Installation and service instructions for contractors Logano plus SB625. Burner shroud not available in UK and Ireland

Transcription

1 Floor standing condensing boiler ITL Installation and service instructions for contractors Logano plus SB (2013/07) GB Burner shroud not available in UK and Ireland Read carefully before carrying out installation and maintenance.

2 Table of contents Table of contents 1 General safety instructions and explanation of symbols Key to symbols Safety regulations About the appliance Type overview Determined use Safety equipment EU Declaration of Conformity Scope of supply Required accessories Operating conditions Suitable fuels Data plate Tools, materials and auxiliary equipment Product description Specifications, dimensions, connections Measurements Specifications Values for calculating the flue gas Information on installation and operation Standards, regulations and directives Notes on low water indicators (LWI) (low water level limiter) Tightness test (water side) Duty to obtain a permit and provide notification Burner selection and settings Installation requirements Ventilation requirements Open flue boilers Room sealed boilers Combustion air quality Heating water quality Using antifreeze Electrical installation Control unit settings Hydraulic connection to the heating system Setting the minimum and maximum pressure limiters Pressure maintenance Transport Securing the load Moving the boiler with a crane, forklift truck or two pallet trucks Lifting the boiler with a crane Moving the boiler with a forklift truck Moving the boiler with two pallet trucks Installation Siting the boiler Levelling the boiler Fitting the thermal insulation Flue gas and water connections for heating system General requirements of the flue system Connecting the flue gas system Fitting a sealing collar (accessory) Connecting the boiler to the pipework Installing the condensate hose and neutralising system Installing the minimum pressure switch and minimum pressure limiter (accessories) Low water limiter (accessory), fitting ( kW) Filling the boiler and checking connections for leaks Fitting the casing Fitting the connection plates Fitting the side panels Routing the burner cable Fitting the back plate Fitting the boiler cover Fitting the front panel Opening and reversing the combustion chamber door Opening and closing the combustion chamber door Refitting the door hinges Fitting the burner (accessory) Fitting the burner plate Fitting the burner to the burner plate Securing the fascia, additional type plate and data plate Fitting and electrically connecting the control unit (accessory) Fitting temperature sensors Commissioning Flushing the heating system Filling the heating system Preparing the heating system for operation Commissioning the control unit and burner Setting control unit parameters Commissioning report De-commissioning Shutting down the heating system Shutting down the heating system in an emergency Inspection and maintenance General notes Preparing the boiler for inspection and maintenance Cleaning the boiler Preparing the boiler for cleaning with brushes Cleaning the boiler with cleaning brushes Cleaning the flue gas collector Replacing the gasket in the flue gas collector and the cover for the reversing chamber Fitting the cleaning cover on the flue gas collector and cover for the reversing chamber Wet-cleaning the boiler Checking and correcting the water pressure When should you check the water pressure in the heating system? Logano plus SB (2013/07)

3 General safety instructions and explanation of symbols Sealed unvented systems Installations with automatic pressurisation systems Inspection and maintenance reports Remedying a burner fault Environmental protection/disposal System examples Layout of the minimum equipment for technical safety in accordance with EN 12828:2003; operating temperature < 105 C; cut-out temperature (high limit safety cut-out) < 110 C Safety equipment in accordance with the EC type inspection Requirements for alternative items of safety equipment and other pieces of equipment Safety valve requirements High limit safety cut-out requirements Maximum pressure limiter requirements Minimum pressure switch as low water limiter requirements Minimum pressure limiter as low water limiter requirements Water level limiter as low water limiter requirements Burner requirements Boiler controller General safety instructions and explanation of symbols 1.1 Key to symbols Warnings The following keywords are defined and can be used in this document: NOTE indicates a situation that could result in damage to property or equipment. CAUTION indicates a situation that could result in minor to medium injury. WARNING indicates a situation that could result in severe injury or death. DANGER indicates a situation that will result in severe injury or death. Important information Additional symbols Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken. This symbol indicates important information where there is no risk to people or property. Symbol Explanation Step in an action sequence Cross-reference to another part of the document List entry List entry (second level) Table 1 Logano plus SB (2013/07) 3

4 2 About the appliance 1.2 Safety regulations Danger through failure to consider your own safety in an emergency such as a fire Never put your life at risk. Your own safety is paramount. If you smell gas Close the gas isolation valve. Open the windows. Never operate electrical switches, including telephones, plugs or doorbells. Extinguish all naked flames. No open fire. Never smoke. Never use lighters. Warn all occupants of the building, but do not ring doorbells. Leave the building and telephone your gas supplier and authorised contractor from an outside phone. If you smell flue gas Switch off the appliance. Open windows and doors. Notify an approved heating contractor. Electric shock hazard Before carrying out any work on the heating system, disconnect the heating system from the power supply across all poles. For example, activate the emergency stop switch outside the boiler room. It is not sufficient to switch OFF the control unit. Secure the power supply against unintentional reconnection. Conform with country-specific rules and regulations when making the electrical connection, commissioning, servicing and carrying out maintenance. Installation and conversion Insufficient ventilation can lead to dangerous flue gas leaks. Only have the boiler installed or modified by an approved heating contractor. Never change any parts in contact with flue gas. With open flue appliances: Never cover or reduce the size of air vents in doors, windows or walls. If draught-proof windows are fitted, ensure there is an adequate combustion air supply. Ensure that the boiler installation room remains free from the risk of frost. The heating system must be installed and operated in accordance with the applicable codes of practice as well as national, regional and local regulations. Thermal disinfection Risk of scalding! Monitor any operation with temperatures in excess of 60 C. Inspection and maintenance Recommendation for customers: Arrange a maintenance and inspection contract with an approved heating contractor, covering an annual inspection and responsive maintenance. The user is responsible for the general and environmental safety of the heating system. Immediately remedy all faults to prevent system damage! Use only original, genuine spare parts from the manufacturer. Damage caused by the use of spare parts and accessories not supplied by the manufacturer are excluded from the manufacturer's warranty. Explosive and highly flammable material Never use or store highly flammable materials (paper, thinners, paints etc.) near the boiler. Combustion/room air Keep the combustion/ambient air free of corrosive substances (e.g. halogenated hydrocarbons that contain chlorine or fluorine compounds). This will help prevent corrosion. Keep the combustion air supply free of dust. Instructing the customer Instruct the customer on the functions and operation of the appliance. Inform customers that they must not carry out any modifications or repairs. Disposal Dispose of packaging in an environmentally responsible manner. 2 About the appliance 2.1 Type overview Type Output SB kw, 185 kw, 240 kw, 310 kw, 400 kw, 510 kw, 640 kw Table 2 Type overview 2.2 Determined use The Logano plus SB625 condensing boiler has been designed for hot water heating systems in e.g. apartment buildings or industrial units. The boiler is only approved for open flue operation. Any pressure-jet gas burner type-tested to EN 676 can be used if its operating range matches the boiler specifications. Only burners that have been tested and approved for electromagnetic compatibility (EMC) may be used. 2.3 Safety equipment To ensure safe operation, the boilers must be equipped with the following safety equipment: The level of safety equipment must comply with at least EN Also observe country-specific regulations if these specify further requirements. If the maximum setting for the high temperature limit stat (110 C) varies in other countries, observe the country-specific limit. Equipment examples are included in chapter 11, page 36. The components making up the safety equipment are available as accessories. 2.4 EU Declaration of Conformity The design and operation of this product conform to the applicable European directives and supplementary national requirements. Conformity has been demonstrated. The Declaration of Conformity can be viewed at or alternatively can be requested from your local Buderus sales office. 2.5 Scope of supply Upon receipt, check that all packaging is in perfect condition. Check the delivery is complete: 1 packed boiler supplied on a pallet. Technical documents, attached to boiler block. 1 boiler casing with thermal insulation and accessories, packed in a carton. 4 Logano plus SB (2013/07)

5 About the appliance 2 1 front panel packed in a carton. 1 siphon set in the combustion chamber. Insulating rings for blast tube in the combustion chamber. It is possible that some of the standard accessories will not be necessary for certain boiler types. 2.6 Required accessories The following accessories are not part of the standard delivery but are required to operate the boiler: Burner Burner plate, drilled or undrilled Boiler safety assembly Safety equipment Neutralising system Cleaning brushes Control unit 2.7 Operating conditions Observe all standards and directives applicable to the installation and operation of this heating system in your country. Observe the information on the data plate. These are definitive and must be observed. Set the burner to the rated heat input QN specified on the data plate as a maximum. CONDITIONS OF USE Unit Value Maximum permissible temperature, C 110 high-limit safety cut-out Maximum operating pressure bar Dependent on boiler size. See Tab. 5 Maximum number of burner starts per annum Table 3 CONDITIONS OF USE Operating conditions Logano plus SB625 Logano plus SB625 Boiler water flow rate Min. boiler water temperature None in conjunction with a Logamatic control unit for modulating operation. Operating Interruption (complete boiler shutdown) Heating system control with mixing valve Minimum return temperature Miscellaneous 1)2) Table 4 Operating conditions None in conjunction with a Logamatic control unit 4212 for constant boiler water temperatures or when supplemented by a third party control unit. 1) Maximum 15,000 burner starts per year In order not to exceed the number of burner starts, observe the information on setting the control unit and burner in the technical guide or installation instructions. If this value is exceeded, however, please contact the manufacturer's service department. 2) The number of burner starts per year is affected by the boiler system's operating settings (parameters in the boiler controller and combustion setting) and system sizing to correspond with the heat demand of the consumer. To avoid exceeding the number of annual burner starts as a result of incorrect operating settings, the manufacturer offers a complete commissioning and maintenance inspections for boilers, burners and boiler controllers (Logamatic control units with function modules). 1) 2.8 Suitable fuels The boiler must only be operated with the specified fuels. Only burners that are suitable for the specified fuels may be used. Gas burner Permissible fuels: Natural gas from the public gas supply in accordance with national regulations with a total sulphur content < 50 mg/m 3. LPG in accordance with national regulations with a content of elementary sulphur 1.5 ppm and volatile sulphur 50 ppm. 2.9 Data plate The combustion of biogas is not permitted. If you contact the manufacturer with any questions about this product, always provide the details on the data plate. These details enable us to assist you quickly and effectively. The information on the type plate is binding and must be observed! The data plate is supplied loose (located in the plastic wallet within the sets of documents). Subject to the boiler location, attach it to the top right or left of the side panel. The data plate includes details of the serial number, output and approval data Tools, materials and auxiliary equipment For the installation and maintenance of the boiler, you require standard tools, as used in space heating as well as gas and water installations, and a torque wrench Product description With the Logano plus SB625 floor standing condensing boilers, all parts that come into contact with hot gas or condensate are made from high grade stainless steel. This makes operation possible without minimum flow and return temperature, minimum flow rate or minimum burner low load. It is also referred to in this manual SB625 as the boiler or the heat appliance. The SB625 has two separate thermohydraulic return connections for the high and low temperature heating circuits. The SB625 must be equipped with a burner that is suitable for the boiler. The boiler function is bases on the three-pass system ( Fig. 1). Optional accessories are listed in the general catalogue. NOTICE: System damage through incorrect burner. Only use burners that meet the technical requirements of the boiler ( chapter 2.12, page 8). The main components of the boiler are ( Fig. 2, page 7): Boiler body [1] in conjunction with a burner The boiler block transfers the heat produced by the burner to the heating water. Thermally insulating casing The boiler shell and thermal insulation reduce energy losses. Control unit (accessory) The control unit monitors and controls all electrical boiler components. Logano plus SB (2013/07) 5

6 2 About the appliance 1 VK 2 RK2 AA RK il Fig. 1 Function diagram of the hot gas path in the floor standing condensing boiler Logano plus SB625 [AA] Flue gas outlet [RK1] Return connection for low temperature heating circuits [RK2] Return connection for high temperature heating circuits [VK] Flow connection [1] Combustion chamber (1st pass) [2] Upper condensation secondary heating surface (condensing plus heating surface, 2nd pass) [3] Water guide element [4] Lower condensation reheating surface (condensing plus heating surface, 3rd pass) 6 Logano plus SB (2013/07)

7 About the appliance Fig. 2 Boiler overview [1] Boiler body [2] Boiler flow connection [3] Flow safety line connection [4] Return connection 2 (high temperature return) [5] Return connection 1 (low temperature return) [6] Flue outlet [7] Drain connection [8] Reversing chamber door (gives access to flue passes two and three) [9] Combustion chamber door ITL Logano plus SB (2013/07) 7

8 2 About the appliance 2.12 Specifications, dimensions, connections The specifications provide information about the output profile of the Logano plus SB625. H K H VK H VSL VK V SL MDW/MDB H RK2 H AA H RK1 RK2 AA RK1 Fig. 3 Specifications, dimensions, connections [A] Clearance [AA] Flue outlet [AKO] Condensate outlet [B] Boiler width incl. casing [B GR ] Base frame width [D AA ] Ø Internal flue gas outlet [EL] Cold water inlet/drain [H] Boiler height incl. control unit [H AA ] Flue outlet height [H AKO ] Condensate outlet height [H B ] Centre of combustion chamber door height [H EL ] Drain height [H K ] Boiler height [H RK1 ] Height, boiler return 1 [H RK2 ] Height, boiler return 2 [H VK ] Height, boiler flow ITL [H VSL ] Height, flow safety line [L] Boiler length incl. casing [L BR ] Burner length [L K ] Boiler block length [MDW] Minimum pressure switch [MDB] Minimum pressure limiter [RK1] Boiler return 1 (low temperature return) [RK2] Boiler return 2 (high temperature return) [VK] Boiler flow [VSL] Safety valve and flow safety line connections (for open vented systems) [1] Side-mounted control unit bracket (left/right) [2] Spigot for low water limiter (WMS) for boiler ratings 400 kw and above [3] Minimum pressure switch (MDW) for boiler rating kw or minimum pressure limiter (MDB) for boiler rating 310 kw (accessories) Measurements Boiler size Abbreviations Unit L mm Length L K mm Burner length L BR mm Subject to burner Width B mm H mm Height H K mm Width/height/ for transport mm 720/ 1340 Length mm Base frame B GR mm Clearance O mm Flue outlet Ø D AA inside DN H AA mm Combustion chamber Length mm Ø mm combustion chamber door Depth mm H B mm Boiler flow connection 1) Ø VK DN H VK mm Table 5 Specifications 720/ / / / / / Logano plus SB (2013/07)

9 About the appliance 2 Boiler size Abbreviations Unit Boiler return connect 1 1) H RK1 mm Ø RK1 DN A 1 mm Boiler return connection 2 1) H RK2 mm Ø RK2 DN R 1½ R 1½ R 1½ A 2 mm Safety valve/flow safety line 2) H VSL mm Ø VSL DN R 1¼ R 1¼ A 3 mm Switch/limiter connection MDW/MDB DN R¼ R2 External diameter mm 32 Condensate outlet H AKO mm A 4 mm Drain Ø EL DN R1 H EL mm Table 5 Specifications 1) According to DIN 2633 PN 6. 2) According to EN PN Specifications Boiler size Abbreviations Unit Rated heat input for gas [burner output Q n (H i )] Weight Values for calculating the flue gas Partial load 40 % kw Full load, max. kw net kg With burner kg Water content l Gas content l Available draught Pa 50 1) /boiler-dependent 1) Pressure drop on the hot gas side mbar Pressure drop on the water side mbar Fig. 13 Standby loss % Fig. 14 Permissible flow temperature 2) C 110 Permitted operating pressure bar Boiler with CE designation CE-0085 AT 0075 Table 6 Specifications 1) With Logano plus SB625 with third party burner. 2) Safety limit (high limit safety cut-out). Maximum possible flow temperature = safety limit (STB) - 18 K. Example: Safety limit (STB) = 100 C, max. possible flow temperature = = 82 C. Boiler size Abbreviations Unit System temperatures 50/30 C Rated output, gas Full load kw Partial load, 40 % kw Flue gas temperature 1) Full load C Partial load, 40 % C Flue gas mass flow rate Full load kg/s Partial load, 40 % kg/s System temperatures 80/60 C Rated output, gas Full load kw Partial load, 40 % kw Flue gas temperature 1) Full load C Partial load, 40 % C Table 7 Specifications Logano plus SB (2013/07) 9

10 3 Information on installation and operation Boiler size Abbreviations Unit Flue gas mass flow rate Full load kg/s Partial load, 40 % kg/s CO 2 content, gas % 10 Table 7 Specifications 1) Arithmetical flue gas temperature used for cross-sectional calculation according to EN (average values across series) The measured flue gas temperature and the actual system temperature may not correspond, depending on the burner setting. Δp H [mbar] a b c 3 Information on installation and operation Observe all standards and guidelines applicable to the installation and operation of this system in your country. The details on the data plate are definitive and must be observed. Installer: The installer must a person who has extensive, specialist, theoretical and practical knowledge, as well as experience in the specialist area and is familiar with applicable standards. Contractor: A contractor is an organisational unit of the industrial sector with specially trained personnel V H [m 3 /h] Fig. 4 Pressure drop on the water side [ p H ] Pressure drop on the heating water side [V H ] Flow rate [a] Logano plus SB625, boiler size 145 to 185 [b] Logano plus SB625, boiler size 240 to 310 [c] Logano plus SB625, boiler size 400 to 640 q B [%] 0,7 0,6 0,5 0,4 0,3 0,2 0, ITL ϕ K [ C] ITL Fig. 5 Standby loss subject to the average boiler water temperature [q B ] Standby loss [ K ] Average boiler water temperature 3.1 Standards, regulations and directives Observe all technical guidelines, country-specific regulations and standards applicable to installation and operation. These include the following but are not limited to: Local Building Regulations concerning boiler room installations. Local Building Regulations regarding air supply and extraction equipment as well as connection to a flue. Requirements for the electrical connection to the power supply. The technical rules of the gas supplier regarding the connection of the gas burner to the local mains gas supply. Regulations and standards concerning the safety equipment level of water-filled heating systems The level of safety equipment must be at least compliant with EN Also observe country-specific regulations if these specify further requirements. 3.2 Notes on low water indicators (LWI) (low water level limiter) For boilers > 300 kw, install a low water indicator. For installation and operation, refer to the technical documents provided by the manufacturer. If the LWI connection provided is not used for the installation of a SYR low water indicator (accessory), seal the connection off with a plug ( chapter 5.7, page 20). 3.3 Tightness test (water side) A leak test has to be carried out in accordance with local regulations. The test pressure depends on the actual pressure in the heating system and should be 1.3 times the prevailing pressure or at least 1 bar. 3.4 Duty to obtain a permit and provide notification Please note that regional approvals may be required for the flue system and condensate connection to the public sewage system. Prior to commencing installation, inform the relevant bodies (e.g. the gas supplier) and the water board. 10 Logano plus SB (2013/07)

11 Information on installation and operation Burner selection and settings Only use specified pressure-jet gas burners with floor standing gas condensing boilers. The sizing and setting of the burner has a significant influence on the service life of the heating system. Every load cycle (burner on/off) causes thermal stresses (load on the boiler body). The number of burner starts must therefore not exceed 15,000 per year. The following recommendations and settings are designed to meet this criterion (see also information on setting the control unit and the hydraulic connection to the heating system). If you still cannot meet this criterion, please contact the Buderus sales or service department. The number of burner starts can be checked in the MEC ( chapter 3.12, page 12), on the third-party control unit or alternatively on the burner control unit. Set the burner output as low as possible. Set the burner to the rated heat input QN specified on the data plate as a maximum. Never overload the boiler! Take fluctuating net calorific values of the gas into account; check the maximum value with the gas supplier. Only use burners that are suitable for the specified fuels. Observe the burner manufacturer's instructions. Burners must only be adjusted by an approved contractor! 3.6 Installation requirements The installation room must meet the following conditions: In the boiler installation room, an ambient temperature of between 0 C and 35 C must be ensured. The installation room must be equipped with the required combustion air vents. An adequate supply of fresh air must be ensured. Take into account additional consumers of ventilation air (e.g. compressors) when sizing. 3.7 Ventilation requirements Ventilation for combustion and cooling should be provided in the boiler house in accordance with BS 6644 and IGE/UP/10. The tables below may be used for guidance Open flue boilers Opening free area sizes given in cm² per kw net. % Load in Summer Low level High level Table Room sealed boilers Opening free area sizes given in cm² per kw net. % Load in Summer Low level High level Table 9 Never restrict or block ventilation openings. Keep the ventilation openings clear at all times. Never install system components that could be damaged by frost near the combustion air vents. If necessary, install a device to preheat the ventilation air (e.g. a heater bank in the combustion air vent). Never store flammable materials or liquids in the immediate vicinity of the heat source. 3.8 Combustion air quality Keep the supply of combustion air free of corrosive substances (e.g. halogenated hydrocarbons that contain chlorine or fluorine compounds). This will help prevent corrosion. Never use or store chlorinated cleaning agents or halogenated hydrocarbons (as contained in spray cans, solvents or cleaning agents, paints and adhesives, for example) in the boiler room. Keep the combustion air supply free of dust. If building work is taking place in the installation room and creating a lot of dust, shut the boiler down. A burner contaminated during building work must be cleaned before commissioning. 3.9 Heating water quality The quality of the fill and top-up water is an essential factor for increased efficiency, functional reliability, long service life and for maintaining the constant operational condition of a heating system. If the system is filled with water that has a high calcium hardness, this will be deposited on the heat exchanger surfaces and will hinder the transfer of heat to the heating water. As a result, the wall temperatures of the stainless steel heat exchanger surfaces will rise and the thermal stresses (load on the boiler body) will increase. This is why the quality of the fill or top-up water must meet the conditions stipulated in the operator's log provided and be recorded in this log. The conditions for boilers > 600 kw require general water treatment independent of the water hardness and the volume of fill and top-up water Using antifreeze Chemical additives that are not certified as harmless by the manufacturer must not be used. Antifreeze based on glycol has been used in heating systems for many years, for example Antifrogen N manufactured by Clariant. The use of other types of antifreeze should not be a cause for concern if the product is comparable with Antifrogen N. Observe the antifreeze manufacturer's instructions. Follow the manufacturer's details regarding mixing ratios. The specific thermal capacity of Antifrogen N antifreeze is lower than the specific thermal capacity of water. To enable the transfer of the required heat output, increase the required flow rate accordingly. This should be taken into account when sizing the system components (e.g. pumps) and the pipework. As the heat transfer medium has a higher viscosity and density than water, take the higher pressure drop through the pipework and other system components into account. Check the resistance of all plastic or non-metallic components in the system separately. Logano plus SB (2013/07) 11

12 3 Information on installation and operation 3.11 Electrical installation DANGER: Risk to life and of system damage through faulty connections. Only carry out electrical work if you are a qualified electrician. Observe local installation regulations ( chapter 3.1). The electrical installations must be suitable for damp areas. The system installer must provide a wiring diagram which records the interface between heating output elements, burner, control unit (Logamatic) and additional safety equipment Control unit settings 3) The temperature setpoints of heating circuits equipped with mixing valve is made up from the set flow temperature and parameter "Boiler rise" in the heating circuit data menu. 4) The temperature setpoint of DHW heating is made up from the set DHW temperature and parameter "Boiler rise" in the DHW menu. Settings for boiler water controller and maximum boiler water temperature The boiler water controller is designed to provide emergency operation with an adjustable boiler water temperature only if the control electronics fail. In standard control mode, the function of the boiler water controller is provided by the maximum boiler water temperature set within the relevant sub-menu in the Logamatic controller. The maximum boiler water temperature can be selected in the control unit in the "Boiler parameters" menu, under menu item "Max. shutdown temperature". We recommend using a Buderus Logamatic control unit from the 4000 series. The purpose of optimum control unit settings is to achieve long burner runtimes and avoid rapid temperature changes in the boiler. Gentle temperature changes result in a longer service life of the heating system. The control strategy must therefore remain in affective operation, i.e. through the boiler water temperature controller switching the burner on and off. Maintain the minimum differential between the selected shutdown temperature of the high limit safety cut-out, the temperature controller, the maximum boiler water temperature and the maximum temperature demand ( Tab. 10, page 12). The maximum boiler water temperature can be selected on the control unit (MEC) in the "Boiler parameters" menu, under menu item "Max. shutdown temperature". Select set temperatures for the heating circuits that are as low as possible. Start heating circuits (e.g. when starting up in the mornings) in 5- minute intervals. If the Buderus Logamatic 4000 control unit is used, burner modulation in standard mode is not released for 3 minutes from startup. Never modulate upwards more quickly than this when operating in manual mode. Adjustable parameter (max. temperature) High limit safety cut-out (STB) 1) Logamatic 4321 Logamatic C 110 C minimum 5 K Temperature controller (TR) 1) 105 C 90 C minimum 6 K Max. boiler water temperature 99 C 84 C minimum 7 K at least 18 K Max. temperature 92 C 77 C demand 2) of HC 3) and DHW 4) Table 10 Adjustable parameters Logamatic 4321 and Logamatic ) Set the high limit safety cut-out and temperature controller as high as possible, but ensure the settings have a gap of at least 5K. 2) Both temperature setpoints must always be at least 7 K below the maximum boiler water temperature. 12 Logano plus SB (2013/07)

13 Information on installation and operation 3 Control unit settings 80 Fig. 6 Control unit settings [1] High limit safety cut-out [2] Temperature control unit [3] MEC Select temperatures ( Tab. 10, page 12) at high limit safety cut-out [1] in the control unit and at temperature controller [2]. Select the maximum boiler water temperature at the MEC [3]. Example DHW demand: Sum of the set DHW temperature (60 C) and parameter "Boiler rise" (20 C) in the "DHW" menu: 60 C + 20 C = Maximum temperature demand 80 C Example heating circuits: Sum of the set temperature of the heating circuit with mixing valve with the highest temperature required (70 C) and parameter "Boiler rise" (5 C) in the "Heating circuit data" menu: 70 C + 5 C = Maximum temperature demand 75 C Notes on setting third party control units The maximum temperature setpoint is not a value that is directly selected. The maximum temperature setpoint is made up from the the setpoints on the individual heating circuits. All maximum temperature setpoints must always be 7 K below the maximum selected boiler water temperature. NOTICE: System damage due to incorrect sensor position! The sensors of the high limit safety cut-out (STB) and of the thermostat (TR) must be fitted in the dedicated pocket ( Fig. 36, page 27) on the top of the boiler. In the case of third party control units, match the sensor pocket to the diameter of the sensors used. Do not change the length of the sensor pocket. Observe the operating conditions in chapter 2.7, page 5 and observe chapter 5.14, page 27 when installing sensors T The third party control unit (building management system or PLC controllers) must ensure a maximum internal boiler water temperature that is sufficiently below the high limit safety cut-out. It must also be ensured that the control electronics rather than the boiler water controller switches the burner on and off. The control unit must ensure that the burner is switched to low load before being shut down. If this is not observed, the safety shut-off valve (SAV) in the gas train may respond. Select control equipment that allows a gentle start-up with a time delay when the system is cold. After the burner demand, an automatic timer (for example) should keep the burner to low load for a period of approx. 180 seconds after startup. A restricted heat demand will prevent uncontrolled starting and stopping of the burner. It must be possible to show the number of burner starts on the control unit used (or alternatively on the burner control unit). Unit Value Temperature control unit s 40 Monitor/limiter s 40 Minimum difference between burner on K 7 and off temperatures Table 11 CONDITIONS OF USE 3.13 Hydraulic connection to the heating system If the system temperatures are different, use both return connectors RK1 (bottom) and RK2 (top). Connect heating circuits with high return temperatures to connector RK1, and heating circuits with low return temperatures to connector RK2. For an optimum energy yield, we recommend supplying a flow rate of 10 of the total nominal flow rate via connector RK1, with a return temperature below the dew point. If there are no varying return temperatures, only return connector RK1 should be connected. Commission the flow rate in the boiler to a temperature difference of at least 7 K using suitable balancing equipment. Size and commission the pump(s) correctly. Logano plus SB (2013/07) 13

14 4 Transport High flow rates and oversized pumps can result in the accumulation of sludge or deposits on the heat exchanger surfaces. Before connecting the boiler, flush sludge and dirt out of the heating system. Ensure that no air enters the heating water during operation. Only operate the boiler in system ensuring no air can enter the boiler. If the boiler is nonetheless used in an open vented heating system, additional measures are required to protect against corrosion and prevent sludge entering the boiler. The technical safety devices also require to be matched (equipment and settings). Consult the manufacturer's sales or service department. Information on cascade circuits: Carry out the fitting of the boiler circuit pumps (volume flow) in accordance with the set boiler output. In the case of parallel switching of the boilers, maintain the same temperature spread for all boilers Setting the minimum and maximum pressure limiters Maximum pressure limiter The maximum pressure limiter (optional accessory) must be set in such a way that the safety valve is prevented from discharging. To achieve this, the maximum pressure limiter must be set to at least 0.5 bar below the set pressure of the safety valve. The maximum safety pressure of the boiler's safety valve depends on the size of the boiler ( Tab. 5, page 8). Example: Safety pressure: P SV = 5 bar Setting value, maximum pressure limiter: 5 bar 0.5 bar = 4.5 bar Advise on the setting of the maximum pressure limiter can be found in the documentation provided with the pressure limiter. Minimum pressure limiter The minimum pressure limiter (optional accessory) must be set in such a way that no steam bubbles form inside the boiler, ensuring the boiler still operates safely. This setting depends on the system conditions and the location of the boiler system. For the setting, the boiling pressure associated with the setting of the high limit safety cut-out is relevant (high limit safety cutout 110 C equals 0.5 bar), as is the heat emitter at the highest static level above the boiler. Example: Boiler system with high limit safety cut-out setting = 110 C Highest heat emitter above the boiler = 12 m (10 m equates to approx. 1 bar) = 1.2 bar Safety margin = 0.2 bar (fixed value) Setting minimum pressure limiter P min = 0.5 bar bar bar = 1.9 bar Advise on the setting of the minimum pressure limiter can be found in the documentation provided with the pressure limiter Pressure maintenance Size the expansion vessels correctly. Set the pre-charge pressure in the expansion vessel correctly. If using pump-controlled pressurisation systems, pressure fluctuations will occur. They can occur very frequently depending on the design of the system and the setting of the appliance. Even if these pressure fluctuations appear to be small, if they occur very frequently they may cause considerable damage to the boiler, as it is designed for a predominantly static pressure. To protection against damage: Ensure that every heat source is equipped with an individual expansion vessel. Set the pre-charge pressure in the expansion vessel correctly. 4 Transport DANGER: Risk to life from inadequately secured boiler. Use suitable means to transport the boiler (e.g. several pallet trucks, a forklift truck or a crane). When transporting, secure the boiler to prevent it slipping. Comply with local health and safety standards The boiler can be transported by crane, forklift truck or several pallet trucks. When raising and transporting the boiler, make sure that the weight is distributed evenly across the forks of the forklift truck/pallet truck. 4.1 Securing the load To secure the load during transportation: The boiler is transported upright on a pallet. Pull securing straps (fixing straps, chains) over the boiler shell and secure them to the transport vehicle. 4.2 Moving the boiler with a crane, forklift truck or two pallet trucks The boiler can be transported by crane, forklift truck or several pallet trucks Lifting the boiler with a crane DANGER: Risk to life through falling load. Only use lifting ropes of the same length. Only use lifting ropes that are in good and safe condition. Only hang hooks on the designated eyebolts on the top of the boiler. Do not attach any means of lifting onto the boiler pipe connections. Only lift the boiler with a crane if you are suitably qualified to operate the crane. Attach lifting rope hooks to the designated lifting eyes on the top of the boiler. The end stop's tilt angle must be 90 ( Fig. 7). 14 Logano plus SB (2013/07)

15 Transport 4 Attach the hoist/crane lifting hooks to the lifting rope Fig. 7 Lifting the boiler with a crane [1] Crane hooks with safety mechanisms [2] Lifting eyes Moving the boiler with a forklift truck ITL Fig. 8 Moving the boiler with a forklift truck ITL Moving the boiler with two pallet trucks Push one pallet truck underneath each of the boiler front and back panels. Lift the boiler evenly with the pallet trucks. DANGER: Risk to life through falling load. Distribute the boiler weight evenly across the forklift truck/pallet truck when lifting and moving the boiler. Observe the weight of the boiler and the maximum loading of the means of transport. When transporting, secure the boiler to prevent it falling. NOTICE: System damage due to damaged boiler body. Only move the boiler with a forklift truck if the forks are long enough to reach completely under the boiler. Prior to lifting the boiler, check that the front and back panels of the boiler are supported by the forks of the forklift truck. Insert the forks of the forklift truck under the front and the back panels of the boiler ( Fig. 8). Slowly lift the boiler with the forklift truck. Fig. 9 Moving the boiler with two pallet trucks ITL Logano plus SB (2013/07) 15

16 5 Installation 5 Installation For the installation and operation of the heating system, observe all country-specific standards, guidelines and local regulations. The information on the data plate is binding and must be observed Siting the boiler DANGER: Risk to life through poisoning! Insufficient ventilation can lead to dangerous flue gas leaks! Never close off or reduce the size of ventilation and extract air vents. Never operate the boiler unless faults are rectified immediately. Inform the operator in writing of any faults and their associated risks. DANGER: Risk of fire through flammable materials or liquids. Never store flammable materials or liquids in the immediate vicinity of the heat source. NOTICE: System damage due to frost! Install the heating system in a room protected from the risk of frost. Installation room requirements: The support surface must be solid and sufficient to bear the load. The installation room must be dry and free from the risk of freezing. The size of the installation room must be adequate to ensure correct operation. Minimum wall clearances Observe the specified minimum wall clearances for the foundations or installation surface ( Fig. 10, and Tab. 12, page 16). The surface on which the boiler is to be positioned must be sufficient to bear the load, even and level. The front edge of the boiler should be flush with the edge of the plinth. The combustion chamber door can be fitted to open from right to left or vice-versa ( chapter 5.10 from page 23). Allow extra space if a flue gas silencer or a control unit are to be installed on the side of the boiler. If separation between the installation site and the boiler is required to prevent the transfer of structure-borne noise, apply anti-vibration measures (e.g. anti-vibration supports) before installing the boiler. Fig. 10 Installation room (for dimensions see Tab. 12), dimensions in mm [ 1) ] In addition to the burner length, take dimension A2 into consideration when installing the burner. [ 2) ] If using a flue gas silencer, take its installation dimensions into account. [ 3) ] When using a side-mounted control unit holder. [ 4) ] Take account of burner dimensions. It is advantageous if there is a drain close to the installation location. Recommended (and minimum) wall clearances mm Boiler size Clearance Clearance Length Width kw 1) 2) A 1 A (460) 1700 (1200) (460) 1700 (1200) (500) 1700 (1200) (500) 1700 (1200) (1600) (700) (700) Table 12 Wall clearances 1750 (1250) 2000 (1500) 2000 (1500) Width/ Height L B Handling / / / / / / /1730 1) If using a flue gas silencer, take its installation dimensions into account. 2) In addition to the burner length, take dimension A2 into consideration when installing the burner ITL 16 Logano plus SB (2013/07)

17 Installation Levelling the boiler Use metal shims to level the boiler. To prevent air collecting in the boiler, level the boiler horizontally. To do this, place a spirit level on the boiler shell. Level the boiler horizontally using the spirit level. Close off the cut-out for the low water indicator [1] with two spring hooks [3] ( Fig. 13). Undo the door bolts [2] and open the combustion chamber door ( Fig. 12). Place the lower front thermal insulation section on the front of the boiler shell and secure to the right and the left onto the wrap-around thermal insulation mat with (two spring hooks on each side [3] ( Fig. 13). Position the thermal insulation strip [2] at the top around the boiler shell ring, and secure to the right and the left onto the lower front insulation section with two spring hooks on each side [3] ( Fig. 13). Place the upper front insulation section on the front of the boiler body. Fig. 11 Levelling the boiler ITL 5.3 Fitting the thermal insulation WARNING: Risk of injury through combustion chamber door falling off when opened! Make sure that both hinge pins ( Fig. 12, [1]) are inserted. When fitting the insulation, ensure that the fabric side of the insulation sheet is arranged on the outside and the cut-outs at the rear. Slide the thermal insulation mat underneath the boiler. Fig. 13 Fitting and fastening the lagging [1] Connection for low water indicator [2] Strip of lagging material [3] Springs Be aware of cut-outs for hinge pins and threaded sleeves when fitting the combustion chamber door. Close the combustion chamber door and secure with door bolts [2] ( Fig. 12, page 17) ITL Fig. 12 Sliding the thermal insulation mat underneath the boiler [1] Hinge pin [2] Door bolts Wrap thermal insulation mats around the boiler shell so that they overlap and fix at the top with 5 spring hooks [3] ( Fig. 13). Logano plus SB (2013/07) 17