Buderus Logamax plus GB142-60 Bedienungsanleitung

Propane Conversion Kit

Instruction

Condensing gas boiler

GB142-24/30/45/60

7215 0100 (10/2007) US/CA

For the contractor

Please read these

instructions carefully!

Required Input Rates

This kit and instructions are for converting the GB142 model boilers

from Natural Gas to Liquid Propane.

Notice! Save these instructions for later use.

GB142-24

84,800 btu/hr

GB142-30

106,000 btu/hr

GB142-45

160,900 btu/hr

GB142-60

214,800 btu/hr

WARNING!

This conversion kit shall be installed 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 dam-

age, 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 manufac-

turer’s instructions supplied with the kit.

CAUTION!

The gas supply shall be shut off prior to disconnecting the elec-

trical power, before proceeding with the conversion.

Contents

GB142-15/24/30/45/60 - We reserve the right to make any changes due to technical modifications!2

Contents 3

1 Safety considerations 3

1.1 Application purpose 3

1.2 Hazard definitions 3

1.3 Observe the following symbols 3

2 Parts list for converting the boiler

to propane 4

3 LP conversion 5

3.1 Testing for gas leaks 6

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) 10

3.6 Lighting Instructions 10

4 Operating Instructions 11

1Safety considerations

GB142-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 3

Contents

1 Safety considerations

For use in Canada the conversion kit shall be carried

out in accordance with the requirements of the provin-

cial 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 kit and instructions are for converting the GB142-

24/30/45/60 from Natural gas to Liquid Propane.

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 elec-

tric shock.

NOTICE

Indicates special instructions on installa-

tion, operation or maintenance that are

important but not related to personal injury

or property damage.

DANGER

due to explosion of gas.

zWork only on gas components when

you have a license to do so.

zNote 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 techni-

can.

DANGER

due to electricity.

zPrior to doing any work on the heating

system, disconnect all electrical power

to the appliance at the emergency

switch.

zIt is NOT sufficient to shut off only the

appliance control!

2Parts list for converting the boiler to propane

GB142-24/30/45/60 - We reserve the right to make any changes due to technical modifications!4

2 Parts list for converting the boiler to propane

Conversion kit propane for the 24/30 kW # 76687

includes:

–orifice # 7099016 (dia. 3.35 mm / 0.131 inch)

–2 o-rings

–bag

–these instructions

–label to be filled out and affixed to the boiler.

Conversion kit propane for the 45 kW # 76688 includes:

–orifice # 7099935 (dia. 4.05 mm / 0.158 inch)

–2 o-rings

–bag

–these instructions

–label to be filled out and affixed to the boiler.

Conversion kit propane for the 60 kW # 7746900156

includes:

–orifice # 76690 (dia. 5.40 mm / 0.213 inch)

–2 o-rings

–bag

–these instructions

–label to be filled out and affixed to the boiler.

3LP conversion

GB142-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 5

3 LP conversion

To convert the boiler to propane, the following instruc-

tions must be adhered to:

Shut down the boiler

zTurn off the gas supply.

zSwitch off the heating system using the main switch

(fig. 1).

zDisconnect the electrical power to the boiler.

zSet the thermostat or other operating control to low-

est setting.

zRemove the casing (fig. 2).

Changing the gas orifice

zLoosen the screw connection on the gas valve

(fig. 3, pos. 1) and pull the plug (fig. 3, pos. 2) from

the gas valve.

zPull both plugs from the fan unit (fig. 3, pos. 3).

zLoosen both retaining clips (fig. 3, pos. 4) on the

burner cover and remove the burner cover together

with the fan unit and the gas valve.

DANGER

if flammable gas explodes.

Only carry out work on gas conduits and fit-

tings if you are licensed for such work.

This appliance is NOT suitable for use with

gas mixtures such as Butane/Propane

Fig. 1

Reset

140

130

120

100

110

Aut

Eco

190

170

150

130

110

Aut

Fig. 2

GB142-24/30 GB142-45/60

Fig. 3

GB142-24/30 GB142-45/60

3LP conversion

GB142-24/30/45/60 - We reserve the right to make any changes due to technical modifications!6

zLoosen the three Phillips screws (fig. 4, pos. 1) and

remove the gas valve from the fan unit.

zRemove the gas orifice (fig. 4, pos. 2).

zFit the correct orifice for the new type of gas supply

(table 1). Make sure not to damage the O-rings.

zRe-assemble all parts in reverse order of disassem-

bly.

zCarry out the start-up activities and complete a new

start-up report.

zAlso check all joints and gaskets affected by the

installation activities while carrying out the tightness

test in operating conditions.

zPlace a new sticker underneath the existing rating

plate sticker indicating the type of gas supply

installed. Fill out the required information on the

conversion label.

zFit the casing again.

3.1 Testing for gas leaks

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

nal tightness of the gas supply valve and confirm this in

the start-up report.

zDisconnect the heating system from the power sup-

ply.

zCheck 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

14 inch W.C. (35 mbar).

zCheck the input rates after converting the boiler to

LPG to the values on the front page.

Fig. 4

Boiler

capacity

Type of gas

supply

Gas orifice

diameter in mm

(inch)

Venturi

article

number

24 kW Natural gas 4.45 (0.174) 423.072A

LPG P3.35 (0.131) 423.072A

30 kW Natural gas 4.45 (0.174) 423.072A

LPG P3.35 (0.131) 423.072A

45 kW Natural gas 5.40 (0.213) 423.170A

LPG P4.05 (0.158) 423.170A

60 kW Natural gas 7.50 (0.293) 423.173A

LPG P5.40 (0.213) 423.173A

Table 1 Gas orifice diameter

WARNING !

–Cover unprotected boiler parts before

leak testing.

–Do not spray the leak testing agent onto

cables, plugs or electrical connection

lines. Do not allow it to drip onto them

either.

DANGER !

Commissioning and maintenance activities

can cause leaks in pipe and screw connec-

tions.

–Carry out a proper leak test.

–Only use approved leak detection

agents for leak detection.

3LP conversion

GB142-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 7

3.2 Inlet gas pressure

zOpen at least one thermostatic radiator valve if

present to allow water to flow through the boiler.

Do not switch on the boiler.

zClose the gas shut-off valve. Loosen the screw plug

on the inlet gas pressure testing nipple by two turns

(fig. 5, pos. 1).

zConnect the pressure gauge connection hose to the

testing nipple (fig. 5, pos. 2).

zSlowly open the gas shut-off valve.

The boiler and its individual shutoff valve must be dis-

connected from the gas supply piping system during

any pressure testing of that system at test pressures in

excess of ½ psi (3.5 kPa).

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 ½ psi

(3.5 kPa).

zBriefly press on the control panel cover to open it.

zSwitch on the heating system by setting the main

switch to position "1" (see fig. 10, page 11).

zPress the "Chimney Sweep" dbutton and hold it

(for approx. two seconds) until the display shows a

decimal point.

zMeasure the gas connection pressure as soon as

the "Burner" LED lights and enter this value in the

start-up report.

The inlet gas pressure must be:

–for natural gas - min. 3.5 to 10.5 inch W.C. (8.7 to

26.1 mbar), nominal supply pressure 7.0 inch W.C.

(17.4 mbar)

–for LPG - min. 8.0 to 13.0 inch W.C. (19.9 to

32.3 mbar), nominal supply pressure 11.0 inch

W.C. (27.4 mbar).

zRepeatedly press the "Service" ebutton until the

temperature indication is displayed.

Fig. 5 Measuring the inlet gas pressure

Fig. 6 Opening the control panel

3LP conversion

GB142-24/30/45/60 - We reserve the right to make any changes due to technical modifications!8

zPress the "Chimney Sweep" dbutton to end the

measurement procedure.

zClose the gas shut-off valve.

zRemove the connection hose again and tighten the

screw plug on the testing nipple.

zOpen the gas shut-off valve again.

3.3 Checking and adjusting the gas/air

ratio

zSwitch off the heating system using the main switch.

zLoosen the screw plug on the measuring nipple for

the burner pressure by two rotations (fig. 7, pos. 1).

zSet the pressure gauge to zero.

zUse a hose to connect the plus terminal of the pres-

sure gauge to the burner pressure measuring nipple

(fig. 7, pos. 2).

zSwitch on the heating system using the main switch.

zPress the "Chimney Sweep" dbutton and hold it

(for approx. two seconds) until the display shows the

decimal point.

zPress and hold the "Chimney Sweep" dand "Ser-

vice" ebuttons (for approx. five seconds) until the

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

zSet the boiler to partial load "L30" by pressing the

"Chimney Sweep" dbutton (higher values) or the

"Reset" cbutton (lower values).

CAUTION

–Contact the relevant gas utility company

if the required inlet gas pressure is not

available.

–Install a gas pressure regulator before

the gas burner fitting if the supply pres-

sure is too high.

Fig. 7 Checking the gas/air ratio

= higher values = lower values

3LP conversion

GB142-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 9

zRead 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 – 0 Pa).

zEnter the value measured in the start-up report.

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

using the adjustment screw (fig. 8, pos. 1). The

adjustment screw is located behind the cover screw.

zRepeatedly press the "Service" ebutton until the

temperature indication is displayed.

zPress the "Chimney Sweep" dbutton until the dec-

imal point is cleared from the display.

zSwitch off the heating system using the main switch.

zRemove the measurement set-up, tighten the screw

in the burner pressure measuring nipple.

zSwitch on the heating system using the main switch.

3.4 Carrying out a tightness test in

operating conditions

zCheck all gaskets and joints in the burner gas circuit

for leaks while the burner is operational, using a

foaming agent.

Fig. 8 Setting the gas/air ratio

DANGER !

Leaks may be caused to pipes and screw

connections during start-up activities if

flammable gas explodes.

–Only use approved leak detection

agents for leak detection such as a

soapy water solution.

CAUTION

due to a short circuit.

–Cover damageable parts before leak

testing.

–Do not spray the leak testing agent onto

cables, plugs or electrical connection

lines. Do not allow it to drip onto them

either.

3LP conversion

GB142-24/30/45/60 - We reserve the right to make any changes due to technical modifications!10

3.5 Measuring the carbon monoxide

content (CO)

zMeasure the carbon monoxide content on the flue

gas sampling point (fig. 9).

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

400 ppm or 0.04 vol. %. Values of 400 ppm and up indi-

cate that the burner adjustment may be wrong, the gas

burner fitting or the heat exchanger are dirty or that

there may be burner faults.

zYou must establish and resolve the cause.

The boiler must be operational when you do this.

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.

Fig. 9 Flue gas sampling point

WARNING !

due to not follow these instructions.

zIf you do not follow these instructions

exactly, a fire or explosion may result

causing property damage, personal

injury or loss of life.

zFollow these operating instructions.

DANGER !

What to do if you smell gas:

zNo open fire! Do not smoke!

zAvoid formation of sparks! Do not touch

any electric switch, phone, electric plug

or bell!

zShut off main gas supply.

zOpen windows and doors!

zNotify all occupants!

zLeave the building!

zImmediately call your gas supplier,

heating contractor or fire department

from a phone outside the building!

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