner rods Qty 3 3 4 4

US gal. 6.1 6.1 7.1 8.2

Water volume
l 23 23 27 31

lbs 487 487 562 684

Dry weight
kg 221 221 255 310
Tab. 3 Dimensions

Logano G234X - Technical specifications are subject to change without prior notice. 7
 2 Product description

2.8.2 Specifications

Fig. 3 Pressure drops (1 psi = 69 mbar, 1 GPM = 0.23 m³/h)

x Flow Rate in GPM ( m³/h)
y Pressure drops in psi

1 160 500/187 700 BTU/hr (boiler rating 38/45)

2 228 400 BTU/hr (boiler rating 64)
3 266 400 BTU/hr (boiler rating 55)

2.8.3 Main gas orifice identification and rated orifice pressure

Main gas orifice

Boiler Number of Rated orifice pressure for natural gas
identification
capacity injectors
0 - 2000 ft (0 - 610 m) [In. W.C.] [mbar]

38 3 3.70 3.0 7.6

45 3 3.70 4.1 10.4

55 4 3.50 4.6 11.5

64 4 3.80 4.4 10.9

Tab. 4 Main gas orifice identification and rated orifice pressure for natural gas

Main gas orifice

identification Rated orifice pressure for propane gas
Boiler Number of
capacity injectors 0 - 2000 ft (0 - 610 m) [In. W.C.] [mbar]

38 3 2.20 10.6 26.5

45 3 2.40 10.5 26.2

55 4 2.30 10.3 25.8

64 4 2.45 10.3 25.9

Tab. 5 Main gas orifice identification and rated orifice pressure for propane gas

8 Logano G234X - Technical specifications are subject to change without prior notice.
 Moving the boiler 3

3 Moving the boiler

This section details how to move the boiler safely. B Remove the straps and the cardboard packaging.
B Loosen the retaining screws.
NOTICE: Risk of system damage from B Lift the boiler at the sides and slide to the edge of the
impact shocks! pallet.
Fragile components could be damaged. B Place a pipe under the boiler and roll it on additional
B Observe the transport instructions on the pipes to the installation location.
packaging. B Place the boiler in its final position.

NOTICE: System damage due to improper

transport!
B Protect sheet metal parts, flue gas pipe,
burner, and control unit during transport.
B Do not lift the boiler using these
components.

Dispose of packaging in an environmentally

responsible manner.

Moving the boiler with hand truck

WARNING: Risk of injury if load is

inadequately secured during transportation.
B Use suitable means of transportation, e.g. Fig. 5 Moving the boiler
a trolley with strap.
B When transporting, secure the boiler to
prevent it falling.

B Position transport equipment (e.g. trolley) at the back

of the boiler.
B Secure packaged boiler to the hand truck.
B Move the packaged boiler to the installation location.

Fig. 4 Moving boiler with trolley

Logano G234X - Technical specifications are subject to change without prior notice. 9
 4 Placing the boiler

4 Placing the boiler

This section explains how to erect and position the boiler 4.2 Recommended wall clearances
correctly in the boiler room. Wherever possible, position the boiler with the
recommended wall clearances. Reducing the minimum
4.1 Boiler room requirements clearances makes the boiler more difficult to access.

NOTICE: Risk of system damage due to The base or foundation on which the boiler is to stand
freezing! must be perfectly flat and level. The boiler may be installed
B Install the heating system in a frost-free on a flammable base, but not on carpet.
room.
Wall clearance
Dimension inches (mm)
WARNING: Damage to the building due to
insufficient load capacity of the floor! A 33 (840)
B Before setting the boiler up, check the B 6 (155)
load capacity of the floor.
C 2 (50)

DANGER: Dangers posed by explosive and Tab. 6 Wall clearances

easily combustible materials!
B Do not use or store easily-combustible Where applicable, allow extra wall
materials (paper, lace curtains, clothing, clearances for additional components such
thinners, paints, etc.) near the boiler. as DHW storage tank, pipe connections, flue
B Maintain a clearance of 16 inches silencer or other flue components, etc.
(415 mm) from the boiler.
A space of at least 33 inches (840 mm) is required in front
of the boiler with the door open to allow sufficient
NOTICE: Risk of boiler damage from accessibility for operation and maintenance. When the
contaminated combustion air! door is closed, a minimum clearance of 2 inches (50 mm)
B Do not use cleaning agents that contain is required at the front and sides, a wall clearance of 6
chlorine or halogenated hydrocarbons inches (155 mm) is also required for the flue pipe and
(e.g. in spray cans, solvents and cleaning 30 inches (762 mm) clearance to the ceiling.
agents, paints, glues).
B Do not store or use these substances in
the boiler room.
B Avoid excessive dust accumulation
(building dust).

Fig. 6 Wall clearances in the boiler room

1 Closed door
2 Open door

10 Logano G234X - Technical specifications are subject to change without prior notice.
 Placing the boiler 4

4.3 Leveling the boiler

The boiler must be leveled horizontally and vertically to
prevent air pockets forming inside.
B Level the boiler vertically and horizontally, inserting
metal shims underneath as required.

NOTICE: Risk of system damage due to

contamination!
B Protect boiler connections from damage
and dirt if the boiler is not to be installed
immediately.

Fig. 7 Leveling the boiler (example)

Logano G234X - Technical specifications are subject to change without prior notice. 11
 5 Installing the boiler

5 Installing the boiler

This section details how to install your boiler correctly. 5.2 Connecting the heating system
This involves the following steps: This section explains how the boiler is connected to the
• Flue gas connection heating system.
• Heating circuit connection
5.2.1 General safety instructions
• Making the electrical connections
• Connecting the fuel supply NOTICE: Risk of boiler damage due to
moisture!
5.1 Preparations B Protect the individual components of the
B Unpack all cartons and boxes. control system and the ignition system
from damp (dripping water, water spray,
B Using the included packing list, check to be sure that
rain) during installation, operation and
you have all the included parts.
servicing (e.g. pump replacement,
programmer replacement, etc.
Every boiler is carefully inspected and tested
before it leaves the factory. However, if you
discover any damage or missing parts, NOTICE: Risk of system damage due to
please inform the supplier immediately. overheating as a result of lack of water!
Before disposing of packing material, make B Make sure that if the boiler is located
sure that no parts are still in it. above the level of the heating system, it is
fitted with a low-water cut-off.
Route the gas connection towards the left B The low-water cut-off must be used when
The gas connection pipe is designed for a the boiler is installed (Æ Fig. 8).
gas connection on the right side.

3
B Loosen the screws on the gas connection pipe
completely.
B Attach the gas connection pipe shifted by 180° and
seal.
B Carry out the leak test.
1 2

2
2
4

2 2

1 2
Fig. 8 Low-water cut-off
1 Boiler
2 Panel radiator
3 Heating system with low-water cut-off
4 Heating system without low-water cut-off

12 Logano G234X - Technical specifications are subject to change without prior notice.
 Installing the boiler 5

Connecting the safety valve in the central heating

NOTICE: Risk of system damage due to high supply
temperature variations in the heating system!
B If the boiler is operated in conjunction with NOTICE: System damage due to faulty
an air conditioning system, it is essential to safety valve!
ensure that the pipes for the refrigerant During the leak test, the safety valve can be
fluid are connected in parallel with the damaged.
boiler system using suitable valves to
B Do not install the safety valve until the leak
prevent the refrigerant from entering the
test (Æ Section 5.5 „Filling the heating
boiler.
system and checking for water
B The pipe system of a boiler connected to leaks“, page 21) has been completed.
the heating coils of hot-air heating
systems that may be exposed to the B Install the included supply manifold and the
circulation of cooled air must be fitted with 90° elbow.
a flow-control valve or some other
B Do not install the safety valve until the leak test has
automatic system for preventing the boiler
been completed.
water from circulating by gravity during the
cooling cycle.

NOTICE: Risk of system damage due to

leaking connections!
B Install the connection cables to the boiler
in such a way that they are not under
stress.

5.2.2 Connect the central heating supply and

return

DANGER: Risk of fire from flammable

materials!
B Maintain a clearance of 2 inches (51 mm)
from pipes carrying hot water and
flammable walls in the installation room.

We recommend installing a dirt filter and a silt Fig. 9 Supply connection

clearance filter (accessory) in the boiler
1 Boiler
return connection to reduce build-up of 2 Supply connection
debris on the water side. 3 Safety valve
4 Supply manifold pipe (factory-installed)
Observe the local regulations for connection 5 90°-elbow (¾ " NPT)
of boiler systems.

Logano G234X - Technical specifications are subject to change without prior notice. 13
 5 Installing the boiler

5.3 Electrical connection 5.3.2 Mount the Logamatic 2000 control unit
The electrical connections to the boiler must conform to (accessory)
the locally applicable regulations and the relevant The boiler is fully functional with the factory-installed
requirements of the National Electrical Code, ANSI/ aquastat. A Logamatic 2000 control unit can be installed
NFPA-70. In Canada the regulations of CSA C22.1 in addition to the factory-installed aquastat.
Canadian Electrical Code, Part 1, must be observed.
Observe the following points regarding the
The boiler must be grounded in accordance with the
electrical connections of the control unit:
regulations of the relevant authorities or else the
requirements of the National Electrical Code, ANSI/ B Carefully route the cables/leads and
NFPA-70. capillary tubes.
B Never kink cables and capillary tubes
DANGER: Risk of fatal injury from electric during installation.
shock!
B Remove the cover plate from the front boiler cover.
B Only carry out electrical work on the
heating system if you are properly B Remove the rear boiler cover.
qualified for the work in question. If you do
not have the proper qualifications, have
the work done by a suitably qualified
electrician.
B Observe the local regulations.
B If cables are connected incorrectly the
system may not operate correctly with
possibly dangerous consequences. When
making the electrical connections follow
the wiring diagrams on pages 61 and 62.

5.3.1 Connecting power supply

B Establish a permanent connection to the factory-
installed aquastat in accordance with the locally
applicable regulations.
B Mount a power switch near the boiler.

Fig. 11 Remove the rear boiler cover.

1 Rear boiler cover

ON

OFF

7 747 010 720-80.1RS

Fig. 10 Main power switch

14 Logano G234X - Technical specifications are subject to change without prior notice.
 Installing the boiler 5

B Position the tabs of the control unit in the slots. B Unscrew left and right screws in the side panels, lift
B Slide control toward the boiler front panel. front panel up, pull outward and remove to the front.
B Push to snap plastic tabs of the control into the knock-
outs.

Fig. 12 Put the control unit on the boiler

B Unscrew the cover screws of the cover unit.
B Remove the cover. Fig. 14 Remove front wall of boiler
B Secure the controls with self-tapping screws. 1 Locking screws
B Route the temperature sensor line through the cable 2 Boiler casing
3 Front wall of boiler
duct and unroll to the required length.
Installation of boiler water sensor
B Remove the temperature/pressure gauge [1] on the
boiler.
B Mount the temperature/pressure gauge [1] on the
supply pipe [2] and seal.

Fig. 15 Removing the temperature/pressure gauge

1 temperature/pressure gauge
Fig. 13 Fastening the control unit 2 supply pipe

Logano G234X - Technical specifications are subject to change without prior notice. 15
 5 Installing the boiler

B Mount the Logamatic sensor well [2] on the boiler Power connection and connections of additional
instead of the temperature/pressure gauge and seal. components
B Place the Logamatic sensor packet [1] under the front
DANGER: Fire hazard from hot boiler
boiler cover towards the front for the sensor well.
components!
Hot boiler components may damage
electrical cables.
B Ensure that the electrical cables are not
touching any hot parts.
B Make sure that all cables are routed
through the conduits provided or on the
outside of the boiler's thermal insulation.

B Establish a permanent connection to the control unit in

accordance with the locally applicable regulations.
Fig. 16 Mounting the Logamatic sensor well on the B Route all wiring to the control unit through the conduit
boiler and connect as specified by the control unit circuit
diagram.
1 Logamatic sensor packet
2 Logamatic sensor well Installing strain relief
3 Logamatic 2000 control unit
The required cable clips are in the scope of delivery of the
B Place entire Logamatic sensor packet fully into the control unit.
immersion well [1] to the stop.
Insert the cable clip together with the cable from the top
The plastic coil [2] is pushed back automatically.
into the slots in the frame. The bar of the lever must point
B At the same time insert the compensating spring [3] upwards.
into the sensor well [1].
Slide the cable clip downwards.
B Press sensor clip [5] (scope of delivery of the control
Counterhold.
unit) from the side or from above to the head of the
sensor well. Flip the lever up.
B Carefully roll up unnecessary wiring and capillaries and
stow in the Logamatic 2000 control unit.

Fig. 18 Installing strain relief

Fig. 17 Sensor well and temperature sensor

1 Sensor well
2 Plastic coil
3 Compensator spring
4 Capillary line
5 Sensor retaining clip

16 Logano G234X - Technical specifications are subject to change without prior notice.
 Installing the boiler 5

Installing outer casing panels 5.3.3 Installing the rear boiler cover
B Swivel display unit to the desired position. B Slide tabs of rear boiler cover under the front boiler
cover and press down at back.
We recommend positioning the display unit B Screw rear boiler cover to rear panel of boiler.
straight on combinations with an L-tank.

Fig. 19 Swivel display unit

Fig. 21 Installing the rear boiler cover
B Position the cover and secure on the control unit.
1 Rear boiler cover

NOTICE: Risk of system damage due to

contamination!
B Protect boiler connections from damage
and dirt if the boiler is not to be installed
immediately.

Fig. 20 Positioning the cover

Logano G234X - Technical specifications are subject to change without prior notice. 17
 5 Installing the boiler

5.4 Connecting the gas supply

5.4.1 Installing gas feed
Heed the following points for connecting the
For details of the required gas pipe diameter, refer to
fuel supply:
Tab. 7 and Tab. 8 on page 19. Make absolutely sure that
B Work on gas components may only be the pipe fittings have the correct thread size.
carried out by qualified and authorized
personnel. B Make sure that a sediment trap is fitted at the inlet for
B Observe the local regulations or else the the gas supply pipe to the boiler.
requirements the National Fuel Gas Code,
The gas feed pipe is designed for a gas
ANSI Z 223.1 when connecting the gas
connection on the right side.
supply. In Canada, the requirements of
For the conversion to left-side gas
CAN/CSA-B.149.1 and 2, Installation
connection, see section 5.1.
Guidelines, must be observed.
To prevent strain on the gas valves,
B A gas shut-off valve must be installed extensions of the gas supply line must be
outside the boiler casing if required by the supported.
local code. We recommend installing a
gas shut-off valve in the main gas pipe to
the boiler.
B The gas pipes must be fastened outside
the boiler.

Fig. 22 Gas valve pipe connection

1 Gas supply
2 Shut-off
3 Sediment trap
4 Retaining screws at the gas feed line (on site)

18 Logano G234X - Technical specifications are subject to change without prior notice.
 Installing the boiler 5

Length of the pipe Gas pipe delivery rate in cubic feet of gas per hour1) (1 ft3/h = 28.3 l/h)
in feet
(1 foot = 0.3 m) 1" 1¼ " 1½ " 2" 2½ "

10 520 1060 1600 3050 4800

20 350 730 1100 2100 3300

30 285 590 890 1650 2700

40 245 500 760 1450 2300

50 215 440 670 1270 2000

75 175 360 545 1020 1650

100 160 305 480 870 1400

150 120 250 380 710 1130

Tab. 7 Gas pipe delivery rate
1) Maximum gas pipe delivery rate in cu ft/hr (1 ft3/h = 28.3 l/h) based on a gas specific gravity of 0.60 and a gas pressure of 0.5 psi (34.5 mbar)
or less and a pressure drop equivalent to a water column of 0.3 inches (7.6 mm).

Iron pipe nominal diameter Equivalent lengths for pipe fittings in feet (1 foot = 0.3 m)
(in inches) Type of pipe fitting
90° elbow T-piece Shut-off valve Gas shut-off
valve
1 3 5 0.6 1.60
1¼ 4 6 0.8 2.15
1½ 5 7 1.0 2.50
2 7 10 1.3 3.00
2½ 8 12 1.6 3.50
Tab. 8 Equivalent lengths for pipe fittings

Logano G234X - Technical specifications are subject to change without prior notice. 19
 5 Installing the boiler

Leak test 5.4.2 Converting boiler to propane

The boiler is factory-set for operation with natural gas.
DANGER: Risk of explosion!
Leakage from the gas pipes and gas
If you wish to convert the boiler to propane,
connections may cause an explosion.
please contact Buderus for the required
B Carry out a proper leakage test using soap conversion components.
solution. Do not attempt to convert the appliance
without the approved Buderus parts and the
relevant technical documentation. The
NOTICE: Risk of system damage due to technical documentation is included with the
short-circuits! conversion parts.
B Cover the areas at risk before carrying out
the leakage test.
B Do not spray leak detector onto cable For information about the identification of the
conduits, plugs or electrical connecting main gas orifice and the nominal gas orifice
leads or allow it to drip onto them. pressure for natural gas and propane gas,
see section 2.8.3, page 8.

Use only sealant that is resistant to corrosion 5.4.3 Installation at high altitudes
by LPG for the pipe connections. The sealing The boiler is designed for installation at altitudes below
compound must be applied sparingly to the 2000 feet (610 m) above sea level.
male thread of the pipe connections.
Contact Buderus if your installation is above
B Test the boiler and gas supply connections for leaks
2000 feet (610 m) above sea level.
before commissioning (Æ page 28).
Do not attempt to restrict the boiler without
Pressure tests the approved Buderus parts and the relevant
technical documentation. The technical
Disconnect the boiler and its gas isolating valve form the
documentation is included with the
gas supply pipe system if that system is subjected to
conversion parts.
pressure tests in which the test pressure exceeds 0.5 psi
(34.5 mbar).
If the gas supply pipe system is pressure tested at a test
pressure of 0.5 psi (34.5 mbar) or less, it is sufficient to
disconnect the boiler from the pipe system by closing the
stop valve.

20 Logano G234X - Technical specifications are subject to change without prior notice.
 Installing the boiler 5

5.5 Filling the heating system and

Maximum Maximum
checking for water leaks operating pressure on-site testing pressure
The boiler is tested for leaks at the factory. Before putting
the heating system into operation, it must be checked to 30 psi (2.1 bar) 45 psi (3.1 bar)
ensure that no leaks will occur during operation. with the included safety
valve
NOTICE: Risk of damage to system due to 58 psi (4 bar) 75 psi (5.2 bar)
temperature stress! with a different safety valve
If you fill the heating system when it is hot, the
resulting temperature stress can cause Tab. 9 Test pressures
stress cracks. The boiler will then leak. B Seal off connection for safety valve in the heating
B Only fill the heating system when it is in a supply and all other unused connections with blanking
cold state. Maximum permissible supply plugs.
temperature 100 °F (38 °C). B Isolate the expansion tank from the system by closing
the valve.
B Open the mixing and shut-off valves on the heating
WARNING: Health risk from contaminated water (primary) side.
domestic water!
B Slowly fill the boiler with tap water.
B Observe all national standards and
B Open the cap of the automatic air vent by one full turn
regulations regarding prevention of
to allow air to escape.
drinking water contamination (e.g. by
water from heating systems). B Slowly fill the heating system. Observe the pressure
gauge while filling.

NOTICE: Risk of system damage due to

excess pressure when testing for leaks!
Pressure, control and safety equipment may
be damaged through excessive pressure.
B When you carry out a leakage test, make
sure that no pressure, control or safety
device that cannot be isolated from the
boiler water chamber is installed.
7 747 019 141-17.1RS

Fig. 23 temperature/pressure gauge

Water treatment
B Have the water analyzed before filling the B Check the connections and piping to make sure they
heating system. are watertight.
B Compare the results of this analysis with B Bleed the heating system via the purge valves on the
the technical documentation on water heating bodies.
quality for boiler water. B Top up with water if the operating pressure drops as a
B Please consult the local water supply result of bleeding the system.
company if there are major differences,
such as extremely hard water or a pH value NOTICE: System damage due to faulty
below 7.0. safety valve!
B Do not install the safety valve until the leak
test (Æ Section 5.5) has been completed.
Carry out the leak test at 1.5 times the normal
B Install the safety valve vertically.
operating pressure (Æ Tab. 9) and in
accordance with the local regulations. B Install the safety valve in accordance with
the requirements of the ANSI/ASME
Boiler and Pressure Vessel Code, Section
IV.
B Observe the local regulations for
connection of boiler systems.

Logano G234X - Technical specifications are subject to change without prior notice. 21
 5 Installing the boiler

B Install safety valve. 5.6 Install front wall of boiler

B Hang front wall of boiler [2] from above, fold down and
screw in securing screws [3] into the front cover
below.

Fig. 24 Supply connection

1 Boiler
2 Supply connection
3 Safety valve
4 Supply manifold pipe (factory-installed) Fig. 25 Install front wall of boiler
5 90°-elbow (¾ " NPT)
1 Appliance insignia plate
2 Front wall of boiler
3 Locking screws

22 Logano G234X - Technical specifications are subject to change without prior notice.
 Installing the boiler 5

5.7 Connecting the flue Total air supply from inside the building
Make sure that the boiler room has two permanent air
5.7.1 Check openings for combustion air supply vents that are connected to one or more other rooms.
and venting When calculating the cross-sectional areas of the vent
To ensure an adequate combustion air supply and venting apertures, the total burner output of all gas-fired
of the heating system, suitable measures must be taken in appliances in the connected rooms must be taken into
accordance with the National Fuel Gas Code, NFPA 54 account. Each vent must have a minimum cross-section of
(ANSI Z223.1), Section 5.3, Air for Combustion and one square inch per 1000 Btu/h (2200 mm2/kw) of the
Ventilation, and the local building codes. In Canada the total burner output of all gas-fired appliances inside the
regulations in accordance with CAN/CSA B 149.1 and 2 connected rooms. Make sure that the cross-sectional
Installation Codes apply. area of each vent is at least 100 square inches (0.06 m2).
One of the vents must be no more than 12 inches
NOTICE: Risk of boiler damage and (300 mm) from the ceiling and the other no more than
malfunctions due to missing or inadequate 12 inches (300 mm) from the floor of the boiler room,
openings for combustion air and venting of measured from the outer edge of the vent aperture.
the boiler room! The smallest dimension of all air intake and outlet
Inadequate venting of the boiler room may openings must be not less than 3 inches (80 mm).
result in excessive ambient temperatures.
Total air supply from outside the building
This can damage the boiler.
Inadequate combustion air supply may cause Make sure that the boiler room has two permanent air
malfunctions in operation. vents, one of which must not be more than 12 inches
(300 mm) from the ceiling and the other not more than
B Make sure that air inlet or outlet vents are 12 inches (300 mm) from the floor of the boiler room,
not closed off or their size reduced and measured from the outer edge of the vent aperture. The
that they are adequately dimensioned. vents must be connected either directly or via air ducts to
B The boiler must not be operated until the the outside or to rooms that have an unobstructed
obstruction has been removed. connection to the open air (crawl passage or roof space).
B Draw the operator's attention to any The smallest dimension of all air intake and outlet
deficiencies and the potential dangers. openings must be not less than 3 inches (80 mm).
• If there is a direct connection to the outside, each
NOTICE: Risk of boiler damage from opening must have a minimum cross-section of one
contaminated combustion air! square inch (25 mm2) per 4000 Btu/h (550 mm2/kW)
of the total combustion output of all gas-fired
B Never use cleaning agents containing
appliances inside the closed room.
chlorine and never use halogenated
hydrocarbons (as, for example, contained • If there is a connection to the outside through a
in spray cans, solvents, cleaning agents, ventilated attic with vertical ventilation ducts, each vent
paints and adhesives). aperture must have a minimum cross-section of one
square inch per 4000 Btu/h (550 mm2/kW) of the total
B Do not store or use these substances in
burner output of all gas-fired appliances inside the
the boiler room.
closed room.
B Avoid excessive dust accumulation.
• If there is a connection to the outside through a
ventilated attic with vertical ventilation ducts, each vent
If impurities in the combustion air are aperture must have a minimum cross-section of one
possible (e.g. installation near swimming square inch per 2000 Btu/h (1100 mm2/kW) of the
pools, dry cleaners or hairdressing salons), total burner output of all gas-fired appliances inside the
sealed combustion is recommended. closed room.
• If the openings are connected to ventilation ducts, the
ducts must have the same cross-section area as the
openings.

Logano G234X - Technical specifications are subject to change without prior notice. 23
 5 Installing the boiler

5.7.2 Requirements for connection to chimneys Test the venting system by the following
or venting systems procedure:
The flue connection must comply with the regulations of Carry out these steps with every heating system that
the National Fuel Gas Code NFPA 54, Part 7, Venting of remains connected to the venting system when the boiler
Equipment, and the local building codes. In Canada the is separated from a common venting system. Every
regulations of CAN/CSA B 149.1 as well as local building heating system must be started in operation and the other
codes apply. heating systems connected to the venting system must
remain switched off.
Flue connections of heating systems with natural venting
must not be connected with any component of a
mechanically operated venting system that operates with A All unused openings of the common system
overpressure. must be sealed.

The cross-section of the flue connection must not be less B Perform a visual inspection of the venting system
than that specified in Tab. 10. to ensure that it has the correct dimensions and
longitudinal inclination. Make sure that the
Diameter of the flue gas system is not blocked, leaking, corroded or has
connection any other faults that cause it to operate
Boiler capacity [inches] improperly.

38 7 C If necessary, close all doors and windows of the

building. Close all doors between the space in
45 7 which the heating systems that remain
connected to the venting system are installed
55 7 and the other rooms of the building. Switch off
64 8 dryers and all appliances that are not connected
to the venting system. Run all venting fans and
Tab. 10 Cross-section of the flue gas connection bathroom exhaust fans at maximum speed. Fans
in use in summer must remain in operation and
If the boiler is to be connected to a brick chimney, the
oven exhaust system flaps must be closed.
chimney must be thoroughly inspected before use. The
chimney must be clean, in compliance with construction D Start up the heating system to be tested. Follow
codes and of sufficient dimensions. the instructions for commissioning. Set the
Chimneys with an internal liner are preferred and are only thermostat for continuous operation.
permitted if the liner complies with all national, state and E After the main gas burner has been operating for
local construction codes. five minutes, check the opening at the back flow
Liners of fire-glazed brick with moisture-proof joints and check for drafts with a match flame or a candle,
liners of corrosion-resistant material are recommended. or with the smoke of a cigarette, cigar or pipe.
Contact the local gas supply utility for advice and F Check this way that all heating systems that
recommendations for flue connection and chimney liners. remain connected to the venting system have
A flue pipe of single-walled sheet metal is required for flue been checked as above to ensure that the
connections for type II models. venting operates properly. Then place all doors,
windows, venting fans, exhaust system flaps, and
An adequate chimney height in compliance with the
all other gas fired appliances back into their
tables of the National Fuel Gas Code, ANSI Z 223.1, is
original state.
required.

Separation of a boiler from a common flue system

If an existing boiler is separated from a common flue
system, the dimensioning of this flue system will be too
big. A proper venting for the remaining heating systems is
then no longer guaranteed.

24 Logano G234X - Technical specifications are subject to change without prior notice.
 Installing the boiler 5

5.7.5 Installation of vent damper

G Any incorrect status of the common venting
Only the vent damper supplied with the boiler must be
system must be corrected to ensure that the
used for venting the boiler.
heating system complies with the regulations of
the National Fuel Gas Code, ANSI Z 223.1. If
the size of any component of the common In Canada the vent damper must not be
venting system is changed, the complete venting installed on a propane-fired heating system
system must be resized to comply with the with a electronic ignition system.
relevant tables in Part 11 of the National Fuel
Gas Code, ANSI Z 223.1. The position of the vent damper must be visible.
The back flow check must be at least 6 inches (155 mm)
In Canada the regulations in accordance with CAN/CSA from all flammable components.
B 149.1 and 2 Installation Codes apply.
The vent damper must be freely accessible for
5.7.3 Installing the flue pipe maintenance.

DANGER: Risk of fatal injury from escaping The vent damper must be open when the main burner of
flue gases! the boiler is operating.
A draft hood that does not work properly can B Place flue gas adapter [3] on the pipe nipples of the
cause dangerous flue gases to escape. draft diverter.
B Note that the draft hood check cannot be B Install pins in the hole of the vent baffle [1].
modified. B Fasten flue baffle to the flue connector adapter with
three (3) corrosion-resistant self-tapping screws.
B Mount the flue pipe on the flue outlet of the draft hood.
B Mount the flue pipe (4) with corrosion-resistant sheet
metal screws.

5.7.4 Connecting flue pipe

Use only flue pipes with a suitable diameter for the boiler.
Every horizontal section of the flue pipe must have a
minimum rise of ¼ inches per foot (21 mm per m) towards
the chimney. The flue pipe must be securely fastened to
prevent it from hanging. A suspension must be installed at
least every 5 feet (1.5 m). Fasten every connection with at
least three (3) corrosion-resistance sheet metal screws.
The end section of the flue pipe must connect to the
inside of the chimney smoke duct.
A minimum clearance of 6 inches (155 mm) is required
between the flue pipes and all flammable materials.
The flue pipe must not be reduced in size and venting
must not be prevented by the installation of additional
components.
B Connect flue pipe to the chimney with the shortest Fig. 26 Installation of vent damper
possible length of flue pipe. 1 Vent Damper
2 Motor
3 Adapter for the flue outlet
4 Draft hood

Logano G234X - Technical specifications are subject to change without prior notice. 25
 5 Installing the boiler

5.7.6 Installing electrical connection of vent

damper

DANGER: Risk of fatal injury from electric

shock!
B Only qualified electricians are permitted to
carry out electrical work.
B Before opening the appliance, disconnect
it from the power supply by means of the
emergency shutoff switch or the relevant
circuit breaker in the main fuse board.
B Take measures to ensure that the heating
system cannot be switched on again
unintentionally.
B Please observe all installation instructions.

DANGER: Fire hazard from hot boiler

components!
Hot boiler components may damage
electrical cables.
B Ensure that the electrical cables are not
touching any hot parts.
B Make sure that all cables are routed
through the conduits provided.

B Disconnect all electrical power to your heating system.

B Route the connection cable of the vent damper through
the wiring retainer behind the boiler and between the
insulation and the casing to the aquastat [1] on the
front of the boiler.

Fig. 27 Installing electrical connection of vent damper

1 Aquastat
B Connect flue baffle to aquastat as shown in the wiring
diagram.

All connection points on the complete

venting system must be checked for correct
installation and sealing immediately after
carrying out one of the installation steps. The
seams and connections must be checked for
gas leaks. Regulations require the complete
flue system to be checked at least once a
year by a qualified technician after installation
and initial operation.

26 Logano G234X - Technical specifications are subject to change without prior notice.
 Commissioning the heating system 6

6 Commissioning the heating system

B Complete the commissioning log during the 6.2 Making the heating system ready for
commissioning procedure (Æ page 35). operation
The burner and gas fittings unit integrated in the boiler
6.1 Test safety valve have been tested in the factory as described in detail in
The safety valve must open and release pressure. If the ANSI Z 21.13 and CSA 4.9 to ensure safe operation of
safety valve fails to release excess pressure, it must be the heating system and to test specific performance
replaced, because otherwise system components may be indicators.
damaged by excessive operating pressure.
DANGER: Risk of fatal injury from electric
current when appliance is opened up!
B Before opening the boiler:
Disconnect the heating system from the
electrical power supply by means of the
emergency shutoff switch or the heating
system circuit breaker on the main fuse
panel.
B It is not sufficient just to switch off the
control panel.
B Take measures to ensure that the heating
system cannot be switched on again
unintentionally.

1. Set the room thermostats to the lowest setting.

2. Inspect flue and combustion air piping and the
openings for combustion air supply and ventilation.
3. Fill heating system with water and bleed the complete
system including the radiators.
4. Unscrew left and right screws in the side panels, lift
front panel up, pull outward and remove to the front.

Fig. 28 Remove front wall of boiler

1 Locking screws
2 Boiler casing
3 Front wall of boiler

Logano G234X - Technical specifications are subject to change without prior notice. 27
 6 Commissioning the heating system

Carrying out leak test 10. Open gas shut-off and measure the supply pressure
5. Open the gas shut-off valve. of the boiler. The connection pressure for natural gas
must be between 7 and 10.5 inches W.C. (17.4 to
NOTICE: Risk of system damage due to 26.2 mbar) and between 11 and 13 inches W.C. for
short-circuits! propane gas (27.4 to 32.4 mbar). If the connection
B Cover any hazardous locations prior to pressure is not in this range with natural gas, contact
locating the leaks. your customer service technician or gas utility
B Do not spray leak detector onto conduits, company. Close the gas shut-off valve.
plugs or electrical connection cables or 11. Always follow the start-up instructions on the next
allow it to drip onto them. page.

6. Check the gas supply line to the gas valve for leaks with
soap solution. If no leaks are found, continue with step
8.
7. If leaks are detected, shut off the gas shut-off valve,
seal the leaks, and repeat step 6.
8. Close the gas shut-off valve. Remove the screw plug
for the gas supply port [2] on the gas valve in order to
measure the gas supply pressure. Install pressure
measuring nipple and attach a pressure gauge.
9. Remove the screw plug for the gas supply port [3] on
the gas valve in order to measure the nozzle pressure.
Install pressure measuring nipple and attach a pressure
gauge.

Fig. 29 Gas valve

1 ON/OFF button (at ON position)
2 Screw plug for gas connection pressure test port
3 Screw plug for nozzle pressure test port

28 Logano G234X - Technical specifications are subject to change without prior notice.
 Commissioning the heating system 6

6.3 Start-up instructions

A This unit is fitted with an ignition module that
For your safety, read before lighting. automatically starts the pilot burner. Do not
attempt to ignite it manually.
DANGER: Risk of fatal injury due to not
observing the start-up instructions and B Check for an odor of gas around the heating
resulting incorrect operation! system. This test must also be conducted at
floor level, because some types of gas are
B If these instructions are not followed
heavier than air and may accumulate at floor
exactly, a fire or explosion may be caused.
level.
This can cause significant property
damage or risk to life and limb. C Switch on the ON/OFF switch on the gas valve
B Observe the start-up instructions. by hand only. Never use a tool as assistance. If
you cannot actuate the ON/OFF switch on the
gas valve by hand, do not attempt to repair it.
DANGER: Risk of explosion! Contact a qualified technician. Any attempt to
If you smell gas there is a danger of use force or to repair the valve may cause a fire
explosion. or explosion.
B Close the gas shut-off valve. D Do not operate the appliance if any part is under
B Open windows and doors. water. Contact a qualified technician
B Do not operate any electrical switches or immediately. The service technician will check
equipment such as telephones, power the appliance and replace the parts of the
plugs and doorbells. control system and gas valve that were under
B Extinguish all open flames. Do not smoke. water.
Do not use lighters.
B Warn all occupants of the building, but do
not ring doorbells.
B If you can actually hear gas escaping,
leave the building immediately. Prevent
others from entering and notify the police
and fire department from outside the
building.
B From outside the building, call the gas
utility company and approved heating
contractor.

Logano G234X - Technical specifications are subject to change without prior notice. 29
 6 Commissioning the heating system

6.4 Making boiler ready for operation

STOP! First read the safety instructions on page 29 of 6.4.2 Placing heating system with Logamatic
these instructions. 2000 control unit in operation
1. If the boiler is not commissioned directly after the The boiler is fully functional with the factory-installed
installation: aquastat. A Logamatic 2000 control unit can be installed
carry out another leak test (Æ page 28). Wait five (5) in addition to the factory-installed aquastat.
minutes until all gas residues have dissipated. Finally
check whether there is any smell of gas, including at Suitable Logamatic 2000 control units can
floor level. If you smell gas, STOP! Seal leaks and be obtained from Buderus as accessories.
repeat the leak test.
If you do not smell gas, go to the next step.
2. Open the gas shut-off valve. Use the on/off switch on the control unit to switch the
heating system on. The burner starts operating if heat is
6.4.1 Commission the heating system with required (Æ observe control unit service manual).
aquastat control 5. Make sure that heat is required at the control. To do
The boiler is fully functional with the factory-installed this, select “Manual operation” operating mode (hand
aquastat. symbol) with the mode selector switch [1].
6. Switch on ON/OFF switch [2] (“ON” position).
3. Switch on ON/OFF switch [1] (“ON” position). This
turns on the boiler with all its components. After carrying out the instructions for starting
4. Make sure that the room thermostat signals a heat described below, the control unit must be set
requirement (set thermostat at least 10 °F above room to “AUT” operating mode (automatic
temperature). operation) with the mode selector.

Fig. 30 Switching on heating system (with aquastat)

1 Main power switch

Fig. 31 Turning on heating system (with Logamatic

2000 control unit)
1 Mode selection switch
2 Main power switch

30 Logano G234X - Technical specifications are subject to change without prior notice.
 Commissioning the heating system 6

6.5 Then carry out start-up procedures.

The following commissioning work must be performed
regardless of the control unit type.
7. Look at the pilot burner through the inspection hole [1]
in the burner cover.

Fig. 32 Inspection hold in the burner cover Fig. 33 Gas valve

1 Inspection hole 1 ON/OFF button (at ON position)
8. Turn gas valve ON/OFF switch [1] counterclockwise to 2 Screw plug for gas connection pressure test port
ON position. 3 Safety screw for nozzle pressure setting
4 Screw plug for nozzle pressure test port
9. The burner control unit must generate ignition sparks 5 Safety screw for ignition nozzle pressure setting
towards the pilot burner. The pilot flame must appear
and then ignite the main burner. 12. Check the supply gas pressure while the boiler is
If the main burner does not ignite, close the gas shut- operating. The connection pressure for natural gas
off. Disconnect heating system from the power supply must be between 7 and 10.5 inches W.C. (17.4 to
and inform your customer service technician or LP gas 26.2 mbar) and between 11 and 13 inches W.C. for
company. propane gas (27.4 to 32.4 mbar). Record the values
10. If the main burner has ignited, the gas valve must be measured in the commissioning log (Æ page 35).
checked for leaks with soap solution. If no leaks are
found, continue with step 12. Boiler Natural Gas Propane
11. If leaks have been found, switch the ON/OFF switch capacity
[Inch [Inch
on the gas shut-off valve [1] clockwise to the OFF W.C.] [mbar] W.C.] [mbar]
position. Disconnect heating system from the power
supply and set the thermostat to the lowest setting. 38 3.0 7.6 10.6 26.5
Seal the leaks. Repeat steps 1 and 2.
For aquastat control units, continue with steps 3 45 4.1 10.4 10.5 26.2
and 4. 55 4.6 11.5 10.3 25.8
For Logamatic 2000 control units, continue with
steps 5 and 6. 64 4.4 10.9 10.3 25.9
Then repeat steps 7 to 10 regardless of the control
Tab. 11 Nozzle pressure
unit in use.

Logano G234X - Technical specifications are subject to change without prior notice. 31
 6 Commissioning the heating system

13. Check nozzle pressure. To set the nozzle pressure

according to Tab. 11 while the boiler is operating, the The adjustment screw for the pilot ignition
safety screw for setting the nozzle pressure [3] on the pressure setting is behind the pilot burner
gas valve must be removed. Turn the adjustment screw adjustment safety screw (Fig. 34, [5]).
clockwise to increase the nozzle pressure. Turn the
adjustment screw counterclockwise to decrease the 17. If the ignition flame is too small or too large, the nozzle
pressure. pressure for pilot burner must be adjusted with the
corresponding adjustment screw.
14. Record the value set in the commissioning log
(Æ page 35). To set the nozzle pressure, screw the 18. Remove the safety screw for ignition nozzle pressure
safety screw for setting the nozzle pressure [3] back setting (Fig. 34, [5]). Turn the inner adjustment screw
into the gas valve. clockwise to reduce the pilot flame and
counterclockwise to enlarge the pilot flame.
19. After adjustment tighten the pilot burner pressure
adjustment safety screw (Fig. 34, [5]) again.
20. Observe pilot flame [1] through the inspection hole in
the burner cover (Æ Fig. 32, page 31). The flame must
have a steady and fixed contour and generally has a
bluish color.
If the main burner flame meets the requirements,
proceed with step 21.
If the main burner flame is too weak or is yellow or goes
out, turn the ON/OFF switch on the gas shut-off valve
(Fig. 34, [1], page 32) clockwise to OFF. Close the
gas shut-off valve and disconnect the heating system
from the power supply and contact the customer
service technician or the gas supply utility.

Fig. 34 Gas valve

1 ON/OFF button (at ON position)
2 Screw plug for gas connection pressure test port
3 Safety screw for nozzle pressure setting
4 Screw plug for nozzle pressure test port
5 Safety screw for ignition nozzle pressure setting
15. Observe pilot flame through the inspection hole in the
burner cover (Æ Fig. 32 page 31).
16. The flame must surround the flame rod by 1/2 to
1 1/2 inches (15 to 40 mm). If this is the case continue
with step 20.

Fig. 36 Main burner

1 Main burner flame

Fig. 35 Correct pilot flame setting

1 1/2 to 1 1/2 Inch (12.7 to 38.1 mm)
2 Pilot flame

32 Logano G234X - Technical specifications are subject to change without prior notice.
 Commissioning the heating system 6

Checking flame sensor 30. If leaks are found, close gas shut-off and switch ON/
21. Test the safety switch by closing the gas shut-off. The OFF button on gas valve [1] clockwise to the OFF
main burner flame (Æ Fig. 36) and the ignition flame position. Shut off the heating system from the power
(Æ Fig. 35) are extinguished. After six (6) seconds at supply.
the most the main gas solenoid valve on the gas valve Seal the leaks. Open the gas shut-off valve and repeat
must close with an audible noise. step 23.
22. After 90 seconds the ignition module must switch to
lock status and stop generating sparks.
23. Shut off the heating system from the power supply.
Open the gas shut-off valve. Switch on unit power
supply.
A normal operating cycle must follow. If the gas shut-
off operates correctly, proceed to step 25.
24. If the gas shut-off does not operate correctly, switch
ON/OFF switch on the gas shut-off valve [1] clockwise
to the OFF position immediately. Close the gas shut-off
valve. Disconnect heating system from the power
supply and inform the customer service technician or
LP gas company.
25. Turn the gas valve ON/OFF button [1] clockwise to
the OFF position.
26. Close the gas shut-off valve.
27. Disconnect heating system from the power supply
and set the thermostat to the lowest setting.
28. Remove pressure measuring nipple and pressure Fig. 37 Gas valve
gauge for measuring gas supply pressure and nozzle
pressure from the gas valve. Close the openings with 1 ON/OFF button (at ON position)
the screw plugs [2] and [3] again. 2 Screw plug for gas connection pressure test port
3 Screw plug for nozzle pressure test port
29. Repeat steps 1 to 10 (depending on the control unit
used) and step 20. 31. To avoid corrosion, carefully wipe off the soap solution
Thus the heating system is started up again. afterwards.
Check the screw plugs [2] and [3] for leaks with soap 32. Check the function of the maximum aquastat to make
solution. sure that it switches off the boiler as soon as the boiler
If no leaks are found, continue with step 31. water temperature set at the aquastat or the Logamatic
2000 control unit is reached. Record the result in the
commissioning log (Æ page 35).

Only for the Logamatic 2000 control unit

Select operating mode AUT (automatic mode) with the
mode selection switch.

Logano G234X - Technical specifications are subject to change without prior notice. 33
 6 Commissioning the heating system

6.6 Shutting off gas supply to boiler 6.7 Inform owner/operator, hand over
B Set thermostat to the lowest value. technical documentation
B Disconnect the heating system from the power supply Familiarize the owner/operator with the entire heating
before carrying out maintenance work. system and the operating instructions for the boiler. Hand
B Turn the gas valve ON/OFF button [1] clockwise to the over the technical documentation to the owner/operator
OFF position. Do not use force. and then both sign the commissioning log (Æ page 35).

NOTICE: Risk of system damage due to

freezing!
The heating system may freeze in frosty
weather if it is not switched on with the main
switch or control unit.
B Protect the heating system against frost
when temperatures below zero are
expected.
B If the main switch or control is switched
off, drain the water from the boiler, the tank
and the pipe of the heating system.

Fig. 38 Gas valve

1 ON/OFF button (at OFF position)
B Hang front wall of boiler [3] from above, fold down and
screw in securing screws [1] into the front cover
below.

Fig. 39 Install front wall of boiler

1 Locking screws
2 Boiler casing
3 Front wall of boiler

34 Logano G234X - Technical specifications are subject to change without prior notice.
 Commissioning the heating system 6

6.8 Commissioning log

Please check off the commissioning work as it is
completed and record the measured values in the table.
Comments or measured
Commissioning operations Page value

1. Type of gas supply Natural Propane Gas

Gas

2. Check combustion air, inlet and outlet openings and flue page 23

3. Check the appliance orifices (correct nozzles Æ Tab. 12), if page 35

necessary adjust gas type.

4. Fill boiler with water and bleed complete heating system page 21

5. Measure gas supply pressure [inches W.C.] or [mbar] page 31 Measurement

value:__________ Unit_____

6. Measure nozzle pressure and adjust if necessary [inches W.C.] page 31 Measurement
or [mbar] value:__________ Unit_____

7. Leak test in operating status page 28

Check of the ignition flame page 32
Check of the main burner flame page 32
Check of the perfect function of the venting system

8. Check maximum aquastat setting page 33

9. Install front wall of boiler page 34

10. Inform operator, hand over technical documentation page 34

11. Installer: Signature:_________________

Operator: Signature:_________________

Main gas orifice identification of the main gas nozzles (0 - 2000 ft / 0 - 610 m)
Boiler capacity 38 45 55 64
1)
Natural gas 3.70 3.70 3.50 3.80
Only convert natural
2.20 2.40 2.30 2.45
gas 2)
Tab. 12 Main gas orifice identification
1) factory setting
2) to propane gas according to conversion instructions

Logano G234X - Technical specifications are subject to change without prior notice. 35
 7 Shut down the heating system

7 Shut down the heating system

B Shut off the fuel supply by closing the main valve.
NOTICE: Risk of system damage due to
freezing!
The heating system can freeze up in cold
weather if it is switched off.
B Leave the heating system switched on as
long as possible.
B Protect your system from freezing by
draining the boiler, the heating system and
hot water pipes at the lowest point.

7.1 Normal shut-down

With aquastat:
B Switch off the on/off switch ("OFF" position). This
switches off the boiler and all its components (e.g.
burner). Fig. 41 Shutting down heating system (with Logamatic
2000 control unit)
B Further shut-down procedure refer to Æ aquastat
documentation. 1 Main power switch
B Shut off the fuel supply by closing the main valve.
7.2 Shutting down the boiler in an
emergency
Use the heating system emergency shut-off
switch located outside the boiler room or the
heating system circuit breaker for emergency
shutdown.

7.2.1 Action in an emergency

Explain to the customer what to do in an emergency, e.g.
a fire.
B Never risk your own life. Your own safety must always
Fig. 40 Heating system shut-down (with aquastat) take the highest priority.
B Shut off the fuel supply by closing the main valve.
1 Main power switch
B Disconnect the heating system from the electrical
With Logamatic 2000 control unit power supply by means of the emergency stop switch
B Switch off the on/off switch ("0" position). This or the appropriate circuit breaker.
switches off the boiler and all its components (e.g.
burner).

36 Logano G234X - Technical specifications are subject to change without prior notice.
 Heating system inspection and maintenance 8

8 Heating system inspection and maintenance

When carrying out maintenance work, observe: 8.2 Checking the flue system including
DANGER: Risk of fatal injury from electric the combustion air supply, inlet and
shock! outlet air openings
B When carrying out servicing work, label all Check the venting system, including the combustion air,
connection cables before disconnecting inlet and outlet openings. All faults must be repaired
them. immediately. Make sure that the combustion air supply
B If cables are connected incorrectly, the and the inlets and outlets are not blocked at any point.
system may not operate correctly with
possibly dangerous consequences. 8.3 Inspection of the boiler and burner
B Perform a visual inspection of the boiler and burner for
B Always check that the heating system is working external contamination.
properly after carrying out any maintenance work. B If contamination is found, clean the boiler and burner.

8.1 Why is regular maintenance

important?
Heating systems must be serviced regularly for the
following reasons:
• to maintain a high level of efficiency and to operate the
system economically (low fuel consumption)
• to achieve a high level of operational safety
• to maintain the cleanest possible combustion
• to ensure reliable operation and a long service life.
Maintenance work may only be carried out by a qualified
service technician. If parts are replaced, only Buderus
approved components may be used. Maintenance must
be carried out once a year. The results of the inspection
must be recorded in the maintenance log (Æ page 44).

Spare parts can be ordered from Buderus

using the parts list.

Logano G234X - Technical specifications are subject to change without prior notice. 37
 8 Heating system inspection and maintenance

8.4 Preparing boiler for cleaning

B Turn the gas valve ON/OFF button [1] clockwise to the
DANGER: Risk of fatal injury from electric "OFF" position. Do not use force.
current when appliance is opened up!
B Before opening the boiler:
Disconnect the heating system from the
electrical power supply by means of the
emergency shutoff switch or the heating
system circuit breaker on the main fuse
panel.
B It is not sufficient just to switch off the
control panel.
B Take measures to ensure that the heating
system cannot be switched on again
unintentionally.

B Decommission the heating system (Æ page 36).

B Remove front wall of boiler

Fig. 43 Gas valve

1 ON/OFF button (at "OFF" position)

Fig. 42 Remove front wall of boiler

1 Locking screws
2 Boiler casing
3 Front wall of boiler

DANGER: Risk of fatal injury from the

explosion of flammable gases!
B Operations on the gas pipes may only be
carried out by a properly licensed gas
contractor.
B Wait five (5) minutes until all gas residues
have dissipated. Check whether there is
any smell of gas, including at floor level. If
you smell gas, STOP!
Check that the gas shut-off is closed.
Repeat the odor test. If you do not smell
gas, go to the next step.

38 Logano G234X - Technical specifications are subject to change without prior notice.
 Heating system inspection and maintenance 8

8.5 Cleaning the boiler B Disconnect connection lines to the gas fitting [7].
The boiler can be cleaned with brushes and/or by a wet
method. Cleaning equipment is available as accessory.

8.5.1 Cleaning the boiler with cleaning brushes

Remove burner:

DANGER: Risk of fatal injury from electric

shock!
If cables are connected incorrectly, the
system may not operate correctly with
possibly dangerous consequences.
B When carrying out servicing work, label all
connection cables before disconnecting
them.
B After maintenance test the heating system Fig. 44 Removing the burner
for proper function. 1 Retaining screw on the gas feed line
2 Gas supply line
3 Igniter sensor cable
DANGER: Risk of fatal injury from electric 4 Connection lines to the flame baffle
current when appliance is opened up! 5 Flame roll out switch
B Before opening the boiler: 6 Pilot gas pipe
Disconnect the heating system from the 7 Connection cables to the gas fitting
electrical power supply by means of the 8 Gas valve
emergency shutoff switch or the heating B Loosen fixing nuts [1] on the burner shield. Pull the
system circuit breaker on the main fuse burner out straight.
panel.
B Make sure that the spacers [2] remain on the studs.
B It is not sufficient just to switch off the
control panel.
B Take measures to ensure that the heating
system cannot be switched on again
unintentionally.

B Disconnect all electrical power to your heating system.

B Close the main shutoff valve.
B Disconnect pilot gas pipe [6] from the gas valve [8].
B Loosen igniter sensor cable [3] from the automatic
igniter.
B Tie gas line [2] with wire or cord (secure).
B Loosen the retaining screw [1] on the gas feed line
B Check the gasket for damage. Replace damaged
gasket. Keep the gasket in a safe place.
B Label wires of flame roll out switch [4] and disconnect
Fig. 45 Removing the burner
from the switch [5].
1 Fixing nuts
2 Studs with spacers

Logano G234X - Technical specifications are subject to change without prior notice. 39
 8 Heating system inspection and maintenance

Cleaning the boiler: 8.5.2 Wet cleaning (chemical cleaning)

B Remove the boiler cover and heat insulation, check for For wet cleaning use a cleaning agent appropriate for the
damage. degree of soiling (soot or scale).
B Unscrew cleaning cover from the draft diverter. Follow the same procedure as for cleaning with brushes
B Cover control unit with foil to prevent entry of metal (Æ page 39).
dust into the control unit.
B Use boiler brush to clean out flue gas passages. Observe the operating instructions of the
B Clean combustion chamber and bottom panel. cleaning agent. Under some circumstances
B Screw cleaning cover into place and replace insulation. you may have to proceed differently from the
B Install boiler cover. method described here.

B Remove the boiler cover and heat insulation, check for

damage.
B Unscrew cleaning cover from the draft diverter.
B Cover the control panel with foil to prevent spray
getting into the control panel.
B Ventilate boiler room well.
B Spray cleaning agent evenly into the heat exchanger
heater passages.
B Carry out the burner assembly and installation in
reverse order to their removal and disassembly
(Æ page 39).

Fig. 46 Cleaning the hot flue passages

1 Cleaning brushes
2 Thermal insulation
3 Foil cover of the control unit

Fig. 47 Wet-cleaning the boiler

B Start up the heating system.
B Heat up the boiler to a boiler water temperature of at
least 122 °F (55 °C).
B Shut down the heating system.
B Allow boiler to cool.
B Remove the burner (Æ page 39).
B Brush out the heat exchanger heater.
B Clean combustion chamber and bottom panel.
B Ventilate boiler room well again.
B Install or clean the burner (Æ page 41).
B Screw cleaning cover into place and replace insulation.
B Install boiler cover.

40 Logano G234X - Technical specifications are subject to change without prior notice.
 Heating system inspection and maintenance 8

8.6 Cleaning the burner B Flush the burner rod with a water jet. Hold burner so
B Remove the burner (Æ page 39). that water enters all slots of the burner rods and drains
out again.
B Check burner tubes for dirt. If necessary, clean burner
as described below. B Remove remaining water by swinging the burner.
B Unscrew ignition burner unit [1] from burner. B Check that the burner rods are free. Remove water and
dirt residue in the slots. If any slots are damaged the
B Disconnect pilot gas pipe [3] from pilot burner unit.
burner must be replaced.
B Remove pilot nozzle [2] and blow out.
B Immerse burner rods in water with cleaning agent and
brush off.

Make sure that the insulation on the burner

shield does not get wet.

Fig. 49 Swinging burner

B Carry out the burner assembly and installation in
reverse order to their removal and disassembly
(Æ page 39).
B Place boiler in operation as directed in section 6,
starting on page 27.
B Check function of the aquastats.
B Test water low cut-off if installed.
Fig. 48 Pilot burner B Check area around boiler for hazards.
1 Igniter sensor cable The area around the boiler must be free from flammable
2 Ignition electrode substances, gasoline or any other flammable or
3 Pilot gas pipe corrosive vapors and liquids.

DANGER: Risk of fatal injury from the

explosion of flammable gases!
Leaks may have been created on pipes and
fittings following maintenance work.
B Carry out a proper leak test.
B Only use approved leak detection agents.

B Complete the maintenance log to confirm that all

maintenance work has been carried out (Æ page 44).
Sign the maintenance protocol and discuss it with the
owner of the heating system.

Logano G234X - Technical specifications are subject to change without prior notice. 41
 8 Heating system inspection and maintenance

8.7 Troubleshooting
Required tools: wiring diagrams (Æ page 61 and 62) and
voltage testers 120 VAC and 24 VAC.

Steps for troubleshooting

1. Beginning of troubleshooting Measures to remedy faulty function
2. Close the gas shut-off valve. Check electrical power supply, low-voltage transformer, thermostat (control) and wiring.
Set thermostat (control unit) to Check that the vent damper (if installed) is open and the limit switch is present.
heat requirement (vent damper
opens).
Switch on power.
3. Observe ignition sparks in gap On models with vent damper check that it is functional and limit switch is present.
between electrode and sensor If necessary, replace vent damper.
through inspection hole. Check igniter sensor cable, grounding, ceramic insulator of ignition electrode and ignition
gap, adjust if necessary.
Check spade connector of the igniter sensor cable contact for signs of scorching or
kinking.
Replace ignition control unit.
4. Open the gas shut-off valve. Check that all manually operated vent dampers are open; check that gas connections and
Ignition flame is burning. pressures are correct and that main orifices are not blocked.
Check electrical connection between ignition module and connection on the gas valve.
Use MV-MV/PV clamps to check 24 V AC at the automatic ignition. If the voltage is
correct replace gas fitting, otherwise replace automatic ignition.
5. Ignition spark stops as soon as Check ignition/monitoring cable and grounding for continuity.
ignition flame burns. Check the ignition and monitoring electrodes.
Check electrical connections between ignition/monitoring electrode and ignition module.
Check whether the ceramic insulator in the ignition electrode is broken.
Check that the ignition flame surrounds the electrode and burns steadily with a bluish
flame.
Adjust pilot flame.
If this does not correct the fault, replace the ignition module.
6. Main burner ignites. Use MV-MV/PV clamps to check 24 V AC closed circuit at the automatic ignition. If there
is no voltage, replace ignition control.
Check electrical connections between automatic ignition and the gas fitting. If OK
replace gas valve.
7. System operates until the heat Check ignition/monitoring cable and grounding for continuity. Note: If the grounding is
requirement ends. weak or faulty, the system may switch off at random, even if the heating system operates
correctly when checked.
Check that the ignition flame surrounds the electrode and burns evenly with a bluish
flame. If OK replace electrode.
If everything is OK replace ignition module.
8. Heat requirement ended, system Check function of thermostat (control unit).
switches off, vent damper closes. Disconnect 24-V connection to gas fitting.
If gas valve closes, check thermostat and connection line again.
If the gas valve does not close, replace gas valve.
9. End of troubleshooting Repeat procedure until heating system operates correctly.

42 Logano G234X - Technical specifications are subject to change without prior notice.
 Heating system inspection and maintenance 8

Sequence of normal operation

START Room thermostat (control unit) signals heat requirement
vent damper opens.

PHASE 1
ignition attempt

Ignition spark generator is working

pilot gas valve opens.

PHASE 2 Pilot burner operation

Main burner
Ignition flame burns, burner control or ignition flame does not burn, burner
unit reports constant ignition flame. control unit starts ignition attempt,
switches off after 90 seconds.

With constant ignition flame

ignition spark generator stops.
Main gas solenoid valve opens.

Main burner operation Power failure

ignition module monitors pilot flame. System switches off.
Does the system restart when power
⇐ is restored?

Ignition flame fault

Main gas valve closes.
Ignition module starts ignition
attempt.

END Specified thermostat value (control) reached

Close main and pilot gas valve.
Gas burners go out.
Vent damper closes.

Logano G234X - Technical specifications are subject to change without prior notice. 43
 8 Heating system inspection and maintenance

8.8 Maintenance log book

Maintenance Page Date: Date:

1. Check of the flue system, including combustion air, inlet, page 23

and outlet openings

2. Inspection of boiler page 37

3. Inspection of burner page 37

4. Cleaning boiler page 39

5. Cleaning burner page 41

6. Measure gas supply pressure [inches W.C.] or [mbar] page 31 Measurement value:_______ Measurement value:_______

Unit_____ Unit_____

7. Measure nozzle pressure [inches W.C.] or [mbar] page 31 Measurement value:_______ Measurement value:_______

Unit_____ Unit_____

8. Leak test in operating status page 28

9. Check of the pilot flame page 32

Check of the main burner flame page 32

10. Check maximum aquastat setting page 33

11. Check of the boiler area for flammable materials, gasoline page 41
or other corrosive liquids

12. Confirmation of properly completed servicing:

Company stamp/signature:

44 Logano G234X - Technical specifications are subject to change without prior notice.
 Heating system inspection and maintenance 8

Date: Date: Date: Date: Date: Date:

1.

2.

3.

4.

5.

6. Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____

Unit_____ Unit_____ Unit_____ Unit_____ Unit_____ Unit_____

7. Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____ Measurement value:____

Unit_____ Unit_____ Unit_____ Unit_____ Unit_____ Unit_____

8.

9.

10.

11.

12.

Logano G234X - Technical specifications are subject to change without prior notice. 45
 9 Spare parts

9 Spare parts
The following spare parts are available from Buderus
Hydronic Systems. If there are several Buderus article
numbers for one item number, the numbers for the various
models are listed in the relevant columns. Otherwise the
table shows the number of components for each model.

Boiler outer casing (Æ Fig. 50)

Item Product- G234X/38 G234X/45 G234X/55 G234X/64
No. Designation number 5 sections 5 sections 6 sections 7 sections

10 Boiler jacket (complete) 5024- 240 240 242 244

20 Left jacket 6302 9212 1 1 1 1

30 Jacket clip SNU-5743 5834 364 2 2 2 2

40 Right jacket 6302 9211 1 1 1 1

50 Front jacket 6302- 9199 9199 9198 9197

60 "Buderus" sign 6790 2840 1 1 1 1

70 Top front cover 5024- 061 061 063 065

80 Top rear cover 5024- 081 081 083 085

Mounting kit no. 1 5015 951 1 1 1 1

Tab. 13 Individual parts boiler casing

46 Logano G234X - Technical specifications are subject to change without prior notice.
 Spare parts 9

Fig. 50 Boiler casing

Logano G234X - Technical specifications are subject to change without prior notice. 47
 9 Spare parts

Boiler heat exchanger (Æ Fig. 51)

Item
Product- G234X/38 G234X/45 G234X/55 G234X/64
No. Designation number 5 sections 5 sections 6 sections 7 sections

10 Bottom cover, non-combustible 5024- 140 140 142 144

20 Suspension plate 5015 257 2 2 2 2

30 Shield rear 5015 273 2 2 2 2

40 Screw M8x25 Æ Mounting kit 4 4 4 4

no. 2

50 Lock washer Æ Mounting kit 4 4 4 4

no. 2

60 M8-8-A3K nut Æ Mounting kit 4 4 4 4

no. 2

70 Block shoe Æ Mounting kit 4 4 4 4

no. 2

80 Return pipe 5584 754 1 1 1 1

90 Supply pipe 5584 752 1 1 1 1

95 3/4“ 90° elbow 9990 8401 1 1 1 1

100 Safety relief valve 5947 650 1 1 1 1

110 Rear jacket 63002- 790 790 791 792

120 Jacket clip SNU-5743 Æ Mounting kit 2 2 2 2

no. 2

130 Shield for rear jacket 5512- 526 526 528 530

135 Screw C-ST 4.8x22 Æ Mounting kit 2 2 2 2

no. 2

140 Conduit 5495 471 1 1 1 1

150 Screw 3.5x9.5-A3T Æ Mounting kit 1 1 1 1

no. 2

160 Partition wall 63002- 776 776 777 778

170 Tridicator set 5900 076 1 1 1 1

180 Draft diverter 6302 2583 6302 2583 6302 2582 5624 535

190 Clean out cover 5371- 923 923 924 925

200 Sealant rope GP 6x1500 mm 6302 0956 1

200 Sealant rope GP 8x3000 6302 0958 1

200 Sealant rope GP 6x10000 5822 706

Buderus sealant - 3055 6301 4362 1 1 1 1

Tab. 14 Individual parts of boiler heat exchanger

48 Logano G234X - Technical specifications are subject to change without prior notice.
 Spare parts 9

Item Product- G234X/38 G234X/45 G234X/55 G234X/64

No. Designation number 5 sections 5 sections 6 sections 7 sections

210 Screw M6x16-MS Æ Mounting kit 2 2 2 2

no. 3

220 Washer A 6.4 Æ Mounting kit 2 2 2 2

no. 3

230 Jacket clip M6-A3F-MCU5315 Æ Mounting kit 2 2 2 2

no. 3

Glue PK-W11 2037 038 1 1 1 1

240 M8 nut Æ Mounting kit 4 4 4 4

no. 3

250 Washer Æ Mounting kit 4 4 4 4

no. 3

260 Screw M8-25 Æ Mounting kit 4 4 4 4

no. 3

270 Adapter for the flue outlet 7" D182.5M 5384 516 1 1 1

270 Adapter for the flue outlet 8" D202.5M 5384 508 1

280 Vent damper RVGP-KS 7 inch BKF 9990 8399 1 1 1

280 Vent damper RVGP-KS 8 inch BKF 9990 8400 1

290 Boiler heat exchanger 67900- 358 358 359 360

300 Sensor well 5446 190 1 1 1 1

310 Thermal insulation 6790 0566 1 1 1 1

320 Burner AE234X "US" replacement 5181- 736 748 738 740

Mounting kit no. 2 5621 818 1 1 1 1

Mounting kit no. 3 5621 819 1 1 1 1

330 Reducer DIN 2950 241 3869 828 1 1 1 1

1“ x 3/4“

340 Pipe extension DIN 2950 526 320 840 1 1 1 1

3/4“ x 80

Tab. 14 Individual parts of boiler heat exchanger

Logano G234X - Technical specifications are subject to change without prior notice. 49
 9 Spare parts

Fig. 51 Boiler heat exchanger

50 Logano G234X - Technical specifications are subject to change without prior notice.
 Spare parts 9

Control unit GAW025 US (Æ Fig. 52)

Item
Product- G234X/38 G234X/45 G234X/55 G234X/64
No. Designation number 5 sections 5 sections 6 sections 7 sections

10 Control unit GAW025 US 5557 946 1 1 1 1

20 Cable protector Æ Installation 1 1 1 1

material no. 4

30 Attachment bracket for flue gas safety switch Æ Installation 1 1 1 1

material no. 4

40 Flue gas safety switch 7079 498 1 1 1 1

50 Screw F ST 3.5x6.5 A3K Æ Installation 2 2 2 2

material no. 4

60 Cable assembly 5182 064 2 2 2 2

70 Screw KA 3.5x16 Æ Installation 2 2 2 2

material no. 4

80 Terminal strip Æ Installation 1 1 1 1

material no. 4

90 Screw C ST 2.9x16 A3K Æ Installation 2 2 2 2

material no. 4

100 Cable clamp Æ Installation 2 2 2 2

material no. 4

110 Cable assembly 6301 5744 1 1 1 1

120 Cable orange/black 7079 806 1 1 1 1

130 Screw (flat head) 3.9x9.5 A3K Æ Installation 4 4 4 4

material no. 4

140 Burner control unit 7747 007 839 1 1 1 1

150 Aquastat 5996 360 1 1 1 1

170 Cable assembly 7079 804 1 1 1 1

Mounting kit no. 4 7079 764 1 1 1 1

Tab. 15 Individual parts control unit GAW025 US

Logano G234X - Technical specifications are subject to change without prior notice. 51
 9 Spare parts

Fig. 52 Control unit GAW025 US

52 Logano G234X - Technical specifications are subject to change without prior notice.
 Spare parts 9

Gas distributor (Æ Fig. 53)

Item
G234X/38 G234X/45 G234X/55 G234X/64
No. Designation Product-number 5 sections 5 sections 6 sections 7 sections

10 Burner assembly 5181- 742 742 744 746

20 Gas pipe 7747 002 195 1 1 1 1

30 M8 nut Æ Installation 2 2 2 2
material no. 5

40 Gasket 5489 280 3 3 3 3

50 Heat shield incl. glue 5181 396 1 1 1 1

60 Glue for heat shield 2037 312 1 1 1 1

All factory installed nozzles are for elevation of

0 - 2000 ft (0-610 m). Contact Buderus for
high elevation kits.

70 Nozzle set NG-0-2000 ft (0-610 m) 5484- 176 (3x) 176 (3x) 168 (4x) 184 (4x)

80 Gasket 5883 094 3 3 4 4

90 Flame escape switch 171°F (77 °C) 5176 272 1 1 1 1

100 Screw M4x16 ST Æ Installation 1 1 1 1

material no. 5

Mounting kit no. 5 5181 883 1 1 1 1

Tab. 16 Individual parts of gas distributor

Logano G234X - Technical specifications are subject to change without prior notice. 53
 9 Spare parts

Fig. 53 Gas distributor

54 Logano G234X - Technical specifications are subject to change without prior notice.
 Spare parts 9

Burner models, gas conversion parts G234X US

(Æ Fig. 54)

The complete burner is supplied only in the

model for natural gas G20 for 0 - 2000 feet
(0 - 610 m). If you want another model
burner, you must also order the appropriate
gas conversion parts. The replaced parts
must remain with the heating system for a
possible future reconversion.

Item Product- G234X/38 G234X/45 G234X/55 G234X/64

No. Designation number 5 sections 5 sections 6 sections 7 sections

10 Burner AE234X "US" replacement 5181- 736 748 738 740

NG Kit G234X 0 - 2000 ft "US" 5993- 394 394 396 398

LP Kit G234X 0 - 2000 ft "US" 5993- 336 338 340 344

Tab. 17 Individual parts gas type conversion parts

Logano G234X - Technical specifications are subject to change without prior notice. 55
 9 Spare parts

Fig. 54 Burner models, gas type conversion parts AE234X US

56 Logano G234X - Technical specifications are subject to change without prior notice.
 Spare parts 9

Gas valve VR8304H4206 G234X FAS US/CA (Æ Fig. 55)

Item
Product- G234X/38 G234X/45 G234X/55 G234X/64
No. Designation number 5 sections 5 sections 6 sections 7 sections

10 Gas valve 5181 870 1 1 1 1

WARNING:
Do not use the screw fitting included
with the gas fitting for the pilot gas
pipe!
Tab. 18 Gas fitting VR8304H4206 ¾ 24V 60Hz

Logano G234X - Technical specifications are subject to change without prior notice. 57
 9 Spare parts

Fig. 55 Gas fitting VR8304H4206 ¾ 24V 60Hz

58 Logano G234X - Technical specifications are subject to change without prior notice.
 Spare parts 9

Pilot burner for G234X (Æ Fig. 56)

Item
Product- G234X/38 G234X/45 G234X/55 G234X/64
No. Designation number 5 sections 5 sections 6 sections 7 sections

10 Allen screw 8x32x3/16 Æ Mounting kit 1 1 1 1

no. 5

20 Pilot burner Q345 1E 5181 443 1 1 1 1

30 Ignition gas nozzle, natural gas, BCR20 5181 648 1 1 1 1

30 Ignition gas nozzle, LP gas, BBR12 5176 998 1 1 1 1

40 Screw fitting for pilot gas pipe 5181 672 1 1 1 1

50 Ignition burner holder Æ Installation 1 1 1 1

material no. 5

60 Screw M5x12 A3K Æ Installation 2 2 2 2

material no. 5

70 Pilot gas pipe 5181 670 1 1 1 1

Tab. 19 Pilot burner for G234X

Logano G234X - Technical specifications are subject to change without prior notice. 59
 9 Spare parts

Fig. 56 Pilot burner for G234X

60 Logano G234X - Technical specifications are subject to change without prior notice.
 10

US 2

Vent damper device

Aquastat Relays (Effikal RVG..-B)
L8148BE... T W TV yellow
4
orange

Fig. 57 Circuit diagram 1

3
B brown
2
Z black
1

R
Circuit diagrams

C1 C2

L1 L2 B1 B2

Intermittent pilot control module S8600H

black
red
blue 24V MV
GND
white
on-off 24V MV/PV
blue
Circulator- switch Blocked vent PV
pump switch Plug
green
GND Plug

black
white
Terminals on boiler block
H N
PV
1 2 3 4 PV MV MV
1

Logano G234X - Technical specifications are subject to change without prior notice.
black
white
Flame roll out
Pilot valve Main valve
safety
shutoff means Pilot burner Intermittent pilot dual
Power supply disconnect means and overload black
1 protection provided as required (Honeywell) valve combination gas
orange
control VR8304
Connecting terminals for thermostat or Logamatic-Control
2 ( in case of connection remove bridge) Burner assembly

Wiring diagram gas-boiler G234X USA-CDN Reviewed : 6340 Wiring diagram : GAW 025 USA
Intermittent pilot Drwg. no.: 63001271 Edition : 1999/02 Page: 1/2
Circuit diagrams
10

61
62
10

US

Wiring Schematic G234X with vent damper

Fig. 58 Circuit diagram 2

Circuit diagrams

H
On-off
switch
L1
Transformer

Z
K1

B
120 VAC
TR High limit 24V 18 WIRE

B
brown orange
K1
2 3
Effical
Vent damper
1 4
black yellow
B1
W blue
K1 3
white
T Flame roll out Gas valve
safety
shutoff means To Pilot Pilot Main
black Burner
2
C1 white
Circulator Blocked GND
PV PV MV
pump M Vent switch MV
black
1
green
blue
white
red

C2 orange
24V
Spark GND PV PV/MV MV
T-Start S8600H
24VGND
black
L2 4
black
TV B2

Wiring diagram gas-boiler G234X USA-CDN Reviewed : 6340 Wiring diagram : GAW 025 USA
Intermittent pilot Drwg. no.: 63001271 Edition : 1999/02 Page: 2/2

Logano G234X - Technical specifications are subject to change without prior notice.
 10

Notes

Logano G234X - Technical specifications are subject to change without prior notice. 63
United States and Canada

Bosch Thermotechnology Corp.

50 Wentworth Avenue
Londonderry, NH 03053
Tel. 603-552-1100
Fax 603-584-1681
www.buderus.us
U.S.A.

Products manufactured by
Bosch Thermotechnik GmbH
Sophienstrasse 30-32
D-35576 Wetzlar
www.buderus.com

Bosch Thermotechnology Corp. reserves the right

to make changes without notice due to continuing
engineering and technological advances.