Buderus Logamax plus GB162-80 kW - Table of Contents; Guideline to Symbols and Safety Instructions

Contents
Logamax plus GB162- 80/100 kW - Subject to modifications resulting from technical improvements!
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Contents
1 Guideline to symbols and safety instructions . . . . 6
1.1 Guideline to symbols . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 General warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Regulations and guidelines . . . . . . . . . . . . . . . . . . . . 8
2.1 Massachusetts Installations Only: . . . . . . . . . . . . . 8
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Heating system water quality . . . . . . . . . . . . . . . . . 9
3.3 Pump test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Freeze protection . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Tools, materials and further equipment . . . . . . . . . 9
3.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Dimensions and connections . . . . . . . . . . . . . . . . . 10
4.1 Without pump group . . . . . . . . . . . . . . . . . . . . . . 10
4.2 With pump group . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Packaging and transportation . . . . . . . . . . . . . . . . . 12
5.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Transporting the boiler . . . . . . . . . . . . . . . . . . . . . 12
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 Requirements for the installation room . . . . . . . . 14
6.2 Requirements for the heating system . . . . . . . . . 14
6.3 Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4 Water and Gas connection . . . . . . . . . . . . . . . . . 15
6.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4.2 Connecting the pressure relief valve (PRV) . . . . 16
6.4.3 Making the gas connection . . . . . . . . . . . . . . . . . 16
6.4.4 Installing the heating supply and return pipe . . . 17
6.4.5 Installing the pump . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4.6 Installing the condensate trap . . . . . . . . . . . . . . . 17
6.5 Connecting the condensate drain pipe . . . . . . . 18
6.5.1 Connecting the expansion vessel in a
single-boiler system . . . . . . . . . . . . . . . . . . . . . . . 19
6.6 Combustion Air and Ventilation Openings . . . . . 19
6.7 Flue gas adapter . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.8 Installation of the Exhaust and Air Intake system
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.9 Multiple boiler vent terminal clearance . . . . . . . . 25
7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 External connection board connections . . . . . . . 27
7.1.1 Routing the cable through the boiler . . . . . . . . . 27
7.1.2 Low voltage connections . . . . . . . . . . . . . . . . . . . 27
7.1.3 120 VAC connections . . . . . . . . . . . . . . . . . . . . . 28
7.1.4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2 Installing function modules (accessories) . . . . . . 29
7.2.1 Installing function modules in the boiler . . . . . . 29
7.2.2 Installing function modules outside the boiler . . 30
7.3 Electrical wiring diagram . . . . . . . . . . . . . . . . . . . 31
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.1 BC10 basic controller . . . . . . . . . . . . . . . . . . . . . 34
8.2 BC10 operating instructions . . . . . . . . . . . . . . . 35
9 Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1 Check for gas leaks . . . . . . . . . . . . . . . . . . . . . . . 41
9.2 Fill the heating system . . . . . . . . . . . . . . . . . . . . . 41
9.3 Fill the condensate trap with water . . . . . . . . . . 42
9.4 Bleed the gas supply valve . . . . . . . . . . . . . . . . . 43
9.5 Check the air/flue gas connection . . . . . . . . . . . 43
9.6 Checking the appliance configuration . . . . . . . . 44
9.7 Measure the gas inlet pressure
(working pressure) . . . . . . . . . . . . . . . . . . . . . . . 44
9.8 Check and adjust the gas/air ratio . . . . . . . . . . . 45
9.9 Carry out a leakage test in operating conditions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.10 Check and adjust the flue gases CO emissions 47
9.11 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.12 Measure the ionization current . . . . . . . . . . . . . . 48
9.13 Test the Ignition Safety shut off device . . . . . . . 48
9.14 Boiler settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.14.1 Set the heating capacity . . . . . . . . . . . . . . . . . . . 49
9.14.2 Set the space heating water temperature . . . . . 49
9.14.3 Set the pump run-over time . . . . . . . . . . . . . . . . 49
9.14.4 Switch DHW mode ON/OFF . . . . . . . . . . . . . . . 49
9.14.5 Set the DHW temperature . . . . . . . . . . . . . . . . . 49
9.15 Final activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.15.1 Close the boiler door and the control panel . . . 50
9.15.2 Hand over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10 Shutting down the system . . . . . . . . . . . . . . . . . . . . . 51
10.1 Shut down the appliance using the basic
controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.2 Shutting down the heating system if there is a
risk of freezing (interruption of use) . . . . . . . . . . 51
10.3 Shutting down the heating system in the event
of an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11.1 Prepare the appliance for inspection . . . . . . . . . 52
11.2 Carry out a visual check for general signs of
corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.3 Gas valve leakage test . . . . . . . . . . . . . . . . . . . . 53
11.4 Measure the ionization current . . . . . . . . . . . . . . 53
11.5 Measure the gas inlet pressure
(working pressure) . . . . . . . . . . . . . . . . . . . . . . . . 53
11.6 Check and adjust the gas/air ratio . . . . . . . . . . . 53
11.7 Carry out a leakage test in operatingconditions 53
11.8 Measure the flue gases CO emissions . . . . . . . 53
11.9 Fill the heating system . . . . . . . . . . . . . . . . . . . . . 53