Buderus SB735 Series Manual

6302 2320 – 10/2003 US/CA For installers

Please read these instructions carefully!

Boiler Installation and

Maintenance Manual

Condensing Gas Boiler SB735

Series

Introduction

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

Boiler Installation and Maintenance Manual SB735 • Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

Technical Changes!

Buderus Hydronic Systems, Inc. reserves the right to

this make changes due to continued technological and

engineering improvments.

Updating Technical Informations

Please contact us if you have suggestions for improving

this manual or when you have noticed incorrect

information.

Manufacturers Address:

Buderus Hydronic Systems, Inc.

50 Wentworth Ave

Londonderry, New Hampshire 03053

www.buderus.net

Document number: 6302 2320

Issue: 10/2003

FThis equipment conforms to the following

European and US requirements:

– 90/396/EWG European gas fired

guidelines

Standards: EN 677, EN 303-1,

EN 303-3, DIN 4702-6

– 92/42/EWG European efficiency

guidelines

– 73/23/EWG European low voltage

guidelines

– 89/336/EWG EMV- European

electromechanical code

guidelines

– 97/23/EG European pressure

vessel guidelines

Standard: TRD 702

– ASME Boiler and Vessel Pressure

Code

Confirmation regarding confirmity with

respect to these guidelines can be obtained

upon request from Buderus Hydronic

Systems, Inc.

TABLE OF CONTENTS

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

Boiler Installation and Maintenance Manual SB735• Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Regulations and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 Hydrostatic test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Packaging and Components . . . . . . . . . . . . . . . . . . . . . . 5

3 Technical Data, Dimensions and Water Connections . . . . . . . . . 6

4 Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 Anti-Vibration Supports . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 Boiler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.1 Installation of the Thermal Insulation

and Jacket Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.2 Boiler Jacket - Pack A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.3 Boiler Jacket - Pack B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.4 Installation of the Control Panel

and Sensor Well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.5 Burner Door and Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.6 Boiler Jacket - Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6.7 Rating Tag Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6.8 Boiler Jacket - Pack C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.9 Venting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.10 Neutralization Equipment and Water Controls Installation. . . . . . . . . . 23

7 Placing the Boiler in Operation . . . . . . . . . . . . . . . . . . . . 24

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8.2 Cleaning of the Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

9 Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

General Information1

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

Boiler Installation and Maintenance Manual SB735 • Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

1 General Information

1.1 General Information

This Boiler Installation and Maintenance Manual

contains important information regarding proper and

safe assembly, start-up and operating and maintenance

procedures for the SB735 series boilers!

The assembly and maintenance instructions are

designed for the installing contractor, who, due to

vocational training, is familiar, knowledgeable and

experienced in heating system and gas piping

installations.

1.2 Regulations and Guidelines

This document also makes reference to additional

accessories that may be used in conjunction with the

SB735 boilers. Observe the proper installation

instructions when installing these accessories.

The installation must conform to the requirements of the

authority having jurisdiction or, in absence of such

requirements, to the latest edition of the National Fuel

Code, ANSI Z223.1.

ADANGER!

due to combustion products.

Route flue gases via venting system to the

atmosphere. Use only approved venting

materials.

Have the system inspected by an authorized

person prior to start-up. Only start-up the

system after approval.

Check system for leaks.

The Buderus SB735 boiler is a condensing boiler

suitable for firing with natural gas or propane only.

The installation of a low water cut-off and pressure relief

valve must be based on local code requirements. Please

install these components per manufacturer’s

instructions and per detail on page 23.

JNOTICE

To avoid build-up of debris inside the heat

exchanger of the boiler, it is recommended to

install a filter on the boiler return connection(s).

1.3 Hydrostatic test

Perform a hydrostatic test. The test pressure should be

1.5 times the actual operating pressure in the heating

system, however a minimum of 14 psi.

JNOTICE!

Observe the listed boiler output ratings as

shown on the boiler rating plate.

Maximum Temperature and Pressure Ratings:

Permissible Fuels:

Logano SB735: Fuel Natural Gas or L.P

Please observe the guidelines of the gas supply

company!

Maximum Temperature and Pressure Ratings

Maximum Supply Temperature: 210 °F

Allowed System Pressure

(Models)

790 43.5 psi

970 43.5 psi

1200 43.5 psi

Maximum Time constant:

- Manual Reset High Limit 40 sec

- Adjustable High Limit 40 sec

Table. 1 Maximum Temperature and Pressure Ratings

Packaging and Components 2

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

Boiler Installation and Maintenance Manual SB735 • Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

2 Packaging and Components

The complete product is shipped in the following

components:

– Boiler vessel, bolted on transport woods

– Supply manifold, packaged with hydronic control

package

– Technical documentation, secured to the boiler

– VE insulation rings for burner and PVC condensate

drain (Siphon) secured to the boiler

– Boiler jacket panels and installation components,

packaged in a wooden crate and cardboard. The

assembly components are located in Pack A.

– The insulation blankets are packaged in 2 plastic

bags.

– A sound attenuating boiler base is supplied standard

with the SB735/1200 model.

– Electronic control panel, in cardboard box (optional).

– A condensate neutralization package can be ordered

separately.

– Hydronic control package, consisting of aquastat,

low water cut-off, relief valve and temperature

pressure gauge (when ordered from Buderus).

– Gas burner and gas train components, if ordered

from Buderus.

– Pre-cut burner mounting plate, if ordered from

Buderus.

Above mentioned components may differ slightly based

on the particular boiler model.

Technical Data, Dimensions and Water Connections3

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

Boiler Installation and Maintenance Manual SB735 • Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

3 Technical Data, Dimensions and Water Connections

Fig. 1 Technical Data, Dimensions and Water Connections

VK = Boiler Supply Connection

RK1 = Low Temperature Return Connection

RK2 = High Temperature Return Connection

H* = Boiler Height with Logamatic 2107/2109=H+6 inch

AKO = Condensate Drain

EK = Water Feed

EL = Boiler Drain

M = Sensing Port for Temperature Sensor

Ø AA = Vent Pipe Diameter

HAA

Ø AA

RK2

AKO

RK1

EK/EL

Boiler Model 790 970 1200

Max. Input [MBH] 2751 3378 4179

Max. Output [MBH] 2605 3251 4079

IBR Net [MBH] 2265 2827 3547

Thermal Efficiency [%] 96.9 96.3 97.6

Combustion Efficiency [%] 94.7 95.6 96.5

Length L Inch 91 ½108 ¼108 ¼

Length LKInch 75 ½92 92

Hight HInch 81 ¼ 81 ¼ 81 ¼

Width BInch545454

Boiler Widthless Jacket Inch 44 ¼ 44 ¼ 46 ¼

Vent Connection-Ø inside Ø AA Inch 14 14 14

Vent Height HAA Inch 19 19 19

Weight Lbs. 4330 5441 5534

Boiler supply

1. First Return Connection

RK1

Inch

2. Second Return Connection RK2Inch 3 4 4

Boiler Drain/Water Feed EK/EL Inch 1½ 1½ 1½

Table. 2 Technical Data, Dimensions and Water Connections

Boiler Installation 4

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

Boiler Installation and Maintenance Manual SB735 • Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

4 Boiler Installation

It is required to have a floor drain available near the

boiler.

It is recommended to place the boiler on solid foundation

of 2" to 4 " height. Use dimension B and L (Table 3) to

size this foundation.

The supporting floor must be level and of sufficient

strength.

Observe the indicated side clearances when placing the

boiler (Fig. 2). Dimensions shown indicate minimum

clearances to combustibles or space needed to swing

open burner door.

Place the boiler horizontally on the supporting

foundation.

JNOTICE!

Make sure to install the base supplied with the

SB735/1200.

Fig. 2 Clearance dimensions for SB735 boilers

Boiler

Model

[Inch]

790 91 43 ¾98“(43“)*

970 107 ½43 ¾98“(43“)*

1200 107 ½46 98“(43“)*

Table. 3 Minimum Boiler Pad

Please observe the burner length LBr with respect to the front

clearance.

8“

32“1)

LBr

(0)

(4“)

(40“)

Anti-Vibration Supports5

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

Boiler Installation and Maintenance Manual SB735 • Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

5 Anti-Vibration Supports

zAnti-vibration supports are standard equipment on

the SB735/1200 model; they can be ordered

separately for the other models.

zInsert the longer part of the longitudinal anti-vibration

bracket (Fig. 3, Item. 4) from the front and the

shorter part (Fig. 3, Item. 3) from the rear into the

channel sections (Fig. 3, Item. 2).

zPosition both rails of the anti-vibration boiler support,

in accordance with dimensions shown in Table 4, on

the floor where the boiler is to be installed.

JNOTICE!

Prepare the foundation, where the anti-vibration

supports are to be located, with a smooth trowel

of ±1/8“ per linear foot and with a slight rise to

the back. This ensures an even load distribution

over the longitudinal anti-vibration brackets,

and adequate boiler ventilation.

zPosition, align and place the boiler on the supports.

The boiler support should be flush with the boiler

back wall. The end-stop plates (Fig. 3, Item. 1)

should contact the channel section of the boiler.

Fig. 3 Anti-vibration support

Item. 1: End-stop plates

Item. 2: Channel section

Item. 3: Short anti-vibration bracket

Item. 4: Long anti-vibration bracket

Table. 4 Support dimensions

1) Standard delivery

2) Accessories

Boiler

Type

Boiler-

Model

Length

[Inch]

Distance

[Inch]

1200 1) 90 46

SB735 970 2) 90 43 ¾

790 2) 73 ½44

Boiler Assembly 6

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

Boiler Installation and Maintenance Manual SB735 • Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

6 Boiler Assembly

JNOTICE!

Make sure, that when fitting the front thermal

insulation, the burner door of the combustion

chamber is closed, to prevent damage to the

stainless steel combustion chamber from

welding or grinding activities.

Order of installation:

1. Thermal insulation/Pack A

2. Pack B

3. Pack C

6.1 Installation of the Thermal Insulation

and Jacket Panels

JNOTICE!

Ensure that the fabric is on the outside when

fitting the insulation blankets.

zPosition the insulation blankets for the boiler body so

that the cut-outs are located over the cross brackets

plates (Fig. 5, Item. 1).

JNOTICE!

Position the narrow insulation blanket for boiler

model 790 at the rear, and note the drain cut-

outs.

JNOTICE!

Note the cut-outs for the low water indicator and

the cross bracket holder

(Fig. 7, Item. 1 + 5)!

zPosition the front insulation blanket with its cut-out,

over the cross bracket holder.

zTuck the insulation blanket in underneath the boiler

(Fig. 5).

Fig. 4 Connections

M = Sensing port for temperature sensor

VK = Boiler supply and relief valve connection

RK2 = High temperature boiler return

RK1 = Low temperature boiler return

AA = Vent connection

AKO = Condensate drain

EK/EL = Water feed/boiler drain

Fig. 5 Insulation blanket

RK2

RK1

AKO

EK/EL

Boiler Assembly6

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

Boiler Installation and Maintenance Manual SB735 • Issue 10/2003

Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de

zOverlap the insulation blankets on the side and wrap

around the boiler body, then fasten with 8 clips.

zUnscrew four hexagon bolts (Fig. 6, Item. 1) from the

right side of the boiler door (Fig. 7, Item. 1) and four

from the left side.

ADANGER OF INJURY!

through falling parts.

Ensure that the hinge bolts (Fig. 21, Item. 1)

are in the boiler door before opening it.

JNOTICE!

The recesses (Fig. 6, Item. 2) in the boiler door

(2 on the left and 2 on the right side) have been

provided for lifting with a crane or hoist, for

example for the complete removal of the door.

zOpen the burner door (Fig. 7, Item. 1)

zPlace the insulation blanket with round cut-out

(Fig. 7, Item. 2), with its wide edge facing upwards,

on the left front of the boiler body (wide edge up) and

secure with four clips (2 left, 2 right) on the

surrounding thermal insulation.

ACAUTION!

Ensure that the wide edge is at the top at the

hinge bolts!

zClose the burner door and re-secure with eight

hexagon bolts.

zPosition the thermal insulation strip (Fig. 7, Item. 3)

laminated on the front of the reversing door.

zPosition the thermal insulation strips (Fig. 7, Item. 4)

for the reversing door from below around the side of

the reversing door and secure with two clips.

JNOTICE!

Observe the hinge bolt cut-outs!

zLocate the rear side thermal insulation (Fig. 8,

Item. 2) in accordance with the cut-outs on the rear

side of the boiler and secure with six clips (Fig. 8,

Item. 1, 3 left and 3 right) on the surrounding thermal

insulation (Fig. 8, Item. 3).

Fig. 6 Screws for opening the burner door

Fig. 7 Burner door insulation blanket

Fig. 8 Rear side insulation blanket

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