Instructions for High Altitude Conversion
Contents
1. Fig 10 Correct pilot flame setting 1 1 2to 1 1 2 inches 2 Pilot flame oe by Fig 11 Main burner 1 Main burner flame We reserve the right to make any changes due to technical modifications 12 Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 25 26 27 28 29 30 31 33 Turn gas valve ON OFF button clockwise to OFF position Close main gas valve Disconnect heating system from the power supply and set the thermostat to the lowest setting Remove pressure measuring nipple and pressure gauge for measuring gas supply pressure and manifold pressure from the gas valve and close the openings with the screw plugs Repeat steps 1 to 10 depending on the control and 20 to restart the heating system Check the screw plugs for leaks with soap solution If no leaks are found continue with step 31 If leaks are found close gas valve and switch ON OFF button on gas valve clockwise to the OFF position Disconnect the heating system from the power supply Seal leaks Open gas valve and repeat step 24 Carefully wipe away the soap solution to prevent corrosion caused by the alkali content of the soap Check the function of the maximum aquastat to make sure that it switches off the boiler as soon as the boiler water temperature set at the aquastat or the Logamatic 2107 control is reached Record the result in the commissionin2. 2 0000 ee ee es 3 Scope OF delivery 84 kd Berk ae ee he Be eee EES 3 Conversion of the boiler at altitudes over 8500 feet 4 Start up instructions 0 0 0 00 cc eee 8 4 1 Making boiler ready for operation 0 02 ee ee 9 4 2 Then carry out start up procedures s on ee 10 Buderus We reserve the right to make any changes due to technical modifications 2 Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 1 Safety Observe these instructions for your safety 1 1 Correct use The conversion kit is for conversion of the G334 X gas fired boiler for operation at altitudes above 8500 feet 1 2 Notes structure Additional symbols for identification of dangers and user instructions WARNING WARNING We reserve the right to make any changes due to technical modifications RISK TO LIFE Identifies possible dangers emanating from a product which might lead to serious injury or death if appropriate care is not taken RISK TO LIFE from electric shock USER NOTE Tip for the optimum utilization and setting of the control s plus other useful information 1 3 Please observe these notes WARNING WARNING RISK TO LIFE from explosion of flammable gases Never work on gas lines unless you are licensed for this type of work RISK TO LIFE from electric shock Disconnect the power supply to the heating system b
3. 13 Check manifold pressure The manifold pressure must be set in accordance with the values in gt Tab 3 To set the manifold pressure the cover gt Fig 9 on the gas valve must be removed Turn the adjustment screw clockwise to increase the pressure and counterclockwise to reduce the pressure This setting must be adjusted while the boiler is operating 14 Record the set value in the commissioning protocol of the installation and maintenance instructions and screw the safety screw gt Fig 9 page 11 into the gas valve again We reserve the right to make any changes due to technical modifications Buderus Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 11 15 Observe pilot flame through the sight glass gt Fig 8 page 10 in the burner housing 16 The flame must envelope the flame guard 1 2 to 1 1 2 inches If this is the case continue with step 20 17 If the pilot flame is too small or too large the pressure for the pilot burner must be adjusted with the corresponding adjustment screw USER NOTE i The adjustment screw is behind the pilot burner pressure adjustment safety screw gt Fig 9 page 11 18 Remove safety screw for pilot burner pressure setting gt Fig 9 page 11 Turn the inner adjustment screw clockwise to reduce the pilot flame and counterclockwise to enlarge the pilot flame 19 After adjustment tighten the pilot burner pressure ad
4. burner does not ignite close the gas valve Disconnect heating system from the power supply and inform your customer service technician or gas company 10 If the main burner has ignited the gas valve must be checked for leaks with soap solution If no leaks are 1 found continue with step 12 If leaks have been found switch ON OFF switch on gas valve clockwise to the OFF position Disconnect heating system from the power supply and set the thermostat to the lowest setting 11 Seal leaks Repeat steps 1 and 2 regardless of the control in use Caution With aquastat control continue with steps 3 and 4 with the Logamatic 2107 continue with steps 5 and 6 Then repeat steps 7 to 10 regardless of the control in use Fig 9 Gas valve 1 ON OFF button at ON position Screw plug for gas supply pressure measuring port Safety screw for manifold pressure setting Screw plug for manifold pressure measuring port Safety screw for igniter pilot burner setting QA RO ND 12 Check the gas supply pressure at the connection while the boiler is operating The connection pressure for natural gas must be between 7 and 10 5 W C and between 11 and 13 W C for propane gas Record the measured values in the commissioning protocol in the installation and maintenance instructions Natural gas Propane Eo inch a Haan 73 4 4 10 4 92 4 4 10 3 116 4 1 10 3 132 4 2 10 2 Tab 3 Manifold pressure
5. 6304 2382 2012 11 US CA For heating engineers Instructions for High Altitude Conversion Logano G334 X gas fired boiler This conversion kit and the accompanying instructions are for conversion of G334 X gas fired boilers for operation at altitudes above 8500 feet Required Sealevel Input Rates of 0 8500 feet G334 X 73 G334 X 92 G334 X 116 G334 X 132 301 MBtu hr 387 MBtu hr 476 MBtu hr 541 MBtu hr WARNING This conversion kit is intended for use by a qualified service company only as specified by the manufacturer s instructions and the current applicable rules and regulations of the local authorities and the regulations of NFPA54 CAN CGA B149 1 and 2 Installation Code must also be observed If these instructions are not followed exactly a fire explosion or release of carbon monoxide may occur with serious property damage or loss of life and serious injury The heating contractor is liable for correct conversion of the heating system with this conversion kit WARNING Please use the enclosed instructions for conversion from natural gas to propane Aart CERTIFIED www ahridirectory org Buderus Note Please keep these instructions for future reference Please read carefully before conversion V1 GCOMECLUSE s as i oo ee eee eed OA wR REE a ee ee Ae oe 3 1 2 Notes structures acs Ga ee deen ae eve Oke REE ee Oe ee ewe 3 1 3 Please observe these notes
6. crews Fig 3 page 5 between the gas valve and the burner again Make sure that the connection pipe gasket removed in step 8 is replaced Check gasket for damage and replace if damaged Attach connection lines for the flame roll out switch Remove wire or rope that was used to hold the gas supply line in step 7 Connect ignition gas line gt Fig 3 page 5 to the gas valve again Connect ignition cables gt Fig 3 page 5 to the automatic igniters Enter the required information on the conversion label and attach on the outside of the boiler jacket as close as possible to the name plate Buderus 6 Fig 4 Removing burner 1 Fixing nuts 2 Threaded studs We reserve the right to make any changes due to technical modifications Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 Carrying out leak test USER NOTE i The boiler has two gas valves Make all measurements and adjustments on both gas valves 22 Open gas valve in the gas line SYSTEM DAMAGE due to short circuit CAUTION Cover the hazardous locations before checking for leaks Do not spray the leak solution on wiring openings plugs or electrical connections Do not allow the solution to drip on these locations 23 Check the gas connection line to the gas valve for leaks with soap solution If no leaks are found continue with s
7. ed exactly a fire or explosion may be caused with serious property damage or loss of life or serious injury Observe the start up instructions DANGER OF EXPLOSION AN If you smell gas there is a danger of WARNING explosion No open flame No smoking Prevent spark formation Do not operate electrical switches including telephones plugs or door bells Shut off main gas supply valve Open doors and windows Warn other occupants of the building Evacuate the building Call gas company or fire department from outside the building A This unit is equipped with an igniter that automatically starts the pilot burner Do not attempt to ignite it manually B_ Check for an odor of gas around the heating system This test must also be conducted at floor level because some types of gas are heavier than air and may accumulate at floor level C Switch on the ON OFF switch on the gas valve 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 Contact a qualified technician Any attempt to use force or to repair the switch may cause a fire or explosion D Do not operate the unit if any part is under water Contact a qualified customer service technician immediately to have the unit checked and to replace the parts of the control and gas valves that were under water Buderus We reserve the right to make any changes due to tec
8. efore conducting any work on it e g switch off the heating emergency switch outside the boiler room Itis not sufficient just to switch off the control 2 Scope of delivery The conversion kit for high altitudes includes the following components main gas orifices and seals conversion date label to be filled out and attached to the unit conversion instructions Technical documents Buderus Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 3 3 Conversion of the boiler at altitudes over 8500 feet Read the instructions before conversion for your safety RISK TO LIFE A due to not observing the attached conversion instructions WARNING f you wish to convert the boiler for operation with propane the conversion from natural gas to propane must be carried out first as specified by the attached conversion instructions The conversion for high altitudes can only be made after this When converting the boiler for operation at high altitudes observe the following directions The boiler must be converted before installation 1 Ifthe boiler has been operating close the gas valve Otherwise continue with step 3 2 Disconnect heating system from the power supply and set the thermostat to the lowest setting 3 Remove safety screws from the left and right side panels then lift the front panel of the boiler and pull it forward Buderu
9. g protocol of the installation and maintenance instructions Replace front panel of boiler With the Logamatic 2107 control only 34 We reserve the right to make any changes due to technical modifications Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 Select AUT automatic mode with the mode selection switch Fig 12 Gas valve 1 ON OFF button at OFF position Buderus 13 Buderus We reserve the right to make any changes due to technical modifications 14 Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 We reserve the right to make any changes due to technical modifications Buderus Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 15 United States and Canada Bosch Thermotechnology Corp 50 Wentworth Avenue Londonderry NH 03053 Tel 603 552 1100 Fax 603 965 7581 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 Buderus
10. hnical modifications 8 Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 4 1 Making boiler ready for operation STOP First read the safety instructions on gt page 8 of this manual 1 Carry out leak test gt page 7 Wait five 5 minutes until all gas residues have dissipated Finally check whether there is any smell of gas including at floor level If there is a gas odor STOP Follow instructions in section B of the safety instructions on gt page 8 of this manual If there is no sign of a gas odor continue with the next step 2 Open main gas valve 4 1 1 Placing heating system with aquastat control in operation The boiler is fully functional with the factory installed aquastat 3 Switch on ON OFF switch building side ON position This switches on the boiler with all its components Then continue with step 7 4 Make sure that the room thermostat signals a heat requirement set thermostat at least 10 F above room temperature ON Jj i OFF wa Fig 6 Switching on heating system with aquastat 1 ON OFF switch main switch We reserve the right to make any changes due to technical modifications Buderus Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 9 4 1 2 Placing heating system with Logamatic 2107 accessory in operation The boiler is fully functional with the factory installed aquas
11. ifications Fig 2 Gas valve Unscrew retaining screws of gas feed line at burner Fig 3 Front view Ignition cable Flame roll out switch Connection lines to the gas valve Gas valve Connection lines to the flame roll out switch Gas supply line Retaining screw on the gas feed line Pilot gas line AN OAGAA WH Buderus Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 5 11 12 13 Unscrew retaining nuts on burner plate and pull gas burner straight out When removing the burner make sure that the spacers remain on the studs Install the new main gas orifices and copper gasket Check with gt Tab 1 and gt Tab 2 to ensure that the correct orifices for operation of the boiler are installed Orifice sizes for natural gas Altitude in feet Model 0 8500 8501 12000 G334 X 73 3 60 3 55 G334 X 92 3 70 3 65 G334 X 116 3 90 3 85 G334 X 132 3 90 3 85 Tab 1 Orifice size for natural gas Orifice sizes for propane Altitude in feet Model 0 8500 8501 12000 G334 X 73 2 35 2 30 G334 X 92 2 40 2 35 G334 X 116 2 50 2 45 G334 X 132 2 50 2 45 Tab 2 Orifice size for propane 14 15 16 17 18 19 20 21 Install gas burners in boiler in reverse order of removal Tighten the fixing nuts well Tighten the s
12. justment safety screw gt Fig 9 page 11 again 20 Observe main burner flame through the sight glass gt Fig 8 page 10 in the burner housing 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 gt Fig 9 page 11 on the gas valve clockwise to OFF Close the gas valve and disconnect the heating system from the power supply and contact the customer service technician or the gas company Checking ignition safety switch 21 Test the safety switch by closing the gas valve The main burner flame gt Fig 11 and the pilot flame gt Fig 10 are extinguished After six 6 seconds at the most the main gas solenoid valve on the gas valve must close with an audible noise 22 After 90 seconds the automatic igniter must switch to lock status and stop generating sparks 23 Disconnect the heating system from the power supply Open main gas valve Switch on unit power supply A normal operating cycle must follow 24 If the gas valve operates correctly proceed to step 25 If the gas valve does not operate correctly switch ON OFF switch Fig 12 on the gas valve clockwise to the OFF position immediately Close main gas valve Disconnect heating system from the power supply and inform the customer service technician or gas company Buderus
13. s 4 Fig 1 Removing front panel of boiler 1 Screws 2 Boiler front panel We reserve the right to make any changes due to technical modifications Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 4 Turn gas valve ON OFF button clockwise to OFF position Do not use force RISK TO LIFE A from explosion of flammable gases WARNING Wait five 5 minutes until all gas residues have dissipated Check whether there is any smell of gas including at floor level If there is a gas odor STOP Follow instructions in section B of the safety instructions on page 8 If there is no sign of a gas odor continue with the next step Replacing main gas orifices USER NOTE When converting the boiler for high altitudes it is only necessary to replace the main gas orifices not the pilot gas orifice Disconnect pilot gas line from gas valve Disconnect ignition cable from automatic ignition Tie gas line with wire or cord secure o Nop Place the gas connection pipe gasket in a safe place 9 Check gasket for damage and replace if damaged RISK TO LIFE due to incorrectly connected wiring WARNING When conducting maintenance work label all cables before disconnecting them 10 Label connection lines of flame roll out switch and disconnect from the flame roll out switch We reserve the right to make any changes due to technical mod
14. tat The Logamatic 2107 control can also be installed in addition to the factory installed aquastat Switch on the heating system with the ON OFF switch on the control The burner starts operating if heat is required gt observe control service manual 5 Make sure that heat is required at the control Select Manual operation hand symbol with the mode selector switch 6 Switch on ON OFF switch I position Then continue with step 7 USER NOTE i After carrying out the instructions for starting described below the control must be set to AUT mode automatic operation with the mode selector Fig 7 Switching on heating system with Logamatic 2107 control 1 Mode selection switch 2 ON OFF switch 4 2 Then carry out start up procedures The following start up procedures must be carried out regardless of the control type 7 Look at the igniter through the sight glass in the burner housing 1 Fig 8 Front view 1 Sight glass Buderus We reserve the right to make any changes due to technical modifications 10 Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 8 Turn gas valve ON OFF switch counterclockwise to ON position 9 The automatic igniter must generate sparks towards the pilot burner The pilot flame must appear and then ignite the main burner If the main
15. tep 25 If any leaks are found close gas valve 24 Seal leaks and repeat step 23 25 Close main gas valve Remove the screw plug for the gas connection port on the gas valve Install pressure measuring nipple and attach a pressure gauge to measure the gas pressure 26 Remove the screw plug for the manifold pressure port on the gas valve Install pressure measuring nipple and attach a pressure gauge to measure the manifold pressure 27 Open gas valve and measure the gas pressure of the boiler The supply pressure for natural gas must be between 7 and 10 5 W C and between 11 and 13 W C for propane gas If the supply pressure for natural gas is not between 7 and 10 5 W C and not between 11 and 13 W C for propane gas contact the customer service technician or the gas company Fig 5 Gas valve 28 Always follow the start up instructions on the next 1 ON OFF button at ON position age pag 2 Screw plug for gas supply pressure measuring port 3 Screw plug for manifold pressure measuring port We reserve the right to make any changes due to technical modifications Buderus Conversion instructions for G334 X gas fired boiler conversion kit High altitudes Issue 2012 11 7 4 Start up instructions Read the instructions before start up for your safety RISK TO LIFE A due to not observing the start up WARNING instructions and resulting incorrect operation lf these instructions are not follow
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