Buderus Logano GA124 Manual de usuario

6 720 804 895 – 2012/10 EN-US For heating engineers

Please read carefully before use

Conversioninstructions

from natural gas to propane

R o o m a i r - i n d e p e n d e n t

special g as- f i red boi l e r

Logano GA124

This conversion kit and the instructions are for conversion of the special gas-

fired boilers of the GA124 model from natural gas to propane.

Requirements

GA124 -17

70 MBtu/hr

GA124 -23

94 MBtu/hr

GA124 -30

123 MBtu/hr

WARNING!

This conversion kit must only be

installed by qualified heating contractor

as specified by the manufacturer’s

instructions and the applicable rules and

regulations of the local authorities. 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.

CAUTION!

Before converting the heating system to

a different type of gas the gas line must

first be shut off and then the power to the

heating system must be disconnected.

Note: Please keep these instructions for future reference.

Contents

2Conversion instructions Logano GA124 special gas-fired boiler • Issue 2012/10

We reserve the right to make any changes due to technical modifications.

1Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Notes structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3 Please observe these notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Conversion to propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Start-up instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.1 Making boiler ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.2 Carrying out final commissioning tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety 1

We reserve the right to make any changes due to technical modifications.

Conversion instructions Logano GA124 special gas-fired boiler • Issue 2012/10

1 Safety

Observe these instructions for your safety.

1.1 Correct use

The conversion kit is used for conversion of the GA124

special gas-fired boiler from natural gas to propane.

1.2 Notes structure

Additional symbols for identification of dangers and user

instructions.

1.3 Please observe these notes

2 Scope of delivery

1. Honeywell gas solenoid valve conversion kit

# 393 691, comprising:

–black safety screw

–pressure adjustment screw

–red spring

–yellow label for gas fitting

2. BBR 12 ignition gas pilot orifice

3. main gas orifices and seals

4. unit label (to be filled out and attached to the unit)

5. Technical documents

WARNING!

RISK TO LIFE

Identifies possible dangers emanating

from a product, which might lead to serious

injury or death if appropriate care is not

taken.

WARNING!

RISK TO LIFE

from electric shock.

USER NOTE

Tip for the optimum utilization and setting

of the control(s) plus other useful

information.

WARNING!

RISK TO LIFE

from explosion of flammable gases.

Never work on gas lines unless you are

licensed for this type of work..

WARNING!

RISK TO LIFE

from electric shock.

Disconnect the power supply to the

heating system before conducting any

work on it, e.g. switch off the heating

emergency switch outside the boiler

room.

It is not sufficient just to switch off the

control.

4Conversion instructions Logano GA124 special gas-fired boiler • Issue 2012/10

We reserve the right to make any changes due to technical modifications.

Conversion to propane3

3 Conversion to propane

Read the instructions before conversion for your

safety.

The following instructions must be followed for

conversion of the boiler to propane:

1. If the boiler was in operation, close the gas shut-off

valve. Otherwise continue with step 3.

2. Disconnect 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.

WARNING!

RISK TO LIFE

due to not observing the attached

conversion instructions.

If 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.

Fig. 1 Removing front panel of boiler

Conversion to propane 3

We reserve the right to make any changes due to technical modifications.

Conversion instructions Logano GA124 special gas-fired boiler • Issue 2012/10

4. Turn gas valve ON/OFF button clockwise to OFF

position. Do not use force.

Replacing main gas orifices

5. Disconnect pilot gas line from gas valve.

6. Disconnect ignition cable from ignition module.

Fig. 2 Gas valve

1ON/OFF button (at ON position)

WARNING!

RISK TO LIFE

from explosion of flammable gases.

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 9 If there is no sign of a gas odor,

continue with the next step.

Fig. 3 Front view

1Flame roll-out switch (boiler size 17)

2Gas connection pipe

3Gas valve

4Ignition cable

5Ignition module

6Wire holder for gas supply line

7Aquasmart

8Pilot gas line

9Air supply hose

10 Gas supply pipe

11 Fuse

6 720 804 894-01.1T

6Conversion instructions Logano GA124 special gas-fired boiler • Issue 2012/10

We reserve the right to make any changes due to technical modifications.

Conversion to propane3

7. Remove the safety screw for the manifold pressure

adjustment on the gas valve.

8. Remove orifice pressure adjustment screw.

9. Remove stainless steel spiral spring.

10. Install the red spring from the Honeywell LP

conversion kit in the gas valve.

11. Screw in the new orifice pressure adjustment screw

from the Honeywell LP conversion kit until it is flush

with the top edge of the pressure adjustment.

Then screw the manifold pressure adjustment screw

six (6) revolutions clockwise. This sets the pressure

to about 10.0 in W.C. This setting must be checked

with a pressure gauge when the conversion is

complete.

12. Install new black safety screw from the Honeywell

LP conversion kit.

13. Clean the housing of the gas fitting (Fig. 4) and

attach the yellow label (Fig. 4) from the Honeywell

LP conversion kit to the gas valve in a conspicuous

position.

14. Tie gas line (Fig. 3, page 5) with wire or cord

(Fig. 3, page 5) (secure).

15. Remove screws between gas valve and burner box.

Place the gas connection pipe gasket in a safe

place.

16. Label wires of flame roll-out switch and disconnect

from the roll-out switch.

17. Remove screws in burner box cover and remove

cover.

18. Unscrew nuts and remove gas burner with burner

box.

19. Release air supply hose (Fig. 3, page 5) and pull

off burner box.

Fig. 4 Gas valve

1Safety screw

2Orifice pressure adjustment screw

3Stainless steel spiral spring

4Gas valve

5Yellow label

Fig. 5 Gas burner

1Fixing nuts

2Screws

3Flame roll-out switch (boiler size 23 and 30)

4Burner box cover

CAUTION!

RISK TO LIFE

due to incorrectly connected wiring.

When conducting maintenance work

label all cables before disconnecting

them.

Conversion to propane 3

We reserve the right to make any changes due to technical modifications.

Conversion instructions Logano GA124 special gas-fired boiler • Issue 2012/10

20. Turn gas burner 180° and unscrew bottom burner

box panel.

21. Install the new main gas orifices and copper

gaskets. Check with Tab. 1 that the correct

orifices for operation of the boiler are installed.

22. Screw bottom burner box panel into place again.

Replacing pilot gas orifice

23. Unscrew ignition pilot line from pilot burner.

24. Remove pilot orifice.

25. Place the new BBR 12 pilot orifice in the pilot burner.

26. Screw the pilot line to the pilot burner unit.

27. Check that the pilot burner unit is correctly seated

compared to the main burner.

28. Install gas burner in boiler in reverse order of

removal. Tighten the fixing nuts well.

Make sure that the front edge of the burner box

cover (Fig. 8, page 8) is properly engaged in the

sealing grommets (Fig. 8, page 8).

Fig. 6 Removing gas burner

1bottom burner box panel

Orifices sizes for propane

Model GA124 -17 GA124 -23 GA124 -30

Orifice size 175 160 160

Number 234

Tab. 1 Orifice sizes

USER NOTE

The orifice sizes are for installations

between 0 and 8500 feet above see level.

Follow the "Conversion instructions for

high altitudes" for installations between

8501 and 12000 feet above sea level.

Fig. 7 Pilot burner

1Ignition cable

2Pilot burner

3Main burner

4Pilot orifice

5Pilot gas line

8Conversion instructions Logano GA124 special gas-fired boiler • Issue 2012/10

We reserve the right to make any changes due to technical modifications.

Conversion to propane3

29. Tighten the screws (Fig. 5, page 6) between the

gas valve and the burner box again. Make sure that

the connection pipe gasket removed in step 15 is

replaced.

30. Attach wires to the flame roll-out switch.

31. Remove wire or rope that was used to hold the gas

supply line in step 14.

32. Connect pilot gas line to gas valve again.

33. Connection ignition wire to the ignition module.

34. Enter the required information on the conversion

label and attach on the outside of the boiler jacket as

close as possible to the nameplate.

Carrying out leak test

35. Open manual gas shut-off in the gas line.

36. Check the gas supply line to the gas valve for leaks

with soap solution. If no leaks are found, continue

with step 38. If any leaks are found, close gas

shut-off valve.

37. Seal leaks and repeat step 36.

38. Close main shut-off valve. Remove the screw plug

for the gas supply port on the gas valve. Install

pressure measuring nipple and attach a pressure

gauge to measure the gas pressure.

39. 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.

40. Open gas valve and measure the gas pressure of

the boiler. The connection pressure must be

between 11" and 13" W.C. If the connection

pressure is not between 11" and 13" W.C., contact

your customer service technician or LP gas

company.

41. Always follow the start-up instructions on the next

page.

Fig. 8 Front view

1Flame roll-out switch (boiler size 17)

2Gas connection pipe

3Gas valve

4Ignition cable

5Ignition module

6Wire holder for gas supply line

7Aquasmart

8Pilot gas line

9Air supply hose

10 Gas supply pipe

11 Fuse

6 720 804 894-01.1T

Fig. 9 Gas valve

1ON/OFF button (at ON position)

2Screw plug for gas supply pressure measuring port

3Screw plug for manifold pressure measuring port

4Pilot gas line connection

Start-up instructions 4

We reserve the right to make any changes due to technical modifications.

Conversion instructions Logano GA124 special gas-fired boiler • Issue 2012/10

4 Start-up instructions

Read the instructions before start-up for your

safety.

AThis unit is fitted with an igniter that automatically starts the

ignition burner. Do not attempt to ignite it manually.

BCheck for an odor of gas around the 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.

CSwitch 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 valve may cause a fire

or explosion.

DDo 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 fittings that were under water.

WARNING!

RISK TO LIFE

due to not observing the start-up

instructions and resulting incorrect

operation.

If these instructions are not followed

exactly, a fire or explosion may be

caused with serious property damage

or loss of life or serious injury.

Observe the start-up instructions.

WARNING!

DANGER OF EXPLOSION

If you smell gas there is a danger of

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.

10 Conversion instructions Logano GA124 special gas-fired boiler • Issue 2012/10

We reserve the right to make any changes due to technical modifications.

Start-up instructions4

4.1 Making boiler ready for operation

STOP! First read the safety instructions on page 9 of

this manual.

1. Carry out leak test (page 8). 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 page 9 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 aquasmart control in operation

The boiler is fully functional with the factory-installed

aquasmart.

3. Turn on ON/OFF switch (contractor installed) (ON

position). This turns 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).

4.2 Then carry out start-up procedures.

The following start-up procedures must be carried out

regardless of the control type.

5. Look at the igniter through the sight glass in the

burner housing.

Fig. 10 Switching on heating system (with aquasmart)

1ON/OFF switch (main switch)

Fig. 11 Front view

1Sight glass

6 720 804 894-02.1T

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