Buderus GB162-65 Bedienungsanleitung

Installation instructions Pump group

Logamax plus

GB162-65/80/100

7217 5100 (03/2010) GB

For heating engineers

Please read thoroughly

before starting installation

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!

1 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 About these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Items supplied with pump group . . . . . . . . . . . . . . . . . . . . . . 5

4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.1 Making the gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.2 Removing the non-return valve (if necessary) . . . . . . . . . . . . . . . . . . . . . 8

5.3 Installing the heating flow and return . . . . . . . . . . . . . . . . . . . . . . . . . .10

5.4 Rotating the pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5.5 Installing the syphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

5.6 Connecting the condensate drain pipe . . . . . . . . . . . . . . . . . . . . . . . . .14

5.7 Connecting the expansion vessel (accessory) . . . . . . . . . . . . . . . . . . . . .14

5.8 Making the electrical connections to the pump . . . . . . . . . . . . . . . . . . . . .15

5.9 Installing the insulation cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Regulations 1

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 3

1 Regulations

1.1 About these instructions

These installation instructions contain important

information about the safe and proper installation of the

Logamax plus GB162-65/80/100 pump group.

These installation instructions are for competent heating

engineers (e.g. Gas Safe registered) who, due to their

professional training and experience, are experts at

dealing with heating systems and gas installations.

1.2 Intended use

The pump group must only be installed on the Logamax

plus GB162-65/80/100 heating boiler.

1.3 Regulations

Please ensure that you comply to all regulations at the

time of installation.

NOTE

The country-specific standards and

guidelines and the technical documents

pertaining to the boiler must be observed

for the installation and operation of the

heating system!

Safety2

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!

2 Safety

Please observe these instructions for your own safety.

You can find a detailed explanation of the format of

these instructions in the Installation and Servicing

Instructions of the Logamax plus GB162-65/80/100.

Observe the following instructions when installing and

operating the pump group:

DANGER OF FATAL ACCIDENT

by unprofessional repair.

Do not repair parts with safety functions.

DANGER OF FATAL ACCIDENT

due to electric shock.

Before opening the boiler: Switch off the

power supply to the boiler by pulling the

mains plug from the socket.

DANGER OF FATAL ACCIDENT

from explosive fumes.

If you smell gas, there is a danger of

explosion.

No naked lights. No smoking.

Do not use lighters!

DO NOT operate any device that is likely

to produce sparks.

Do not operate any electrical switches,

including telephones, plugs or doorbells.

Shut off the main gas supply!

Open doors and windows.

Warn the residents but do not sound the

doorbells!

Contact the gas supplier from a tele-

phone located outside the building!

If you can hear gas leaking, evacuate the

building immediately, prevent other

people from entering, and notify the

police and fire service immediately (from

a telephone OUTSIDE the building).

Items supplied with pump group 3

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 5

3 Items supplied with pump group

Check that the packaging is intact upon delivery.

Check that all items have been supplied with the unit.

fig. 1 Items supplied with Logamax plus GB162-65/80/100

pump group

Item 1: Isolating valve, red (CH boiler flow) with drain cock,

pressure gauge, thermometer (for pump

UPER 25-80) and 4-bar safety valve

Item 2: Isolating valve, blue (CH boiler return) with pump,

drain cock and non-return valve (removable)

Item 3: Connecting bracket

Item 4: Gas valve, yellow (GAS)

Item 5: Flat rubber seal 1½’’ (2×)

Item 6: Insulation cover

Item 7: Technical documents

NOTE

Please contact your supplier if anything

is damaged or missing.

Dimensions4

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!

4 Dimensions

AIC

FGC

AIC

FGC

CDO

Gas P

Gas B Gas B

CHF/CHR

CHRCHF

PF/PR PF PR

fig. 2 Dimensions and connections (dimensions in mm)

1 DO NOT remove the cap CS (not used in UK)

2 The pump group is accessory and can be ordered separately.

This figure shows a pump group, that isn’t ment for DHW supply, but ONLY for central heating hot water supply. There is also a pump group with

3-way valve (accessory) available, which is ment for DHW supply.

CS = Cap (DO NOT remove)

FGC/AIC = Flue gas/air intake connection Ø 100/150

CDO = Condensate drain outlet Ø 24 mm O/D

GAS P = Gas connection to pump group; Rp1’’ female thread

GAS B = Gas connection to boiler; Rp1’’ female thread

CHF = Boiler flow; G1½’’ union nut with female thread

CHR = Boiler return; G1½’’ union nut with female thread

PF = Pump group flow; G1½’’ male thread, flat seal

PR = Pump group return; G1½’’ male thread, flat seal

Installation 5

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 7

5 Installation

General installation instructions

Connect all pipes without forcing them into place.

Make sure that the connections are tight and carry

out a gas and water tightness test after completing

the connection work (also see the boiler installation

and servicing instructions).

5.1 Making the gas connection

Install the gas valve (fig. 4, item 1) onto the gas pipe

(GAS) in the boiler.

Connect the main gas supply to the gas isolating

valve (fig. 4, item 2) free of strain.

fig. 3 Rubber seal

DANGER OF FATAL ACCIDENT

from explosive fumes.

Only carry out work on gas pipes and

fittings if you are properly certified (e.g.

Gas Safe registered).

DANGER OF FATAL ACCIDENT

due to gas escaping.

Make sure that the factory-fitted flat

rubber seal is located in the threaded

connection (boiler side) (fig. 3, see

detailed picture).

fig. 4 Making the gas connection

Item 1: Gas isolating valve

Item 2: Gas connection

NOTE

We advise you to integrate a gas filter in the

gas line.

Make the gas connection according to

the country-specific standards and regu-

lations.

Carry out gas leak test on gas connec-

tion using leak detection spray

DANGER OF FATAL ACCIDENT

from explosive fumes.

Pipes and screw connections may leak after

commissioning and maintenance activities

have been carried out.

Carry out a leakage test.

Only use approved detection products to

locate leaks.

Installation5

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!

5.2 Removing the non-return valve (if necessary)

If the system pressure is not sufficient according to

table 3, page 11, you can remove the integrated non-

return valve from single-boiler systems.

Selecting the correct pump group

Select the correct pump group using table 1.

1) Only remove the non-return valve from the pump group (beneath

the pump) when installing single-boiler systems

2) Do not use a pump group or switch, but select a separate pump

using the installation and servicing instructions with the boiler.

Logamax plus

GB162-65

Logamax plus

GB162-80

Logamax plus

GB162-100

Multi-boiler

system

(cascade

system)

UPER 25-80/

UPS 25-80 pump

group with pump

UPER 25-80/

UPS 25-80 pump

group with pump

UPER 25-80/

UPS 25-80 pump

group with pump

Single-boiler

system with

Buderus

diverter valve

UPER 25-80/

UPS 25-80 pump

group with pump

UPER 25-80/

UPS 25-80 pump

group with pump

UPER 25-80/

UPS 25-80 pump

group with pump

Single-boiler

system without

diverter valve

UPER 25-80/

UPS 25-80 pump

group with pump

UPER 25-80/

UPS 25-80 pump

group with pump

Table 1 Selecting the correct pump group

DAMAGE TO THE UNIT

in cascade systems or in single-boiler

systems with a switch due to the heating

medium flowing back.

Only remove the non-return valve from

the pump group of a single-boiler system

if the residual head (see table 3, page 11

is not sufficient.

Logamax plus

GB162-65

Logamax plus

GB162-80

Logamax plus

GB162-100

Multi-boiler

system (cascade

system)

not allowed not allowed not allowed

Single-boiler

system with

Buderus diverter

valve

not allowed not allowed not allowed

Single-boiler

system without

diverter valve

Check the

residual head

Check the

residual head

not effective,

use pump

Table 2 Removing the non-return valve

Installation 5

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 9

Removing the non-return valve

Remove the non-return valve before installing the

heating flow and return circuits otherwise it cannot be

fully removed anymore!

Remove the pump (fig. 5, item 1).

Remove the flat rubber seal (fig. 5, item 2).

Remove the non-return valve (fig. 6, item 1).

This will damage the non-return valve beyond repair.

Rotate and shake the pump group.

fig. 5 Removing the pump

fig. 6 Removing the non-return valve

fig. 7 Removing the non-return valve

DAMAGE TO THE UNIT

due to reduced flow or pipes becoming

clogged up.

Make sure that no fragments of the non-

return valve stay behind in the pipe.

Installation5

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!

Then fit back the flat rubber seal (fig. 8, item 2) and

the pump (fig. 8, item 1).

5.3 Installing the heating flow and return

Install the blue and red isolating valve (fig. 9, item 3

and item 4) with the flat rubber seals in place on the

CHR and CHF (boiler return and flow) connections.

Connect the flow pipe to the red isolating valve (fig. 9,

item 5) free of strain. If necessary, use the screw

fitting (accessory, fig. 9, item 7).

Connect the return pipe to the blue isolating valve

(fig. 9, item 6) free of strain. If necessary, use the

screw fitting (accessory, fig. 9, item 7).

Calculate the flow and return pipe diameters taking

into consideration the residual head downstream of

the pump group with the minimum required volume

flow (see table 3 and fig. 24 on page 19).

The minimum diameters of the flow and return pipes

are 1½’’ and Ø 35 mm.

fig. 8 Fitting the pump

fig. 9 Installing the isolating valves

Item 1: Pressure relief valve

Item 2: Pump

Item 3: Isolating valve, blue

Item 4: Isolating valve, red

Item 5: Flow connection

Item 6: Return connection

Item 7: Screw fitting 1’’ female thread (accessory)

NOTE

To prevent pollution in the heating system

we advise you to integrate a dirt filter in the

return circuit. When connecting the heating

boiler to an existing heating system, this dirt

filter must be installed.

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