This document serves as a record book and guide for the water quality requirements of the Buderus Logamax plus GB162-80 kW/100 kW condensing gas boiler, intended for heating contractors. It emphasizes the critical role of water quality in maintaining the boiler's performance, longevity, and warranty validity.
Function Description
The Logamax plus GB162-80 kW/100 kW is a condensing gas boiler designed for heating systems. Its efficient operation relies heavily on the quality of the system water, as poor water quality can lead to various issues such as scale formation, corrosion, and reduced heat transfer efficiency. The boiler is designed to work with specific water quality parameters, and this record book helps ensure these parameters are met and maintained. The document also highlights the importance of proper system setup, including the installation of a dirt trap and, in certain cases, secondary heat exchangers, to protect the boiler from contaminants and ensure optimal performance. The use of anti-freeze and inhibitors is also addressed, with specific guidelines to prevent damage and maintain warranty.
Usage Features
The manual outlines several key usage features and considerations for the Logamax plus GB162-80 kW/100 kW boiler:
- System Requirements: For proper operation, the heating system must include a dirt trap (y-strainer) and a desludging device, installed between the boiler and the lowest point in the return of the system. This helps prevent dirt and sediment from entering the boiler. A low loss header and boiler connection set, supplied with the boiler, are also mandatory. If oxygen-permeable plastic pipes are used (e.g., for floor heating), the system must be separated using secondary heat exchangers to prevent oxygen ingress, which can lead to corrosion.
- Water Quality Parameters: The document specifies strict water quality requirements. For systems without anti-freeze, total hardness should be less than 300 ppm (17.5 gr/gall US), chloride less than 100 ppm (5.8 gr/gall US), and sulfate less than 100 ppm (5.8 gr/gall US). For systems with anti-freeze, total hardness should be less than 100 ppm (5.8 gr/gall US), chloride less than 25 ppm (1.5 gr/gall US), and sulfate less than 25 ppm (1.5 gr/gall US). If mains water does not meet these standards, demineralized water (distilled, deionized, or reverse osmosis treated) or secondary heat exchangers must be used.
- pH-Value: The pH-value of the system water is crucial. For systems without anti-freeze, the pH should be between 7.0 and 8.5. For systems with anti-freeze, it should be between 8.0 and 8.5. The pH-value must be checked annually and adjusted if necessary, following the anti-freeze manufacturer's instructions. A calibrated pH-measuring instrument with an accuracy of less than 0.1 is required for accurate readings.
- Anti-freeze Use: Only Buderus-approved anti-freeze fluids and concentrations are permitted. Approved products include Noble Company Noburst AL, Interstate Intercool Biogreen 50 AA, and Interstate Intercool NFP-50 AA. The anti-freeze concentration should not exceed 40%, as exceeding 50% voids the boiler's warranty. The use of anti-freeze affects heat transfer, requiring a potential increase in radiator surface area (e.g., 15% more surface for 30% anti-freeze concentration). When using anti-freeze, only CPVC or stainless steel flue material is allowed; PVC flue material must not be used.
- Inhibitor Use: Approved inhibitors include Sentinel X100 (at 2% concentration) and Fernox F1 protector (at 0.5% concentration). Any other additives must be approved by the boiler manufacturer for use with aluminum boilers.
- Filling Water: It is not permitted to use well water to fill or replenish the system.
- Corrosion Prevention: To prevent corrosion damage, it is essential to avoid constant oxygen ingress into the heating water, which can be caused by undersized or faulty expansion vessels.
Maintenance Features
The document outlines several maintenance features and practices essential for the Logamax plus GB162-80 kW/100 kW boiler:
- Annual Service Records: Warranty claims are valid only in conjunction with properly completed annual service records in the operator's log and the servicing and maintenance log (part of the installation and service manual). This record book provides a structured log for documenting water quality checks and other relevant information.
- Dirt Trap Cleaning: The installed dirt trap must be cleaned at every annual service to ensure it effectively removes sediment and debris from the system.
- Heating System Cleaning: Prior to filling the heating system (excluding the boiler itself), it must be thoroughly flushed with mains water for 30 minutes to 1 hour. The boiler must be isolated from the heating system during this process by closing the shutoff valves underneath it. This prevents dirt and cleaning agents from entering the boiler. Approved cleaners for this purpose include Fernox F3 cleaner, Rhomar hydro-solv 9100 cleanser, and Sentinel X300 cleaner.
- Water Quality Checks: The water quality, including pH-value, total hardness, chloride, and sulfate levels, must be checked regularly, at least annually. The findings should be recorded in the operator's log. If the pH-value is not within the specified range, it must be corrected.
- Anti-freeze Concentration Checks: If anti-freeze is used, its concentration must be regularly checked annually, following the manufacturer's instructions. A measuring instrument with an accuracy of at least 1% is required for this.
- Cross-Contamination Prevention: Measures must be taken to prevent cross-contamination with potable water, such as disconnecting the filling loop or installing a safety valve.
- Operator's Log: The operator's log, included at the end of the document, is a crucial tool for tracking important system parameters over time. It includes fields for the date, water quality check results (with space to enclose analysis results), type of fill water, added water volume, total water volume, added anti-freeze volume, anti-freeze concentration, pH-value, primary flow over the boiler, and company stamp/signature. This log helps ensure consistent adherence to water quality requirements and provides a historical record for troubleshooting and warranty purposes.
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