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CAUTION! Observe the safety instructions of this installation and maintenance manual before placing the boiler in operation. 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 directions of this installation and maintenance manual must be followed precisely. Contact a qualified service company, service provider or the gas company if support or additional information is required. CAUTION! The operating manual is a component of the technical documentation and must be handed over to the operator of the heating system. Discuss the instruction in this manual with the owner or operator of the heating system to ensure that they are familiar with all information required for operation of the heating system. NOTICE! In the Commonwealth of Massachusetts this appliance must be installed by a licensed plumber or gas fitter. Logano plus GB312 _ #$ % &$ '$ GB312 Applications Manual !!" _ GB312 Applications Manual Table of Contents 1 Product description 1.1 Package contents 1.2 Dimensions and specifications 2 Installing the boiler 2.1 Recommended wall clearances 2.2 Leveling the boiler 3 Water quality requirements 3.1 3.2 3.3 3.4 Maintenance of user manual Prevention of damage by corrosion Water hardness Checking max quantity of first fill water based on water quality 3.5 pH requirements 3.6 Operator’s log 4 Openings for combustion air supply & venting 4 7 6 7 CSD-1 Kit 7.1 Operating Addendum for the GB312 in High Temperature Applications 33 10 8 Internal boiler wiring diagram 34 10 11 9 MC10 wiring diagram 12 10 Sequence of operations 12 12 13 13 13 15 11 High altitude adjustment 11.1 General 11.2 Adjustments 11.3 CO² adjustment of the burner / adjustment of the gas valve 11.4 Setting for speed of burner fan 5.1 5.2 5.3 5.4 Connecting the air supply (for direct vent operations) Installing the wall exit for air supply pipe Installing the roof exit for air pipe Design of flue and air pipe for balanced flue operation (refer to NFPA54 ANSIZ223.1 for dimensions) 5.5 Venting system calculation/sizing chart 6 Piping the boiler 6.1 6.2 6.3 6.4. 6.5 6.6 Connecting central heating supply Fitting the heating system return Installing the DHW Tank Installing the condensate drain Connecting the fuel supply Pipe sizing 35 36 37 37 37 37 40 16 12 Examples of installations 5 Venting requirements 31 17 19 19 20 21 22 12.1 Legend 12.2 Single boiler systems 12.3 Multiple boiler systems 42 42 43 49 13 Pump and low loss header selection 57 13.1 Pump & low loss header (hydro-separator) selection 13.2 Low loss header selection per manufacturer 57 58 26 26 26 26 26 27 29 !!"#$ % &$ '$ _ GB312 Applications Manual 1 Product description #$ ( '$) )*% *'+! 10 11 7 747 010 720-01.2RS Fig. 1 1 2 3 4 5 6 7 8 9 10 11 Logano plus GB312 - main components Programmer (MC10 and BC10) Gas burner Boiler front panel Trap Boiler heat exchanger with insulation Burner control unit Gas valve Boiler outer casing B-kit with flow check valve (supplied as standard, not factory installed) Gas isolating valve (supplied as standard, not factory installed) Mating flange, 2½" (included in B-kit, not factory installed) #$ )$ ( , -./0 -( /01 -$2$ '$ /03 - /0 -*4 *4 5 6)776 )6 8 )8'5 6 ) - 77/0! #$ #$$2$ )$$ $ $$ ' #$$ $ #$ % &$ '$ !!" _ GB312 Applications Manual 2 1 Fig. 2 1 2 3 4 5 6 7 8 9 10 11 12 3 4 12 11 10 5 9 6 8 7 7 747 010 720-85.1RS Logamatic BC10 basic programmer - controls On/off switch Dial for DHW set point “DHW heating” LED Status display screen Control knob for maximum boiler temperature “Heat demand” LED Base plate with slot for a programming unit e.g. RC35 (available : Fall 2008) (behind the cover panel) “Burner” LED (ON/OFF) Socket for connecting diagnostic plug “Status display” button “Flue gas test” button “Reset” button +!( #$ * +! )$$ 07) $$ )' )$, -# $$ 5)) -9 $:;< $2 $ -9 = 7)$ )$+! )( $) )$ 7 ) $ 7'$ $$>+3? ?#$>+3 6' 7 !!"#$ % &$ '$ _ GB312 Applications Manual 1.1 Package contents #$ '$+! +! @= 76$4$$4 @+$4$4 @:)4 7 AAA Component Boiler (fully assembled with outer casing, Logamatic MC10 programming unit, BC10 and gas isolating valve) Technical documentation Packaging 1 box on a pallet Set of adjustable feet 1 foil package 1 foil package B-kit (temperature/pressure gauge, 1 box pressure relief valve, supply connector, flow/return mating flange, check valve) #$ % &$ '$ !!" _ GB312 Applications Manual 1.2 Dimensions and specifications 1.2.1 Logano plus GB312 dimensions 59¾'' 55⅛'' 8½'' 28¼'' TM 45'' 40⅛'' 24¼'' 8.7'' 4 '' ⅝ - 1'' 1⅜" 19½'' 8½' RK 7 747 010 720-02.3RS Fig. 3 Connections and dimensions for Logano plus GB312 (sizes in inches) AA AL = Flue connection = Combustion air pipe connection (balanced flue operation only) VK = Boiler supply AKO = Condensate outlet GAS = Gas connection + main isolating valve ST = Pressure relief valve connection RK = Boiler return TM = Pressure/temperature gauge Boiler size (output - no. of heat exchanger sections) Model Width B Inches 39⅛ Dimension XAA Inches 13⅛ 15⅛ 17¼ 19¼ Dimension XRK (= XAL = XGAS) Inches 10⅝ 14¾ 10⅝ 14¾ Dimension F Inches 31½ Dimension A Inches 5 1½ AA = Flue pipe diameter Inches Flue adaptor for desired manufacturer's flue system 90 - 4 120 - 4 160 - 5 200 - 6 240 - 7 47⅜ 39¾ 21⅜ 10⅝ 48 5 1½ 6⅜ 8 6 ⅜" x 6 " 6 ⅜" x 5 " 8" x 8 " Dimension YAA Inches 1 8½ 1 9½ Dimension ZAA Inches 5¾ 12 ¼ AL = Diameter of combustion air pipe (balanced flue only) Inches Connections VK and RK 280 - 8 55½ 4 (Use rubber plumbing adapter to connect) 2½" NPT Tab. 1 Dimensions and connection sizes !!"#$ % &$ '$ _ GB312 Boiler size (output - no. of heat exchanger sections) Model 90 - 4 120 - 4 Connection ST (B-kit) 160 - 5 Applications Manual 200 - 6 240 - 7 280 - 8 ¾ " NP T Diameter GAS 1 " NP T 1 " NP T 1 ¼ " NP T Tab. 1 Dimensions and connection sizes 1.2.2 Specifications Observe all standards and guidelines applicable to the installation and operation of the heating system in your country. The information on the boiler rating plate is definitive and it is imperative that it is observed. Boiler size (output - no. of heat exchanger sections) Model 90 - 4 120 - 4 160 - 5 200 - 6 240 - 7 280 - 8 Natural gas I-B-R Input max. load Btu/hr 328,300 440,500 588,300 732,600 880,700 1,028,800 min. load Btu/hr 132,150 132,000 176,000 220,000 264,000 309,000 I-B-R gross output 180/80 ° F max. load Btu/hr 305,000 409,000 544,000 676,000 810,000 944,000 I-B-R net rating 180/80 ° F max. load Btu/hr 265,000 356,000 473,000 588,000 704,000 821,000 Rated heat input 122/86 ° F max. load Btu/hr 307,090 409,460 545,940 682,430 818,910 955,400 (50/30 ° C) min. load Btu/hr 128,050 171,190 212,310 255,220 Flue gas mass flow rate 180/80 ° F max. load lb/min 4.85 6.53 9.14 11.40 13.88 16.15 Flue gas mass flow rate 122/86 ° F max. load lb/min 5.05 7.12 9.29 11.61 14.02 16.65 Flue gas temperature 180/80 ° F max. load °F 83 90 127 138 140 134 Flue gas temperature 122/86 ° F CO2 content, natural gas max. load max. load °F 120 133 129 131 131 135 min. load Available flue pressure (flue draft + air supply pressure) Air supply volumetric flow rate 127,390 fm % 9.1 in. W.C. 0.4 (100 Pa) cfm 95 95 130 Blower 160 298,140 190 220 G1G 170 Honeywell gas valve V4730C1071 V4730C10 63 V4730C1097 Gas injector diameter Natural gas calorific value 1075 BTU/ft3 17.0 mm Heating water circuit Boiler water capacity US gallons Primary pressure drop psi Maximum flow temperature, heating/hot water mode (at full output) °F 180/180 High temperature cut-out safety limit (manual reset high limit setting ) °F 200 4.2 4.2 5.3 6.3 7.1 7.9 240 - 7 280 - 8 Fig. 4 (graph) Boiler size (output - no. of heat exchanger sections) Unit Permissible operating pressure psi 50 V/Hz 120 V / 60 Hz 90 - 4 120 - 4 160 - 5 200 - 6 Electrical data Enclosure class IP 40 Mains power supply Power consumption max. load W 84 150 190 230 270 370 min. load W 40 40 45 50 50 50 Maximum permissible fuse rating A 10 (slow blow) Appliance dimensions and weight Transport clearance dimensions, width x depth x height Weight Inches 34x25x60 lbs 455 42x25x60 530 50x25x60 585 665 730 Tab. 2 Specifications #$ % &$ '$ !!" _ GB312 Applications Manual 100 90-4 10 120-4 160-5 200-6 240-7 1 280-8 y 0,1 1 10 100 1000 x 7 747 010 720-30.1RS Fig. 4 x y Primary circuit flow resistance, GB312 with check valve Flow rate in gal/min (GPM) Primary pressure drop in psi Boiler rating Gas flow rate Natural gas Calorific value 1075 BTU/ft 3 cu ft/hr 90 - 4 120 - 4 3 2 4 .6 434.4 160 - 5 5 7 9 .0 200 - 6 720.6 720.6 240 - 7 8 6 8 .8 280 - 8 1013.4 Tab. 3 Gas flow rate (based on gas temperature of 60 °F and air pressure of 30 in. Hg) The boiler is factory-set for: – Natural gas Note: • #$) 7). J. • #$ %%47 7 $. !!"#$ % &$ '$ _ GB312 Applications Manual 2 Installing the boiler 2.1 Recommended wall clearances <$ $ 6$ ) $8 $ 7( " 9 3 6 + $ 8 ' Dimension A B 1) C D E 1) Wall clearance (inch) Recomminimum mended 20 28 28 22 20 28 20 28 6 14 D E B Tab. 4 Recommended and minimum wall clearances (dimensions in inches). It is imperative that the minimum clearance (dimension E) is maintained. C A 1) This clearance dimension is dependent on the flue system fitted Where applicable, allow extra wall clearances for additional components such as DHW tank, pipe connections or other flue components, etc. 7 747 010 720-09.1RS Fig. 5 Wall clearances in the boiler room Notes: (multiple boiler installations) A. ' @>)K:L ) @>)KL MNM )44 B. 9#O)$ #$ % &$ '$ !!" _ GB312 Applications Manual 2.2 Leveling the boiler #7 $ '$ ))$ 6$ 7 Caution: Risk of boiler damage due to inadequate load-bearing capacity of floor or unsuitable base. • Make sure that the surface on which the boiler stands has sufficient load-bearing capacity. • The boiler may stand on a base made of combustible material but not on carpet. • Place the boiler in its final position. • Level the boiler horizontally by turning the adjustable feet and using a spirit level. 7 747 010 720-10.1RS Fig. 6 Leveling the boiler 1 2 Adjustable feet Spirit level !!"#$ % &$ '$ _ GB312 Applications Manual 3 Water quality requirements .'J $ ) About this chapter: #$P ) $ )') #$ $'$'4)' 02 '$$) 2$' 4$ $% 4 $ )$$ #$P )$' J%$ 6'$-)$ 2 -4 '$$ 3.2 Prevention of damage by corrosion Additional protection against corrosion + )2 $ $ '6)26, - S2 7 -)2 7 - *7 0)$ 6 * $ )$2$ Warranty claims in respect of GB312 boilers are only valid in conjunction with the requirements specified herein and properly completed annual service records in the operator’s log and the servicing and maintenance log. USER NOTE • If the appliance is installed in an existing heating system, dirt may accumulate in the boiler, leading to localized overheating, corrosion and noise. • Alway install a WYE-STRAINER in existing heating systems. 3.1 Maintenance of user manual 0 $J )%*% $ ' $6$ Q++=R $ $ 493 0 4 <TN* 7J #$ $$ $7 )$6 ' $ $' $ )$6 7 7 Pump PK Fig. 7 WYE Strainer location 1 #$ % &$ '$ WYE Strainer !!" _ GB312 Applications Manual 3.3 Water hardness U '%$ 0 $ 7 7) *) 6$ )*) $%*% $ ' $$ 3.4 Checking the maximum quantity of first-fill water based on water quality USER NOTE If the system capacity exceeds the calculated allowable water volume Vmax, damage to the boiler can result. #$4$'J ' J6$$)' $ $$ N2 , + )$2J )%*% $ '6V26)$ '$ )"336O!!5$S1!-1 <$ %J ++= Z=W"336O!!5$ ; ++!W1! 2'7V2 Vmax = 0.0243 x Calculation basis #$%*% $ '$ J $ $ $ 7)' $$ * U$)' )$2 J )%'$ '$ , Vmax (ft3)= 0.0243 × QOut CaCO3 280 ppm Boiler size (Btu/h) (ppm) Tab. 5 Formula for calculating the maximum quantity of (untreated) water that may be introduced 955,400 Btu/h = 83 ft3 Boiler output Qout [Btu/h] 122/86°F 90-4 307,090 120-4 409,460 160-5 545,940 200-6 682,430 240-7 818,910 280-8 955,400 Boiler output 3.5 pH requirements V2W27) %*% $ ' )X$ $7$ 7))$ )XWY O1 @#$ );)$)Y ! 1 3 Z=W# 5$# @('7$' $ $2$ ++=W+ $ W5 0 ) $ ++=6$* )$ ' )' @;$4 $ 4$' 7 @& ;)) Y !;1 3; *($'$)$ '6 $ ) $ $4; => *>$.4"$7) ).4"3 )7 !!"#$ % &$ '$ _ GB312 Applications Manual Vmax [gallon] Limit curves 7 6$V2% 4 )$)' $ 2000 1900 1800 1700 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 0 50 100 150 200 250 300 350 hardness (CaCO3) [ppm] or [mg/l] Fig. 2 400 450 500 550 7 747 010 722-01.1RS Water treatment limit curv es for the various boiler sizes The rule for V max is: Above the limit curve = water treatment necessary Below the limit curve = no water treatment necessary (Units: 1ft 3 = 7.48 gallon, 1ppm = 1mg/l, 1 grain/gal = 17.1 pm or mg/l) USER NOTE Any additives introduced into the heating system water must be approved by the manufacturer for use with aluminum boilers. When is water treatment necessary? @0)$J )%' $ V26 ' @0)$J )%' $ V26' @#$ )6$'77 + >$>$ $ )S #$ $ ) $%' 3!g h!g7 @: ') 2$ 2$ ) ' #$ % &$ '$ !!" _ GB312 Applications Manual 3.6 Operator’s log Details of GB312 heating system: _________________________________________________________________ Date commissioned:__________________________________________________________________________ Max. water volume Vmax: __________ gal at CaCO3 concentration of ___________ ppm Anti freeze product used? Date Rhomar Rho Gard (50-60% Concentration): Water volume unthreated (measured) gal Noble Company Noburst AL (50% Concentration): CaCO3Total Concentration of anticoncentrati- water volume freeze in system % on ppm unthreated gal Company (stamp) Signature Total fill water in gal Added water in gal !!"#$ % &$ '$ _ GB312 Applications Manual 4 Openings for combustion air supply and venting # J 7 )$$ 64 '$$ (+6(.3O 90i 69 3 6)+ V * 6$ 0 + $ '$+5+9O" 0 + Caution: Risk of boiler damage and malfunctions due to missing or inadequate openings for combustion air and venting of the boiler room. The openings for combustion air supply and venting are always required regardless of whether the combustion air is drawn from the room (conventional flue) or supplied directly to the boiler through ducts (balanced flue). Inadequate venting of the boiler room may result in excessive ambient temperatures. This can damage the boiler. Inadequate combustion air supply may cause malfunctions in operation. • Make sure that air inlet or outlet vents are not closed off or their size reduced and that they are adequately dimensioned. • The boiler must not be operated until the obstruction has been removed. • Draw the operator's attention to any deficiencies and the potential dangers. Caution: Risk of boiler damage from contaminated combustion air. • Never use cleaning agents that contain chlorine or halogenated hydrocarbons (e.g. in spray cans, solvents and cleaning agents, paints, glues). • Do not store or use such substances in the boiler room. • Avoid excessive dust accumulation. If impurities in the combustion air are possible (e.g. installation near swimming pools, dry cleaners or hairdressing salons), operation independent of room air is recommended. #$ % &$ '$ Caution: Dangers posed by explosive and easily combustible materials. • Do not use or store easily combustible materials (paper, lace curtains, clothing, thinners, paints, etc.) near the boiler. • Maintain a clearance of 16 inches from the boiler. Overall air supply within the building 4$$$' 7 $ $ <$ $* )$7 6$ )*% $ 4 N$7 $7 * ) J $!!!5$)$ )*% $ 4$$* )$7 !!J $ = )$7 $ L)$ $$ $ L)$8)$6)$ )$7 #$ ) 7 $ L Total air supply from outside the building 4$$$' 7 6 )'$$ $ L)$ $$ $ L)$8) $6)$)$7 #$7 $ 7$$$7 * $ ') #$ ) 7 $ L -0)$ $6$ $7 * ) J $O!!!5$)$ )*% $ -0)$ $$$7 '$77 6$7 $7 * ) J $O!!!5$)$ )*% $ #$ 7 $ )$$ -0)$ $$$$S 7 6$7 $7 * ) J $!!! 5$)$ )*% $ #$ $ $))$ -0)$ $$$7 7 '6$ $7 * ) J $ O!!!5$ #$7 $ )$$ !!" _ GB312 Applications Manual 5 Venting requirements #$$$' $ #$, -N2$ -; -+ $) -4 $ General notes #$J87)+ 0V 67j90i 5 +9O " #$ )h"*O+ )UY1U! 0 + 68 )U+*hh < )$)' ), 6WDLQOHVVVWHHOȺXHV\VWHPIRU86$DQG&DQDGD7DEOH Manufacturer Flue System Heatfab Saf-T Vent EZ Seal AL29-4C Starter Adapter Part No. GB312/90 to GB312/160 = 9601GB ADAPTER (6" nominal size) GB312/200 to GB312/280 = 9801GB ADAPTER (8" nominal size) Z-Flex Z-Vent IV special gas vent GB312/90 to GB312/160 = 2SVSGBA06 (6" nominal size) GB312/200 to GB312/280 = 2SVSGBA08 (8" nominal size) Metal Fab Corr Gaurd GB312/90 to GB312/160 = 6CFGBA (6" nominal size) GB312/200 to GB312/280 = 8CFGBA (8" nominal size) Pro-Tech Fasnseal Security Chimney CI-System GB312/90 to GB312/160 = FSA-GB312-6 (6" nominal size) GB312/200 to GB312/280 = FSA-GB312-8 (8" nominal size) GB312/90 to GB312/160 = tbd (6" nominal size) GB312/200 to GB312/280 = tbd (8" nominal size) &39&ȺXHV\VWHPIRU86$RQO\7DEOH CPVC Manufacturer Specification Manufacturer CPVC Starter Adapter Part No. Spears CPVC pipe to Heatfab GB312/90 to GB312/160 = 96GBCPVC ADAPTER (6" nominal size) Schedule 80 ASTM D1784 GB312/200 to GB312/280 = 98GBCPVC ADAPTER (8" nominal size) Z-Flex GB312/90 to GB312/160 = 2SVSGBP06 (6" nominal size) GB312/200 to GB312/280 = 2SVSGBP08 (8" nominal size) Metal Fab GB312/90 to GB312/160 = 6CGBPA (6" nominal size) GB312/200 to GB312/280 = 8CGBPA (8" nominal size) Pro-Tech GB312/90 to GB312/160 = FSA-GB312-6-PVCF (6" nominal size) GB312/200 to GB312/280 = FSA-GB312-8-PVCF (8" nominal size) Security Chimney GB312/90 to GB312/160 = tbd (6" nominal size) GB312/200 to GB312/280 = tbd (8" nominal size) Note:. $ )7 0)+.V+ + 6 7K;7 LU+9hh #$ 6$7 $7 %$8 ) = 6$76$76 $ ) #$)' 87) + , &39&ȺXHV\VWHPIRU&DQDGD7DEOH Manufacturer Flue System IPEX* System 636 CPVC * This system is only available up to 4" size & only applies to GB312/90 for 55ft TEL or the GB312/120 for 30ft TEL. !!"#$ % &$ '$ _ GB312 (5 '$. !6V )NJ 6)$ (+ (.3O90i 6+9 O"$ #$8 ) ) 9 3 3 )2 )! O! $< + !!.)$ 72$ =7$)' '$ $8 , -#$* )$8 $ -9$$)$2$ -0 8'$ ')$ kL) < $% )7 $8 () 6 $7 ) 7 S )$7 All instructions relating to all parts of the flue system, and especially the instructions of the flue system manufacturer, must be followed. Use only flue pipes with the appropriate diameter for the output rating of the boiler and made by the recommended manufacturers listed in Table 6, 7 or 8. Flue system for multi-boiler systems (cascading systems) #$ * (5)* J%$ 7 $8 ) #$8 7 4*8')8$$ $ In the case of exhaust systems sealed with silicon from a cartridge, the slilicon must be allowed to cure for 24 hours before commissioning the boiler. Danger: Risk of fatal injury from escaping flue gases in the boiler room. • The seal in the condensate pan flue connection must be present, undamaged and correctly inserted. • Fitting a barometric damper in the flue system is not permitted. #$ % &$ '$ Applications Manual Caution: Risk of system damage due to inadequate condensate drainage. • The condensate that forms in the flue pipe must be drained away from the boiler via the condensate drain on the condensate pan. • Always use a condensate neutralizer. • Provide periodic maintenance to the condensate drain piping and neutralizer system to ensure proper operation. Caution: Risk of system damage due to inadequate condensate drainage. • In high temperature applications it is necessary to use mineral oil in the condensate trap to maintain a .trap seal so CO gases do not escape into the boiler room. Caution: Disruption of operation due to high wind. If no T-piece or 90° downward-turned elbow is fitted on the end of flue pipe, high winds may cause the boiler to shut down. • Always make sure that there is a T-piece or a 90° downward-turned elbow fitted depending on the design of the flue system. • Use only a T-piece or 90° downward-turned elbow Category IV) made by the selected flue system manufacturer. With regard to possible restrictions and inspections for flue systems, consult the local building and fire safety authorities. Observe the national regulations. In the Commonwealth of Massachusetts the legal requirements concerning the installation and maintenance of carbon monoxide detectors must be followed. Danger: Risk of fatal injury due to poisoning by escaping flue gas. • After carrying out any of the installation instructions referred to, check that all connections throughout the entire flue system are properly joined and sealed. • Check seams and joints for leaks. • Have the entire flue system checked once a year by a qualified heating contractor. !!" _ GB312 Applications Manual 5.1 Connecting the air supply (for direct vent operations) #$ $$$$ 2 ' 6$$$ 8 $$ $$ 8 ( 8 6 ).V++.V+67 S #$8 ) )8 9 h6 ) 2 )! O! $< + )$72$ We recommend that the air supply pipe diameter matches the flue pipe diameter. Boiler rating Required air supply volumetric flow rate Recommended air supply pipe diameter [ft 3/min] [inches] 90 - 4 95 5 120 - 4 95 6 160 - 5 130 6 200 - 6 160 8 240 - 7 190 8 280 - 8 220 8 Tab.9 10 Min 3 Min Fig. 10 Connecting the air supply for balanced flue operation 1 2 Screw Cover plate Use a 90° elbow for the combustion air inlet at the entrance to the boiler to avoid an interference with the gas connection. Air supply volumetric flow rate/Air supply pipe diameter @+ $"!l'$4 $$$ @+ $ $ J @)4 $ $6 S$' #"2 < $% )7 $ () 6 $ ) 1 2 Min @>7$ ) 7 @U '$7)$ 2 48"Max 5.2 Installing the wall exit for air supply pipe 3 3 4 #7 )2$6$2$ 4 )))$$ 7 ' 6 S 6$% )$6 $ )$8 * $ )$ * )) #$ ( ( h $ $ J)% 7 747 010 720-14.2RS Fig. 9 1 2 3 4 Vertical flue system Roof penetration Fire protection collar Fastening the flue pipe Flue pipe adaptor (available separately) !!"#$ % &$ '$ _ 5 GB312 1 Applications Manual 6 2 Contact vent pipe manufacturer for installation guidelines to support vertical lengths of pipe. 2 3 4 12 min Fig. 11 Design of air supply or exhaust pipe wall exit 1 2 3 4 5 6 Outer wall retaining plate Sealant T-piece or 4) 90° elbow 90° elbow - down turned Inner wall centering and retaining plate Tee termination (optional) Note: (2$ 6$ ) >)(.3O90 i ) 5.3 Installing the roof exit for air pipe #7 )86$8 4 )))$$7 ' 6 S 6$%) $6 $ )$8 $ )$ )) #$ $ $ J)% B 3 2 1 4 min A 4 min 7 747 010 720-16.3 Fig. 12 Design of air pipe roof exit 1 3 B T-piece or 2) 90° elbow Flue outlet Minimum horizontal distance from air intake of another appliance = 10 ft, minimum distance from own air intake for directly vented appliances = 4 ft. #$ % &$ '$ !!" _ GB312 Applications Manual 5.4 Design of flue and air pipe for balanced flue operation (refer to NFPA54 ANSIZ223.1 for l dimensions) 1 2 1 1 1 1 1 4 2 3 2 3 7 747 010 720-17.2RS 7 747 010 720-19.2RS Fig. 13 Wall-exit air supply pipe, roof-exit exhaust Fig. 15 Roof-exit air supply pipe and exhaust 1 1 2 3 4 Flue outlet (type of outlet depends on chosen manufacturer, e.g. 90° elbow or T-piece) See Fig. 9. Air inlet (T-piece fitted horizontally or 90° elbow) External wall Roof 2 3 Flue outlet (type of outlet depends on chosen manufacturer, e.g. 90° elbow or T-piece), observe clearances specified in Fig. 5 Air inlet terminal (90° elbow pointing away from flue outlet) Roof 1 2 H 2 2 4 3 1 4 1 3 7 747 010 720-20.2RS Fig. 14 Wall-exit air supply pipe and exhaust 1;2 3 4 H Flue outlet (external-wall flue requires horizontally or vertically mounted T-piece), observe clearances specified in Fig. 11 Air intake terminal (90° elbow facing vertically downwards) External wall Refer to NFPA54, ANSIZ223.1 National Fuel Gas Code for details 7 747 010 720-21.2RS Fig. 16 Roof-exit air supply pipe, wall-exit exhaust 1 2 3 4 Flue outlet (external-wall flue requires horizontally mounted T-piece or 90° elbow facing downwards) Air inlet (90° elbow or T-piece) External wall Roof !!"#$ % &$ '$ _ GB312 Applications Manual 5.5 Venting system calculation/sizing chart + 0V76 ) Note: #J7 $ !6 )) . $ ))%$ Calculation example +$7 )$ )' , V7 7 vent pipe: @$*"!'WY)J7 $ @$* W!)J7 $ @h1 ))Wh1)J7 $ @#W13)J7 $ combustion air pipe: @$*"!'W)J7 $ @$* W!)J7 $ @3! ))W3!)J7 $ @#W1)J7 $ What size vent (exhaust) pipe is needed? 3M What size combustion air pipe is needed? 3M 5.5.1 VV V+ 0 * 9(3 Operating Conditions: @#8m , ! O!M<+ *V ! M<+ *+ ! M<+ @ 94#,3!( @+= ,,"g Venting Parameters: @N2$$S , @N2$7, @9+ 0 4,.V+ '$"!l ' '' @"!l'WY)J7 $ @O3l'WO)J7 $ @> W!)J7 $ @ ))W)J7 $ GB312 Venting System TableVent (Exhaust) Outlet Vertical 7DEOH Models Input (MBH) Vent Connection at Boiler Venting Diameter (inches) Total Equivalent Length of Vent (max) Vent Diameter for (minus one) size diameter and TEL in feet Vent Diameter for (minus two) size diameter and TEL in feet GB312-90 328 6" 6" 100 5" = 100ft 4" = 55ft GB312-120 440 6" 6" 100 5" = 80ft 4" = 30ft GB312-160 588 6" 6" 100 5" = 50ft 4" = NA GB312-200 733 8" 8" 100 7" = 100ft 6" = 70ft GB312-240 881 8" 8" 100 7" = 100ft 6" = 55ft GB312-280 1029 8" 8" 100 7" = 100ft 6" = 35ft GB312 Venting System TableCombustion Air (inlet) Vertical Models Input (MBH) Combustion Air Inlet Connection at Boiler Combustion Air Pipe Diameter (inches) Total Equivalent Length of Combustion Air Pipe (max) Combustion Air Pipe Diameter (minus one inch) maximum TEL in feet Combustion Air Pipe Diameter (minus two inch) maximum TEL in feet GB312-90 328 4" 5" 100 4" = 55ft 3" = NA GB312-120 440 4" 6" 100 5" = 95ft 4" = 30ft GB312-160 588 4" 6" 100 5" = 50ft 4" = NA GB312-200 733 4" 8" 100 7" = 100ft 6" = 70ft GB312-240 881 4" 8" 100 7" = 100ft 6" = 55ft GB312-280 1029 4" 8" 100 7" = 100ft 6" = 35ft Note: Breeching pressure measured at outlet of boiler vent connection. #$ % &$ '$ !!" _ GB312 Applications Manual 5.5.2 VV ;S + 0 9( Operating Conditions: @#8m , ! O!M<+ *V ! M<+ *+ ! M<+ @ 94#,3!( @+= ,,"g Venting Parameters: @N2$$S , @N2$7, @9+ 0 4,.V+ '$"!l ' '' @"!l'WY)J7 $ @O3l'WO)J7 $ @> W!)J7 $ @ ))W)J7 $ GB312 Venting System TableVent (Exhaust) Outlet Vertical 7DEOH Models Input (MBH) Vent Connection at Boiler Venting Diameter (inches) Total Equivalent Length of Vent (max) Vent Diameter for (minus one) size diameter and TEL in feet Vent Diameter for (minus two) size diameter and TEL in feet GB312-90 328 6" 6" 100 5" = 100ft 4" = 55ft GB312-120 440 6" 6" 100 5" = 80ft 4" = 30ft GB312-160 588 6" 6" 100 5" = 50ft 4" = NA GB312-200 733 8" 8" 100 7" = 100ft 6" = 70ft GB312-240 881 8" 8" 100 7" = 100ft 6" = 55ft GB312-280 1029 8" 8" 100 7" = 100ft 6" = 35ft GB312 Venting System TableCombustion Air (inlet) Horizontal Models Input (MBH) Combustion Air Inlet Connection at Boiler Combustion Air Pipe Diameter (inches) Total Equivalent Length of Combustion Air Pipe (max) Combustion Air Pipe Diameter (minus one inch) maximum TEL in feet Combustion Air Pipe Diameter (minus two inch) maximum TEL in feet GB312-90 328 4" 5" 100 4" = 40ft 3" = NA GB312-120 440 4" 6" 100 5" = 75ft 4" = NA GB312-160 588 4" 6" 100 5" = NA 4" = NA GB312-200 733 4" 8" 100 7" = 100ft 6" = 45ft GB312-240 881 4" 8" 100 7" = 100ft 6" = NA GB312-280 1029 4" 8" 100 7" = 100ft 6" = NA Note: Breeching pressure measured at outlet of boiler vent connection. !!"#$ % &$ '$ _ GB312 Applications Manual 5.5.3 ;S V ;S + 0 9(O Operating Conditions: @#8m , ! O!M<+ *V ! M<+ *+ ! M<+ @ 94#,3!( @+= ,,"g Venting Parameters: @N2$$S , @N2$7, @9+ 0 4,.V+ '$"!l ' '' @"!l'WY)J7 $ @O3l'WO)J7 $ @> W!)J7 $ @ ))W)J7 $ GB312 Venting System TableVent (Exhaust) Outlet Horizontal 7DEOH Models Input (MBH) Vent Connection at Boiler Venting Diameter (inches) Total Equivalent Length of Vent (max) Vent Diameter for (minus one) size diameter and TEL in feet Vent Diameter for (minus two) size diameter and TEL in feet GB312-90 328 6" 6" 100 5" = 100ft 4" = 40ft GB312-120 440 6" 6" 100 5" = 75ft 4" = NA GB312-160 588 6" 6" 100 5" = NA 4" = NA GB312-200 733 8" 8" 100 7" = 100ft 6" = 45ft GB312-240 881 8" 8" 100 7" = 100ft 6" = NA GB312-280 1029 8" 8" 100 7" = 65ft 6" = NA GB312 Venting System TableCombustion Air (inlet) Horizontal Models Input (MBH) Combustion Air Inlet Connection at Boiler Combustion Air Pipe Diameter (inches) Total Equivalent Length of Combustion Air Pipe (max) Combustion Air Pipe Diameter (minus one inch) maximum TEL in feet Combustion Air Pipe Diameter (minus two inch) maximum TEL in feet GB312-90 328 4" 5" 100 4" = 40ft 3" = NA GB312-120 440 4" 6" 100 5" = 75ft 4" = NA GB312-160 588 4" 6" 100 5" = NA 4" = NA GB312-200 733 4" 8" 100 7" = 100ft 6" = 45ft GB312-240 881 4" 8" 100 7" = 100ft 6" = NA GB312-280 1029 4" 8" 100 7" = 65ft 6" = NA Note: Breeching pressure measured at outlet of boiler vent connection #$ % &$ '$ !!" _ GB312 Applications Manual 5.5.3 ;S V V+ 0 9(h Operating Conditions: @#8m , ! O!M<+ *V ! M<+ *+ ! M<+ @ 94#,3!( @+= ,,"g Venting Parameters: @N2$$S , @N2$7, @9+ 0 4,.V+ '$"!l ' '' @"!l'WY)J7 $ @O3l'WO)J7 $ @> W!)J7 $ @ ))W)J7 $ GB312 Venting System TableVent (Exhaust) Outlet Horizontal 7DEOH Models Input (MBH) Vent Connection at Boiler Venting Diameter (inches) Total Equivalent Length of Vent (max) Vent Diameter for (minus one) size diameter and TEL in feet Vent Diameter for (minus two) size diameter and TEL in feet GB312-90 328 6" 6" 100 5" = 100ft 4" = 40ft GB312-120 440 6" 6" 100 5" = 75ft 4" = NA GB312-160 588 6" 6" 100 5" = NA 4" = NA GB312-200 733 8" 8" 100 7" = 100ft 6" = 45ft GB312-240 881 8" 8" 100 7" = 100ft 6" = NA GB312-280 1029 8" 8" 100 7" = 65ft 6" = NA GB312 Venting System TableCombustion Air (inlet) Vertical Models Input (MBH) Combustion Air Inlet Connection at Boiler Combustion Air Pipe Diameter (inches) Total Equivalent Length of Combustion Air Pipe (max) Combustion Air Pipe Diameter (minus one inch) maximum TEL in feet Combustion Air Pipe Diameter (minus two inch) maximum TEL in feet GB312-90 328 4" 5" 100 4" = 55ft 3" = NA GB312-120 440 4" 6" 100 5" = 95ft 4" = 30ft GB312-160 588 4" 6" 100 5" = 50ft 4" = NA GB312-200 733 4" 8" 100 7" = 100ft 6" = 70ft GB312-240 881 4" 8" 100 7" = 100ft 6" = 55ft GB312-280 1029 4" 8" 100 7" = 65ft 6" = 35ft Note: Breeching pressure measured at outlet of boiler vent connection !!"#$ % &$ '$ _ GB312 Applications Manual 6 Piping the boiler 6.1 Connecting central heating supply 6.2 Fitting the heating system return @( $$ $ $8 @0 $ $8 & $ $ 7 @' 7 $$477 & '$ ) @( $$ $ $8 @0 $ $8 & $ $ 7 2½" NPT RK VK 1 5 2½" NPT 4 1 4 3 2 7 747 010 720-81.1RS Fig. 18 Fitting the return pipe 6 3 2 Note: Flow Direction Arrow 7 747 010 720-04.1RS 1 2 3 4 RK Boiler return Return pipe (external with NPT male thread) Threaded flange - 2½" NPT female Gasket Boiler return Fig. 17 Fitting the B-kit and supply pipe 1 2 3 4 5 6 VK Pressure relief valve Supply pipe (external with NPT thread) Pressure/temperature gauge Threaded flange - 2½" NPT female Check valve (observe direction of flow Gasket Boiler supply 6.3 Installing the DHW Tank :;<# 4$S )$ 9 ' $ ) %.LW3DUWVOLVW Quantity Description 1 Supply Manifold 4 2½" Pipe Size Gaskets 1 Check Valve 1 Pressure and Temperature Gauge 1 Relief Valve - 50psi 12 Nuts - " 8 Bolts - " x 2½" L 4 Bolts - " x 5" L 24 Washers - " 12 Lock Washers 6.4 Installing the condensate drain Notes on condensate drainage. • The condensate that forms in the boiler and possible in the flue pipe must be properly drained away from the boiler. • The condensate which forms in the flue pipe can be drained via the boiler (install flue pipe with downward slope towards the boiler). • Make sure that drainage of the condensate into the public sewer system conforms with the applicable national regulations. • Also observe any applicable local regulations. #$ % &$ '$ !!" _ GB312 Applications Manual @>7$ @U '$ %$'$2 ! )' Note: For high temperature applications add 1 cup of mineral oil to the trap 2 Danger: Risk of fatal injury from poisoning. If the trap is not filled with water or other connections are left open, escaping flue gas can place lives at risk. • Fill the trap with water. (or mineral oil on high temperature applications) • Seal the trap and flue connections. • Make sure that the washer and seal are properly seated in the cap. 1 5 6 4 @$$ 3 Condensate may possibly escape through the trap vent hole. • Be sure to run the drain pipe from the trap so that it slopes downwards. Danger: Risk of fatal injury from poisoning. • The boiler's internal trap must be used, make sure that the condensate from the flue system drains correctly. A condensate neutralizer is available as an accessory. (Buderus part no. - NE0.1) • Install the neutralizer according to the installation instructions. • Fit the trap supplied to the condensate pan drain outlet. 1 7 747 010 720-23.1RS Fig. 19 Installing the condensate drain 1 2 3 4 5 6 Trap Condensate pan Trap outlet to neutralizer/waste pipe Trap vent Blanking cap Hole for condensate drain hose 6.5 Connecting the fuel supply Danger: Risk of fatal injury from the explosion of flammable gases. • Work on gas components may only be carried out by qualified and authorized personnel. 6.5.1 Installing gas supply piping ()$J6) # $)' 4 $$% $7$$S @4$ %$ ) $$ !!"#$ % &$ '$ _ GB312 Fit and seal the gas isolating valve supplied to the boiler's gas connection. @#$) $ =7$ $J $ (+690i +5+9 O" + 6'$ $ <$J 6$ '$$ +)+ 9) :7)(9N+9:* '$9N+9:*7 Length of pipe in feet 10 20 30 40 50 75 100 150 Applications Manual Gas pipe delivery rate in cubic feet of gas per hour 1) 1" 1¼" 1½" 2" 2½" 520 1060 1600 3050 4800 350 730 1100 2100 3300 285 590 890 1650 2700 245 500 760 1450 2300 215 440 670 1270 2000 175 360 545 1020 1650 160 305 480 870 1400 120 250 380 710 1130 Tab. 14 Gas pipe delivery rate 1 1) Maximum gas pipe delivery rate in cu ft/hr based on a gas specific gravity of 0.60 and a gas pressure of 0.5 psi or less and a pressure drop equivalent to a water column of 0.3 inches. 4 Iron pipe nominal diameter (in inches) 2 1 1¼ 1½ 2 2½ 3 Equivalent lengths for pipe fittings in feet Pipe fitting type 90° T-piece Shutoff Gas elbow valve cock Equivalent lengths in feet 3 5 0.6 1.60 4 6 0.8 2.15 5 7 1.0 2.50 7 10 1.3 3.00 8 12 1.6 3.50 Tab. 15 Equivalent lengths for pipe fittings 7 747 010 720-22.1RS Fig. 20 Gas valve pipe connection 1 2 3 4 Gas supply Manual shut-off valve (supplied) Sediment trap Gas connection with isolating valve : $ 77)$ )$& '$$$ 2n 0)$ & '$$$ n6 )% $)$ $7 77 @#$ )4 ) U $ ) $ #$ $2 $)$ #$ % &$ '$ !!" _ GB312 Applications Manual 6.6 Pipe Sizing ( 69 h h h #$ . 9S "A" "B" "C" Pump PK Pump PK Pump PK 7KUHHGB312 System (18°F Delta T) Recommended Near Boiler Piping Size 7DEOH Models GB312/90 Pipe A 2½" Pipe B 2" Pipe C 1½" Header E 2½" GB312/120 System Supply "A" "B" "C" GB312/160 GB312/200 GB312/240 GB312/280 3" 4" 4" 4" 4" 2½" 3" 3" 4" 4" 2" 2½" 2½" 2½" 3" 3" 4" 4" 4" 4" 7KUHHGB312 System (36°F Delta T) Recommended Near Boiler Piping Size 7DEOH Models GB312/90 GB312/120 GB312/160 GB312/200 GB312/240 GB312/280 Pipe A 2" 2½" 2½" 3" 3" 4" Pipe B 1½" 2" 2" 2½" 2½" 3" Pipe C 1¼" 1½" 1½" 2" 2" 2½" Header E 2" 2½" 2½" 3" 3" 4" System Return "E" 99 ! ! 6#Y!) .o ;;*9 !!"#$ % &$ '$ _ GB312 Applications Manual h h ( . 9S "C" "D" "B" "C" "D" Pump PK Pump PK Pump PK "A" Pump PK )RXUGB312 System (18°F Delta T) Recommended Near Boiler Piping Size 7DEOH Models GB312/90 GB312/120 GB312/160 GB312/200 GB312/240 GB312/280 Pipe A 3" 4" 4" 4" 5" 6" Pipe B 2½" 3" 4" 4" 4" 4" Pipe C 2" 2½" 3" 3" 4" 4" Pipe D 1½" 2" 2½" 2½" 3" 3" Header E 3" 4" 4" 4" 5" 6" )RXUGB312 System (36°F Delta T) Recommended Near Boiler Piping Size 7DEOH Models GB312/90 GB312/120 GB312/160 GB312/200 GB312/240 GB312/280 Pipe A 2½" 3" 3"" 4" 4" 4" Pipe B 2" 2½" 2½" 3" 3" 4" Pipe C 2" 2" 2½" 2½" 2½" 3" Pipe D 1½" 1½" 2" 2" 2" 2½" Header E 2½" 3" 3" 4" 4" 4" System Supply "A" "B" System Return "E" 99 ! ! 6#Y!).o ;;*9 #$ % &$ '$ !!" _ GB312 Applications Manual 7 CSD-1 Kit @+$#$$ + $) '$; . p . @#$ YYOY!""13)$ @''$ +h!"Y!h @;$'$ :3+#3< @''*<+= ; '$ @. $)' , <+=*33! ;*O!!hN!" 130 140 141 142 143 144 145 150 110 40 100 50 51 10 30 60 60 20 70 80 90 120 High Pressure (H.P.) Switch location set point = 2"WC Nat. Gas. 30 30 NOTE: • It works on a zero pressure regulated combination gas valve. • If the pressure regulator inside the combination gas valve fails, the H.P. switch will cut-out during burner operation. 7747101925-02-Zuluft, Venturi VM312 US Fig. 21 Air inlet, venturi GB312 US !!"#$ % &$ '$ _ GB312 10 20 60 61 62 100 20 40 50 Applications Manual 20 30 40 50 30 50 40 50 70 40 80 81 Low Pressure (L.P.) Switch location Setpoint = 3"WC Nat. Gas. 90 91 NOTE: • The minimum gas supply pressure is 3.5"WC. Fig. 22 7747101926-02-Gasarmatur VR4730, Gasanschlussrohr VM312 US Gas valve VR4730, gas connecting pipe GB312 US Pressure Relief Valve 50 psig Mating Flange 2½" NPT female connection 240 Check Valve Supply Connection at Boiler Supply Manifold 210 Gasket (typical) Item no. Description Buderus part number 210 Low water cut-off SAFGARD 3/4"M 550 240 High temperature cut-off 3/4"M L4006E1109 Fig. 23 Boiler Supply Manifold and Controls. #$ % &$ '$ !!" GB312 Applications Manual _ 7.1 Operating Addendum for the GB312 in High Temperature Applications 02 $$))$ ) #$) 3 #$ $77)$+! #$ ) =# #$' $$ 2$ ))8''$ 9N +9:$$))$ !!"#$ % &$ '$ US IONIZATION Plug MV1 M FAN PWM-FAN IGNITOR MV2 L N L N L N L N fan valve 2 2 valve 1 1 ignition DUAL VALVE COMBINATION Netz SAFe N L mains supply (SOCKET NOT USED) BUS SAFe NOTE: Blocked Air Pressure Switch • GB312/90 to 160 : Off =-1.6"WC On =-1.48"WC • GB312/200 to 280: Off =-2.4"WC On =-2.24"WC Ionization PWM pW p FG FR • GB312 all models : Off =3"WC On =2.75"WC NOTE: Safe Gas Pressure Switch = NG 1 3 black • GB312 all models : Off =1.6"WC On =1.48"WC NOTE: Blocked Vent Pressure Switch blue 2007/11 brown black white 2 white 3 black 2 3 1 1 2 3 4 5 6 7 8 3 2 white black white 2 black Page: 1/1 GB312 USA/CD BLOCKED VENT PRESSURE SWITCH 1 3 BLOCKED AIR PRESSURE SWITCH PRESSURE CONTROL SET NO adjustments necessary or possible on all pressure sensors WATER PRESSURE SENSOR LOW GAS PRESSURE SWITCH (OPTIONAL) 1 IN CASE OF CONNECTION REMOVE JUMPER 3-4 3" WC Setpoint HIGH GAS PRESSURE SWITCH (OPTIONAL) IN CASE OF CONNECTION REMOVE JUMPER 5-6 2" WC Setpoint SAFE GAS PRESSURE SWITCH Wiring diagram : 2 white 7365 Edition : 1 Reviewed : 7747019193 SUPPLY-FLOW TEMPERATURE SENSOR Drwg. no.: RETURN-FLOW TEMPERATURE SENSOR Boiler Control Unit MC10 SAFe 120V AC Version FK BUS BOILER-HIGH-LIMIT TEMPERATURE SENSOR Wiring diagram gas-boiler GB312 USA/CD !!" #$ % &$ '$ + Applications Manual GB312 _ 8 Boiler internal wiring diagram SAFe bus connection to burner control unit Basic controller BC10 EMS bus connection to function modules 1) The total current drawn must not exceed 5 A. AWG18 RC35 control unit or blank cover Connection to room controller (RC) AWG18 Replacement fuse 10 A slow Note! Installation, circuit breaker, emergency shut-off switch, and all safety components must comply with local regulations. Caution! Yellow/green ground conductor must not be used as control lead. Make sure terminals are connected with correct polarity. Controller must be hard wired. Device fuse 10 A slow Logamatic MC10 Location for Function modules xM10 External lock out Jumper must be removed when connected (EV) AWG18 AWG18 DHW temperature sensor (FW) Basic controller BC10 1 Outdoor Temperature sensor (FA) AWG18 Heat demand, external (WA) AWG18 Heating system circulation pump (PH-HK1) or DHW circulation pump (PZ) max. 5A 1) AWG14 Tank charging pump (PS) or Motorized 3-way valve (DWV) max. 5A 1) max. 5A 1) Supply pump (PZB) AWG14 AWG14 Mains power supply, function modules 120V 60Hz Mains FM Mains 120V 60Hz max. permiss. fuse rating 10A Mains SAFe ................BUS for SAFe burner control unit EMS..................BUS for function modules RC ....................Room controller (e.g. RC35) EV.....................External shut-off contacts FW....................DHW sensor FA..................... Outdoor temperature sensor WA....................Heat demand, external PZ.....................Supply pump PH-HK1 ............Heating system pump (circuit 1) PZ.....................DHW circulation pump DWV .................Motorized 3-way valve ON/OFF switch PS ....................Tank charging pump Mains FM .........Mains connection for function Netz ..................Mains connection for Logamatic MC10 programming unit Sfty devices .....Safety circuit for connecting external devices, e.g. gas pressure monitor. Triggering disables the burner control unit. Mains SAFe..... Mains connection for SAFe burner control unit Key to abbreviations max. 5A 1) AWG14 Mains SAFe Low voltage Wiring example for safety devices (external) Basic equipment for boiler system control and DHW heating Mains power supply, SAFe burner control unit 120V 60Hz Sfty devices Fuse 10A slow Control voltage 120V~ Component 2 Component 1 GB312 Applications Manual _ 9 MC10 wiring diagram !!"#$ % &$ '$ powerup state 12: check gas pressure 0,1-5s state 40: catch flame signal 0,1-1s state 13: check safety pressure 0,1-7s state 55: stabilize startload 10s state 20: holding tme Ignition cold 0,1- 4s state 56: stabilize partload 18s state 23: turn on fan 0,1-30s state 00: resting state 0,1s - ∞ state 60: at work 0,1s-23h state 25: pre purge 5s start signal state 30: Safeguard against extraneous light 5s state 05: safety-check 4s state 31: wait for startspeed 0,1-30s state 10: turn on safety-relay 0,5s - state 11: open valve 2 2s state 35: main gas valve 3s state 180: controlled shut down 0,5s state 32: ignition 3s state 190: recycling 10s - ∞ From every state (with own error number) From every state (with own error number) no start signal state 200: non-volatile lock out 0,1s - ∞ !!" #$ % &$ '$ Applications Manual GB312 _ 10 Sequence of operations _ GB312 Applications Manual 11 High Altitude Adjustment 11.1 General 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. These instructions must be followed precisely. Contact a qualified service company, service provider or the gas company if support or additional information is required. 11.1.1 Input Rates 11.3 CO² adjustment of the burner / adjustment of the gas valve #$+=¢7)$ $& +=¢*5+=* $)' +=¢7 #' ( 6 £0 P$YO #$+=7 $8$$ !! ) 0) )" V g+=¢ +=7 !!) $ 6 '+=¢7'$+= !!)$ & ,QSXWUDWHVIRUHOHYDWLRQVIW$6/7DEOH Models Input rate (Mbtu/hr) GB312-90 328 GB312-120 441 GB312-160 588 GB312-90 min-/max- load 9.1 / 9.1 <100 GB312-200 733 GB312-120 min-/max- load 9.1 / 9.1 <100 GB312-240 881 GB312-160 min-/max- load 9.1 / 9.1 <100 GB312-280 1029 GB312-200 min-/max- load 9.1 / 9.1 <100 GB312-240 min-/max- load 9.1 / 9.1 <100 GB312-280 min-/max- load 9.1 / 9.1 <100 &2 &2OHYHOVIRUHOHYDWLRQVIW$6/7DEOH å Models CO² (Vol. %) CO (ppm (af) ) 11.2 Adjustments #$$$& )$ )'& +=& )$ $ $ ) $77 + )$) 7)$ !!"#$ % &$ '$ _ GB312 Applications Manual 11.3.1 Set BC10 control to “flue gas test” operation #$ $$ )$8 #$ $$ 8' )! : $86$ $$ $ @. $$ $$ 6 $ $ $8$ )LJ6WDUWLQJWKHÀXHJDVWHVW 11.3.2 Opening the Service menu and viewing monitor data on the RC35 Menu • 9 $ OK + $ Info + *4' • # $ ¤ • .$ Menu OK $ *4' • # $ ¤ Menu • .$ OK $ *4' • # $ "# ¤ Menu • .$ OK $$ #$ 6 $' #$ ))$ 5 #$ % &$ '$ !!" _ GB312 Applications Manual 11.3.3 Adjusting and checking CO² level at maximum output •>)) >+3 •< $Y!g •0 $ $$ $ $8 $ )$8' •&$7" g+=¢ $$$* & '( 36 %& "' *2" -# $'4'$+=¢7 -# $' *4' $ +=¢7 )LJ6HWWLQJWKH&2ðDWPD[LPXPRXWSXW +LJKRXWSXWDGMXVWLQJVFUHZ 11.3.4 Adjusting and checking CO² level at minimum output •9!g $ #6 $$ $$ #$ $8 •9 $$ )2 3 M $) 6$$'M •.$ $ M )2 $$'M Reset •>)) >+3 )LJ6HWWLQJPLQLPXPRXWSXW •< $!g •&$7" g+=¢ $'* & '( 36 %& "' *2" -# $'4' $+=¢7 -# $' *4'$ +=¢7 )LJ6HWWLQJWKH&2ðDWPLQLPXPRXWSXW /RZRXWSXWDGMXVWLQJVFUHZJDVYDOYH+RQH\ZHOO9& &DSVFUHZ !!"#$ % &$ '$ _ GB312 Applications Manual 11.3.5 Check and monitoring CO² level at maximum output •.$ $ $$ •>)) >+3 •< $Y!g •+$4+=¢ 11.3.6 Recording measured values •#4$)' $ 8 $ $ 0 ,9 Y !6 3O, -( -( -8 S -+ 2 +=¢2 =¢ -+ 2 += •+ $8 $ )LJ5HFRUGLQJWKHPHDVXUHGYDOXHV 5HFRPPHQGHGORFDWLRQIRUWHVWLQJSRLQWRQÀXHSLSH 11.4 Settings for speed of burner fan #$) 7)$ $& $ )$+! $ )#)$ 4466'6''' 7 .$K+$ 'L K9L $)3 .$K9L O $2) +! '$',K !L .$K>L $7) $* Reset .$K+$ 'L $7)$ p . ) ) 3 #$ % &$ '$ !!" _ GB312 Applications Manual #$ $ )$ 0 )& $) )$$ #' %&SDUDPHWHUUDQJHIRUIDQDGMXVWPHQWRI*%ERLOHUV7DEOH Parameter Input range Factory setting for sea level operation Burner input load correction: 2 0 to +9 (- setttings lower than 0 will be ignored by the control) 2.0 = )2 ! hg %&SDUDPHWHUVHWWLQJVIRUDGMXVWPHQWRIIDQVSHHG7DEOH GB312 boiler size 0 - 2000ft (0 - 610m) 2001 - 4500ft (611 - 1372m) 4501 - 7000ft (1373 - 2134m) 7001 - 9500ft (2135 - 2896m) 9501 - 12000ft (2897 - 3666m) 90 120 160 2.0 2.1 2.2 2.3 2.4 200 240 280 2.0 2.2 2.4 2.6 2.8 !!"#$ % &$ '$ _ GB312 Applications Manual 12 Installation examples 12.1 Legend #$ % &$ '$ !!" _ GB312 Applications Manual 12.2 Single boiler systems FW DHW Sensor System Circulator L4006A PS DHW Loading Pump Isolation Relay AM10 Single Zone Relay TStat OTS PZB 9 '$!6:;< 9OO)' !!"#$ % &$ '$ BUS SAFe 2 White EMS 1 H Single Zone Switching Relay N 1 2 Red EV 24 VAC 1 W Factory installed jumper R 6 N/C COM 4 N/C T 4 N/O T T Stat 2 Orange RC 3 L4006A 5 DHW Sensor 2 Grey FW 1 6 N/O 2 Blue FA 1 Not used with AM10 2 Green WA 1 N/C 61 63 63 Dark Green PH-HK1 61 Dark Green PZB GB312 MC10/BC10 Common Isolation Relay N/O Not Used 13 Purple PZ 14 25 74 Purple DWV 73 24 Gray PS Purple Not used with AM10 75 N L Yellow Netz Module PS - DHW Loading Pump EMS Bus Connection to boiler Boiler Circulator N White Netz Main Power 115 V 60 Hz L 1 18 Low water cut off – dry contacts 17 Orange N 2 Red On/Off 1 2 Blue OTS N Tan Netz L Power to SAFe AM10 (Outdoor Reset Module) 2 White BUS 1 Outdoor sensor !!" #$ % &$ '$ Applications Manual GB312 _ < ) '$!6:;< 9O) _ GB312 Applications Manual AM10 FW DHW Sensor PS DHW Loading Pump L4006A System Circulator Single Zone Relay TStat OTS PZB 9 '$!6:;< 9Oh)' !!"#$ % &$ '$ BUS SAFe 2 2 Orange RC 1 Red EV 1 2 2 Grey FW 1 2 Blue FA 1 Not used with AM10 2 Green WA 1 H Single Zone Switching Relay N DWV 13 Not used with AM10 25 PS – DHW Loading Pump 24 Gray PS 74 Purple 5 73 PZB 14 Dark Green 63 63 Purple 61 6 N/O PZB - Boiler Circulator 61 Dark Green 24 VAC PZ W PH-HK1 R 6 N/C COM 4 N/C T 4 N/O T T Stat GB312 MC10/BC10 3 L4006A 75 N L Yellow Netz Module EMS Bus Connection to boiler N White Netz Main Power 115 V 60 Hz L 1 18 Low water cut off – dry contacts 17 Orange N 2 Red On/Off 1 2 Blue OTS N Tan Netz L Power to SAFe AM10 (Outdoor Reset Module) 2 White BUS 1 Outdoor sensor !!" #$ % &$ '$ White EMS 1 Factory installed jumper DHW Sensor System Circulator Applications Manual GB312 _ O< ) '$!6:;< 9O3) _ GB312 Applications Manual Thermostatic Mixing Valve L4006A High Temperature Zone Low Temperature Zone FW DHW Sensor PS DHW Loading Pump TStats Multi Zone Relay AM10 OTS PZB 39 '$!6:;< $S 9O1)' !!"#$ % &$ '$ BUS SAFe 2 White EMS 1 2 Orange RC 1 Red EV 1 2 Factory installed jumper 2 Grey FW 1 DHW Sensor 2 Blue FA 1 Not used with AM10 T Stat ZC ZR L4006A Zone 1 Zone 2 T Stat 25 74 DWV Input Power 75 N L Yellow Netz Module EMS Bus Connection to boiler PS – DHW Loading pump 24 Gray PS 73 Purple Dark Green Purple 61 Dark Green 13 PZ 63 Zone 4 Not used with AM10 Zone 4 Zone 3 High Temp Zone Circulator 120 V Circulators Zone 2 Zone 3 PZB - Boiler Circulator 61 PH-HK1 63 PZB 14 Dark Green GB312 MC10/BC10 Zone 1 2 Green WA 1 Multi Zone Switching Relay End Switch Low Temp Zone Circulator N White Netz Main Power 115 V 60 Hz L 1 18 Low water cut off – dry contacts 17 Orange N 2 Red On/Off 1 2 Blue OTS N Tan Netz L Power to SAFe AM10 (Outdoor Reset Module) 2 White BUS 1 Outdoor sensor !!" #$ % &$ '$ Applications Manual GB312 _ h< ) '$!6:;< $S 9OY) _ GB312 Applications Manual 12.3 Multiple boiler systems PZB AM10 Multi Zone Relay OTS TStats CM10 PZB System Flow Sensor PH System Circulator PS DHW Loading FW DHW Pump Sensor Thermostatic Mixing Valve L4006A Low Temperature Zone High Temperature Zone #''$'$6+!6:;< $S 93! 3)' !!"#$ % &$ '$ BUS SAFe 2 White EMS 1 N L Yellow Netz Module Power from MC10 2 Orange RC 1 N 1 L Red EV 2 DHW Sensor 2 Grey FW 1 61 Brown PH 63 2 Blue FA 1 Not used with AM10 2 Green WA 1 3 4 14 Blue 13 15 6 25 75 L Power to CM10 Module N Yellow Netz Module EMS Bus Connection to boiler #2 EMS Bus Connection to boiler #1 PS - DHW Loading Pump 24 Gray PS 74 DWV 13 Not used with AM10 10 Stripe 9 20 Stripe 19 73 Purple Purple 14 PZB 63 63 8 18 PZ Dark Green 61 17 Orange 7 White PZB - Boiler Circulator 61 PH-HK1 Dark Green 16 White 5 White GB312 Boiler #1 MC10/BC10 2 Brown 12 Tan 11 1 CM10 (2 Boiler Cascade Module) Factory installed jumper Yellow Netz Module System Circulator System flow sensor N White Netz Main Power 115 V 60 Hz L 1 18 Low water cut off – dry contacts 17 Orange N 2 Red On/Off 1 2 Blue OTS N Tan Netz L Power to SAFe AM10 (Outdoor Reset Module) 2 White BUS 1 Connection to end switch on Multi Zone Switching Relay Outdoor sensor !!" #$ % &$ '$ Applications Manual GB312 _ < )''$'$6+!6:;< $S 9O") BUS SAFe 2 1 1 2 Orange RC White EMS 1 Factory installed jumper 2 Red EV 1 DHW Sensor 2 Grey FW 2 1 2 Green WA Low Temp Zone Circulator End Switch Multi Zone Switching Relay Not used with AM10 1 Blue FA ZC ZR Zone 1 T Stat L4006A Zone 1 Zone 2 T Stat Zone 3 Zone 4 14 24 Gray PS Input Power Not used Zone 4 13 High Temp Zone Circulator 120 V Circulators Zone 2 Zone 3 PZB - Boiler Circulator 63 PZ PH-HK1 61 Purple Dark Green 73 25 74 DWV 63 PZB 61 Purple Dark Green GB312 Boiler #2 MC10/BC10 75 N L Yellow Netz Module L EMS Bus Connection from boiler #2 to CM10 19 and 20 Main Power 115 V 60 Hz N White Netz 18 Low water cut off – dry contacts 17 Connection to AM10 On/Off N Orange L Power to SAFe N Tan Netz GB312 Applications Manual _ 9O") !!"#$ % &$ '$ _ GB312 Applications Manual #' '$O (O3h PZB MC10 PZB MC10 FA 4323 FK FZB PZB 93)' #$ % &$ '$ !!" “EMS” Terminal on GB series boiler #2 1 Red EV 2 2 Not used with Logamatic 4323 1 Grey FW 1 2 Blue FA 1 2 Green WA 2 2 “EMS” Terminal on GB series boiler #1 White EMS 1 1 2 1 1 White UBA EMS 2 UBA EMS White 1 U 2 White 2 Flow sensor for strategy 1 FK Green 1 FA Blue FM456 (2 Boiler Strategy Module) 2 1 1 2 Orange RC White EMS 2 Outdoor sensor PZ 13 PH-HK1 61 14 Plug from NM482 From Main power supply Logamatic 4323 N N White Netz Logamatic 4323 Boiler Circulator 63 Purple Dark Green L L 25 74 Buderus 2 43 2 44 Flow sensor for mixing valve 1 FV 1 Main Power N White Netz L Pink 2 2 WF 5 AMP 63 Circulator for heat zone 61 Black PH Input ext. Heat demand 3 2 Flow sensor for PZB pump 1 FZB Green FA 2 Not used 1 18 L 63 2 U 4 L Plug for additional module 3 Brown Power to SAFe N Tan Netz System Circulator 61 Green PZB 5 AMP 1 Low water cut off – dry contacts 17 Blue N Orange ZM433 (Main Module) L Zero volt contact Input Pump fault N Yellow Netz Module Lt Brown 75 120 Vac Mix valve motor 41 Black SH/SR 5 AMP Mec 2 or BFU (Optional) 1 BF Brown Not used with Logamatic 4323 24 Gray PS 73 DWV 63 PZB 61 Purple Dark Green N GB312 MC10/BC10 GB312 Applications Manual _ O< )#' '$O (O3h 93) !!"#$ % &$ '$ _ GB312 Applications Manual 3( '$O (O3Y PZB MC10 PZB MC10 PZB MC10 PZB MC10 FA 4323 FK FZB PZB 933)' #$ % &$ '$ !!" “EMS” Terminal on GB series boiler #4 “EMS” Terminal on GB series boiler #3 White 2 1 UBA EMS 1 2 Grey FW 1 2 Blue FA 1 2 Green WA 2 2 “EMS” Terminal on GB series boiler #2 White EMS 1 1 1 White UBA EMS White 2 2 2 EMS 1 1 UBA EMS “EMS” Terminal on GB series boiler #2 2 3 White 1 U 2 White 2 Flow sensor for strategy 1 FK Green FM457 (4 Boiler Strategy Module) Not used with Logamatic 4323 White Red EV 1 2 EMS 2 1 1 4 UBA EMS White 2 1 1 2 Orange RC White EMS 1 FA Blue PZ 13 PH-HK1 61 2 Plug from NM482 From Main power supply Logamatic 4323 Outdoor sensor 14 N N White Netz Logamatic 4323 Boiler Circulator 63 Purple Dark Green L L 25 74 Buderus 2 43 2 44 Flow sensor for mixing valve 1 FV 1 2 2 WF 5 AMP Black PH 63 Input ext. Heat demand 3 Circulator for heat zone 61 Main Power N White Netz L N 2 Flow sensor for PZB pump 1 FZB Green FA Blue 2 Not used 1 18 L 63 2 U 4 L Plug for additional module 3 Brown Power to SAFe N Tan Netz System Circulator 61 Green PZB 5 AMP 1 Low water cut off – dry contacts 17 Orange ZM433 (Main Module) Pink L Zero volt contact Input Pump fault N Yellow Netz Module Lt Brown 75 120 Vac Mix valve motor 41 Black SH/SR 5 AMP Mec 2 or BFU (Optional) 1 BF Brown Not used with Logamatic 4323 24 Gray PS 73 DWV 63 PZB 61 Purple Dark Green N GB312 MC10/BC10 GB312 Applications Manual _ h< )( '$O (O3Y 93O) !!"#$ % &$ '$ _ GB312 Applications Manual Y. 9 . :<$'; . $J 7 .S ''$1l( hl(:# Distance must not exceed 4 times pipe Ø #$ % &$ '$ !!" _ GB312 Applications Manual 13 Pump & low loss header (hydro-seperator) selection 13.1 Pump selection based on delta T. G7 &)6LQJOH%RLOHU,QVWDOODWLRQ BOILER DATA 7DEOH BOILER PUMP SELECTION HYDRO-SEPERATOR Models Flowrate (gal/min) Boiler pressure drop (PSI) Check valve pressure drop (PSI) Grundfos pump selection B & G pump selection Taco pump selection Caleffi Hydroseperator selection Sinus Hydroseperator selection Nominal Size GB312-90 30 3.4 0.3 UP26-99 607S 1400-20 548082A 7-26-200 3" Flanged GB312-120 45 4.6 0.6 UPS40-40 607S 1400-65 548082A 7-26-200 3" Flanged GB312-160 60 4.5 0.6 UPS40-80/4 608S 1400-70 548082A 7-26-200 3" Flanged GB312-200 75 5.2 0.9 UPS50-80/4 609S 1400-70 548102A 7-26-250 4" Flanged GB312-240 90 5.2 1.2 UPS50-80/4 611S 1632 548102A 7-26-250 4" Flanged GB312-280 106 5.5 1.7 UPS80-80 612S 1632 548102A 7-26-250 4" Flanged G7 &)6LQJOH%RLOHU,QVWDOODWLRQ BOILER DATA 7DEOH BOILER PUMP SELECTION HYDRO-SEPERATOR Models Flowrate (gal/min) Boiler pressure drop (PSI) Check valve pressure drop (PSI) Grundfos pump selection B & G pump selection Taco pump selection Caleffi Hydroseperator selection Sinus Hydroseperator selection Nominal Size GB312-90 15 0.9 0.1 UP15-42 607S 1400-10 548052A 7-25-120 2" Flanged GB312-120 23 1.2 0.2 UP26-64 607S 1400-10 548052A 7-25-120 2" Flanged GB312-160 30 1.2 0.2 UP26-99 607S 1400-20 548082A 7-26-200 2" Flanged GB312-200 37 1.3 0.2 UPS32-40 607S 1400-20 548082A 7-26-200 3" Flanged GB312-240 45 1.3 0.3 UPS40-40 607S 1400-40 548082A 7-26-200 3" Flanged GB312-280 53 1.4 0.4 UPS40-40 608S 1400-45 548082A 7-26-200 3" Flanged !!"#$ % &$ '$ _ GB312 Applications Manual 13.2 Low loss header selection per manufacturer CALEFFI 0XOWLSOHERLOHUDSSOLFDWLRQV7DEOH Nominal Size Combined Flowrate (gal/min) Mains pipe size Caleffi Hydro-seperator selection ASME registered Caleffi Hydro-seperator selection Non-ASME up to 247 gpm 4" NA548102A 548102A 4" Flanged up to 300 gpm 5" NA548120A not offered 5" Flanged up to 484 gpm 6" NA548150A not offered 6" Flanged up to 792 gpm 8" NA548250A not offered 8" Flanged up to 1,330 gpm 10" NA548300A not offered 10" Flanged up to 1,850 gpm 12" NA548300A not offered 12" Flanged SINUS 0XOWLSOHERLOHUDSSOLFDWLRQV7DEOH Combined Flowrate (gal/min) Mains pipe size Sinus Hydro-seperator selection Nominal Size up to 115 gpm 4" 7-26-250 4" Flanged up to 190 gpm 5" 7-26-300 5" Flanged up to 250 gpm 6" 7-26-400 6" Flanged up to 375 gpm 8" 7-26-450 8" Flanged up to 480 gpm 8" 7-26-500 8" Flanged up to 745 gpm 10" 1-51-218 10" Flanged up to 1,030 gpm 12" 1-51-220 12" Flanged up to 1,320 gpm 14" 1-51-222 14" Flanged #$ % &$ '$ !!" GB312 Applications Manual _ !!"#$ % &$ '$ $#$$ + 3!< '$7 6;!!3 # ,h!*33*!! (2,h!*31O*h1 ''' . ), $#$$ 4; 9$ !* :*33Yh<S ''' $#$$ + 7$$ 4$ '$ $ 7 %7&%_