Buderus Logamax plus GB162-80 kW, Logamax plus GB162-100 kW Instructions Manual

Gas valve replacement

Condensing gas boiler

Logamax plus
GB162-80 kW/100 kW

6 720 615 152 (01/2008) US/CA

For the contractor

Please read these
instructions carefully!

Required Input Rates

This instruction is for replacing the gas valve for the GB162 model
boilers with Natural Gas.

Notice! Save these instructions for later use.

Logamax plus GB162-80 kW
290,000 btu/hr

Logamax plus GB162-100 kW
333,000 btu/hr

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 gas valve.
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.

Instructions

Contents

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

2

Contents

1 Safety considerations 3

1.1 Application purpose 3

1.2 Hazard definitions 3

1.3 Observe the following symbols 3

2 Parts list 4

3 Gas valve replacement 5

3.1 Testing for gas leaks 9

3.2 Inlet gas pressure 9

3.3 Checking and adjusting the gas/air ratio 11

3.4 Carrying out a tightness test in operating
conditions 12

3.5 Measuring the carbon monoxide
content (CO) 12

3.6 Lighting Instructions 13

4 Operating Instructions 14

1 Safety considerations

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

3

Contents

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 accor

­dance 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.

NOTICE:

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.

z Work only on gas components when

you have a license to do so.

z Note 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.

z Prior to doing any work on the heating

system, disconnect all electrical power
to the appliance at the emergency
switch.

z It is NOT sufficient to shut off only the

appliance control!

2 Parts list

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

4

2 Parts list

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

7746900399 includes:

– assembly # 774601465A

z gas valve Natural Gas

z venturi

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

– bag

– these instructions

– o-ring (fan-venturi)

– sealing (gas pipe)

– Torx keys Tx25 and Tx30

– Torx screws (flange).

Thermal

power

gas

boiler

Type of

gas

supply

Attitude

in ft

Gas orifice

diameter in

mm (inch)

Venturi

article

number

GB162-

80 kW

Natural
gas

0 - 10,200 8.40 (0.331) 73983

GB162-

100 kW

Natural
gas

0 - 10,200 8.40 (0.331) 73983

Table 1 Gas orifice diameter

3 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

z Turn off the gas supply underneath the boiler.

z Switch off the heating system using the main switch

(fig. 1).

z Disconnect the electrical power to the boiler.

z Set the thermostat or other operating control to

lowest setting.

z Open the boiler door by turning the vent key through

¼ rotation

(fig. 2).

DANGER

if flammable gas explodes.

Only carry out work on gas conduits and
fittings if you are licensed for such work.

fig. 1 Mains switch

Reset

01

1

140

130

120

90

100

110

Aut

0

Eco

190

170

150

13090110

Aut

0

fig. 2 Opening the boiler door

1

2

3