Buderus Logamax plus GB162-100 kW Guía

For the contractor

Please read these instruc-

tions carefully

Gas valve replacement

instructions

Condensing gas boiler

Logamax plus

Required Input Rates

Logamax plus GB162-80 kW Logamx plus GB162-100 kW

290,000 btu/hr 333,000 btu/hr

This instruction is for replacing the gas valve for the GB162

model boilers with Natural Gas.

WARNING!

Replacement of a gas valve must be done by a qualified service

agency in accordance with the manufacturer‘s instructions and all

applicable codes and requirements of the authority having

jurisdiction.

The information in these instructions must be followed to minimize

the risk of fire or explosion or to prevent property damage,

personal injury or death. The qualified service agency is

responsible for the proper installation of this kit.

The installation is not proper and complete until the operation of

the converted boiler is checked as specified in the manufacturer‘s

instructions supplied with the gas valve.

CAUTION!

The gas supply shall be shut off prior to disconnecting the

electrical power, before proceeding with the conversion.

Notice! Save these instructions for later use.

GB162-80 kW

GB162-100 kW

6 720 615 152 (11/2011) US/CA

Contents

Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!

Contents

1 Safety considerations 3

1.1 Application purpose 3

1.2 Hazard definitions 3

1.3 Observe the following symbols 3

2Partslist 4

3 Gas valve replacement 5

3.1 Testing for gas leaks 7

3.2 Inlet gas pressure 7

3.3 Checking and adjusting the gas/air ratio 8

3.4 Carrying out a tightness test in

operating conditions 9

3.5 Measuring the carbon monoxide content (CO) 9

3.6 Lighting Instructions 10

4 Operating Instructions 11

Safety considerations

Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 3

1 Safety considerations

For use in Canada the gas valve replacement shall be

carried out in accordance with the requirements of the

provincial authorities having jurisdiction and in

accordance with the requirements of the CAN-B149.1

and CAN1-B149.2 Installation Code. See also E.I.V.

Please observe the following safety instructions.

1.1 Application purpose

This document describes how to replace the gas valve for

the Logamax plus GB162-80 kW/100 kW.

1.2 Hazard definitions

The following defined terms are used throughout the

documentation to bring attention to the presence of

hazards of various risk levels. Notices give important

information concerning the operation of the product.

1.3 Observe the following symbols

DANGER:

Indicates the presence of hazards that will

cause severe personal injury, death or

substantial property damage.

WARNING:

Indicates the presence of hazards that can

cause severe personal injury, death or

substantial property damage.

CAUTION:

Indicates presence of hazards that will or

cause minor personal injury or property

damage.

CAUTION:

Risk of electric shock.

Indicates presence of hazards due to electric

shock.

Indicates special instructions on installation,

operation or maintenance that are important

but not related to personal injury or property

damage.

DANGER:

due to explosion of gas.

BWork only on gas components when you

have a license to do so.

BNote that the assembly of gas and vent

connections, the initial start-up, the

electrical connections, the maintenance

and service can only be performed by a

licensed service contractor or technican.

DANGER:

due to electricity.

BPrior to doing any work on the heating

system, disconnect all electrical power to

the appliance at the emergency switch.

BIt is NOT sufficient to shut off only the

appliance control!

2Parts list

Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!

2 Parts list

The gas valve spare part for the 80 kW/100 kW

# 7746900399 includes:

• assembly # 774601465A

– gas valve Natural Gas

– venturi

– orifice # 432.438A (dia. 8.40 mm / 0.331 inch)

•bag

• these instructions

• O-ring (fan-venturi)

• O-ring (gas train)

• sealing (gas pipe)

• Torx keys Tx25 and Tx30

• Torx screws (flange).

Gas valve replacement

Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 5

3 Gas valve replacement

To replace the gas valve the following instructions must

be adhered to:

Shut down the boiler

BTurn off the gas supply underneath the boiler.

BSwitch off the heating system using the main switch

(Æfig. 1).

BDisconnect the electrical power to the boiler.

BSet the thermostat or other operating control to lowest

setting.

Fig. 1 Mains switch

BOpen the boiler door by turning the vent key through

¼ rotation (Æfig. 2).

Fig. 2 Opening the boiler door

Changing the gas valve assembly

BLoosen the screw connection on the gas valve

(Æfig. 3, [1]) and pull the plugs (Æfig. 3, [2]) from the

gas valve.

Fig. 3 Undoing the connections to the gas valve

BPull both plugs from the fan unit (Æfig. 4, [1]).

Fig. 4 Removing the connectors from the fan

BPull the air suction tube from the fan (Æfig. 5).

Fig. 5 Pulling the air suction tube from the fan

DANGER:

flammable gas explodes.

Only carry out work on gas conduits and

fittings if you are licensed for such work.

Reset

140

130

120

100

110

Aut

Eco

190

170

150

130

110

Aut

6720615033-002.1TD

6720615033-003.1TD

1 2

6720615033 004 1T

6720615033-005.1TD

6720615033-006.1TD

3Gas valve replacement

Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!

BLoosen both retaining clips on the burner cover

(Æfig. 6).

Fig. 6 Opening the retaining clips

BRemove the burner cover together with the fan unit and

the gas valve (Æfig. 7).

Fig. 7 Removing the burner cover with the gas/air unit

BUndo the three screws (Æfig. 8, [1]) and remove the

gas valve with the venturi from the fan unit

(Æfig. 8, [2]).

BTake the gas valve and venturi from the box.

Fig. 8 Removing the screws and gas valve with venturi

BInstall the venturi and gas valve on the fan unit using a

new O-ring (Æfig. 9) and follow the instructions above

in reverse order.

Fig. 9 Placing a new O-ring on the fan unit

BInstall the gas flange from the natural gas assembly on

the new gas valve (Æfig. 10, [1]), insert the O-ring

(Æfig. 10, [2]) supplied.

Fig. 10 Installing the gas flange

Thermal

power

gas

boiler

Type of

gas

supply

Altitude

in ft (m)

Gas orifice

diameter in

mm (inch)

Venturi

article

number

GB162-

80 kW/

100 kW

Natural

gas

0 - 4,000

(0 - 1,220)

8.40

(0.331)

73983

Tab. 1 Gas orifice diameter

6720615033-007.1TD

6720615033-008.1TD

6720615033-009.1TD

6720615033-013.1TD

6720615033-014.1TD

Gas valve replacement

Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 7

BRemove the seal from the gas pipe and install a new

seal (Æfig. 11).

Fig. 11 Installing a new seal on the gas pipe

BRefit all parts in reverse order. When re-installing the

burner plate, make sure that the notch is on the right-

hand side (Æfig. 12).

BCarry out the start-up activities and complete a new

start-up report.

BAlso check all joints and gaskets affected by the

installation activities while carrying out the tightness

test in operating conditions.

BClose the boiler door and lock the fastener by turning

the vent key through ¼ rotation in a clockwise

direction.

Fig. 12 Re-installing the burner plate

3.1 Testing for gas leaks

Prior to start-up of the boiler you must check the external

tightness of the gas supply valve and confirm this in the

start-up report.

BDisconnect the heating system from the power supply.

BCheck the exterior tightness of new conduit sections

up to and including the direct sealing point on the gas

burner fitting. The maximum test pressure allowed on

the input of the gas burner fitting is 60 inch W.C.

(150 mbar).

BCheck the input rates after to the values on the front

page.

3.2 Inlet gas pressure

BOpen at least one thermostatic radiator valve if present

to allow water to flow through the boiler. Do not switch

on the boiler.

BClose the gas shut-off valve. Loosen the screw plug on

the inlet gas pressure testing nipple by two turns

(Æfig. 13, [1]).

BConnect the pressure gauge connection hose to the

testing nipple (Æfig. 13, [2]).

BSlowly open the gas shut-off valve.

The boiler and its individual shutoff valve must be

disconnected from the gas supply piping system during

any pressure testing of that system at test pressures in

excess of 60 inch W.C. (150 mbar).

The boiler must be isolated from the gas supply piping

system by closing its individual manual shutoff valve

during any pressure testing of the gas supply piping

system at test pressures equal to or less than 60 inch

W.C. (150 mbar).

6720615033-015.1TD

6720615033-016.1TD

CAUTION:

due to a short circuit.

BCover damageable parts before leak

testing.

BDo not spray the leak testing agent onto

cables, plugs or electrical connection

lines. Do not allow it to drip onto them

either.

DANGER:

Leaks may be caused to pipes and screw

connections during commissioning and

maintenance activities.

BCarry out a proper leak test.

BOnly use approved leak detection agents

for leak detection.

3Gas valve replacement

Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!

Fig. 13 Measuring the gas supply pressure

BBriefly press on the control panel cover to open it.

Fig. 14 Opening the control panel

BSwitch on the heating system by setting the main

switch to position "1" (Æfig. 1, page 5).

BPress the "Chimney Sweep" button and hold it (for

approx. two seconds) until the display shows a decimal

point.

BMeasure the gas connection pressure as soon as the

"Burner" LED lights and enter this value in the start-up

report.

Statically measured1) gas supply pressure must be:

• for natural gas - min. 5.0 to 10.5 inch W.C. (12.4 to

26.1 mbar), nominal supply pressure 8.0 inch W.C.

(19.9 mbar)

BRepeatedly press the "Service" button until the

temperature indication is displayed.

BPress the "Chimney Sweep" button to end the

measurement procedure.

BClose the gas shut-off valve.

BRemove the connection hose again and tighten the

screw plug on the testing nipple.

BOpen the gas shut-off valve again.

3.3 Checking and adjusting the gas/air

ratio

BSwitch off the heating system using the main switch.

BLoosen the screw plug on the measuring nipple for the

burner pressure by two rotations (Æfig. 15, [1]).

BSet the pressure gauge to zero.

BUse a hose to connect the plus terminal of the pressure

gauge to the burner pressure measuring nipple

(Æfig. 15, [2]).

Fig. 15 Checking the gas/air ratio

BSwitch on the heating system using the main switch.

BPress the "Chimney Sweep" button and hold it (for

approx. two seconds) until the display shows the

decimal point.

BPress and hold the "Chimney Sweep" and

"Service" buttons (for approx. five seconds) until

the display shows "Lxx" (e. g. L80).

BSet the boiler to partial load "L25" for the 80 kW and

"L20" for the 100 kW boiler by pressing the "Chimney

Sweep" button (higher values) or the "Reset"

button (lower values).

BRead out the differential pressure.

The differential pressure (pGas – pAir) must be

-0.02 inch W.C. (- 5 Pa) (±0.02 inch W.C. = ± 5 Pa)

(read-out on pressure gauge: -0.04 – 0 inch W.C. =

-10–0Pa).

BEnter the value measured in the start-up report.

1) Measured statically perpendicular to flow at full load.

6720615033-017.1TD

6720615033-018.1TD

BContact the relevant gas utility company if

the required inlet gas pressure is not

available.

BInstall a gas pressure regulator before the

gas burner fitting if the supply pressure is

too high.

6720615033-019.1TD

Gas valve replacement

Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 9

BIf the gas/air ratio is not correct it can be adjusted using

the adjustment screw (Æfig. 16, [1]). The adjustment

screw is located behind the cover screw.

Fig. 16 Setting the gas/air ratio

BRepeatedly press the "Service" button until the

temperature indication is displayed.

BPress the "Chimney Sweep" button until the

decimal point is cleared from the display.

BSwitch off the heating system using the main switch.

BRemove the measurement set-up, tighten the screw in

the burner pressure measuring nipple.

BSwitch on the heating system using the main switch.

3.4 Carrying out a tightness test in

operating conditions

BCheck all gaskets and joints in the burner gas circuit for

leaks while the burner is operational, using a foaming

agent.

3.5 Measuring the carbon monoxide

content (CO)

BMeasure the carbon monoxide content on the flue gas

sampling point (Æfig. 17, [1]).

The CO values in an air-free condition must be below

400 ppm or 0.04 vol. %.

Values of 400 ppm and up indicate that the burner

adjustment may be wrong, the gas burner fitting or the

heat exchanger are dirty or that there may be burner faults.

BYou must establish and resolve the cause.

The boiler must be operational when you do this.

Fig. 17 Measuring the carbon monoxide content

DANGER:

Leaks may be caused to pipes and screw

connections during start-up activities if

flammable gas explodes.

BOnly use approved leak detection agents

for leak detection such as a soapy water

solution.

CAUTION:

due to a short circuit.

BCover damageable parts before leak

testing.

BDo not spray the leak testing agent onto

cables, plugs or electrical connection

lines. Do not allow it to drip onto them

either.

6720615033-020.1TD

6720615033-021.1TD

3Gas valve replacement

Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!

3.6 Lighting Instructions

For your safety, read before lighting.

A) This boiler is equipped with an ignition device which

automatically lights the pilot. Do not try to light the pilot by

hand.

B) Check for smell of gas around the boiler area.

Be sure to smell next to the floor because some gas is

heavier than air and will settle on the floor.

C) Do not use this boiler if any part has been under water.

Immediately call a qualified service technician to inspect

the boiler and to replace any part of the control system

and any gas control which has been under water.

WARNING:

due to not follow these instructions.

BIf you do not follow these instructions

exactly, a fire or explosion may result

causing property damage, personal injury

or loss of life.

BFollow these operating instructions.

DANGER:

What to do if you smell gas:

BNo open fire! Do not smoke!

BAvoid formation of sparks! Do not touch

any electric switch, phone, electric plug or

bell!

BShut off main gas supply.

BOpen windows and doors!

BNotify all occupants!

BLeave the building!

BImmediately call your gas supplier, heating

contractor or fire department from a phone

outside the building!

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