Buderus Logamax plus GB162-L.B. 80 kW, Logamax plus GB162-L.B. 100 kW, Logamax plus GB162-80 kW, Logamax plus GB162-100 kW Installation Instructions Manual
Condensing gas boiler
6720645916-00.1N
CAUTION!
Before putting the boiler into operation read this manual carefully.
DANGER!
Improper installation, adjustment, alteration, service or maintenance can
cause injury, loss of life or property damage. Refer to this manual.
For assistance or additional information consult a qualified installer,
service agency or the gas supplier.
CAUTION!
The operating manual is part of the documentation that is delivered to the
installation's operator. Go through the information i n this manual with the
owner/operator and make sure that he or she is familiar with all the
necessary operating instructions.
NOTICE!
In the Commonwealth of Massachusetts this boiler must be installed by a
licensed Plumber or Gas Fitter.
Danger: If the information in these instructions is not followed
exactly, a fire or explosion may result causing property damage,
personal injury or loss of life.
• Do not store or use gasoline or other flammable vapors and liquids
in the vicinity of this or any other appliance.
• What to do if you smell gas
– Do not try to light any boiler.
– Do not touch any electrical switch; do not use any phone in your
building.
– Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
– If you cannot reach your gas supplier, call the fire department.
• Installation and service must be performed by a qualified installer,
service agency or the gas supplier.
Notice!
• This manual is available in the English and French language.
• This manual must be retained for future reference.
Installation instructions
Logamax plus
GB162-L.B. 80 kW
GB162-L.B. 100 kW
6720645916 (2014/10) US
Read carefully before carrying out installation and maintenance.
6720645916-01.TD
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Fig. 1 Logamax plus GB162-L.B. with pump group
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)2
[1] BC10 basic controller receptacle
[2] Installation option for room controller, e.g. RC35
[3] Cover with user manual compartment
[4] BC10 basic controller, can be expanded e.g. by the RC35 room controller
[5] Connection box (low-voltage and 120 VAC connections)
[6] Fan harness and mains lead of the pump
[7] Condensate drain outlet
[8] Condensate collector
[9] Boiler front door
[10] Automatic air vent
[11] Retaining clips
[12] Air intake for the fan
[13] Gas pipe
[14] Flue gas pipe
[15] Door lock
[16] Flue gas sensor
[17] Flue measuring point
[18] Measuring point for air intake
[19] Flue gas connection
[20] Air intake connection
[21] Fan
[22] Gas valve
[23] Venturi
[24] Burner cover
[25] Flow temperature sensor
[26] Ionization electrode
[27] Sighting glass
[28] Glow igniter
[29] Safety temperature sensor
[30] Heat exchanger
[31] Pressure sensor
[32] Return temperature sensor
[33] Universal Burner Automatic Version 3 (UBA 3)
[34] Draw with function module integration options
[35] Cover shield
[36] Condensate trap
Pump group (scope of delivery)
[37] Isolating valve, blue (CH boiler return) with pump, drain cock, check valve and thermometer
[38] Manual gas shut off valve, yellow (GAS)
[39] Isolating valve, red (CH boiler flow) with drain cock, pressure gauge and thermometer
[40] Pressure gauge
[41] Isolating valve
[42] Thermometer (optional accessory)
[43] Drain valve
[44] Safety valve 30 psi (2 bar) (or 50 psi [3.45 bar] = optional)
The pump group also includes an insulation cover (see also pump group installation instructions).
Low loss header (single appliance only):
[45] Low loss header (not illustrated)
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 3
Contents
Contents
1 Explanation of symbols and safety information . . . . . . . . . . . 5
1.1 Guideline to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Regulations and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Massachusetts Installations Only . . . . . . . . . . . . . . . . . . 6
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Heating system water quality . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Pump test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Freeze protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Tools, materials and further equipment . . . . . . . . . . . . . 8
3.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Dimensions and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Without pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 With pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Packaging and transportation . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Transporting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 Requirements for the installation room . . . . . . . . . . . . 12
6.2 Requirements for the heating system . . . . . . . . . . . . . . 12
6.3 Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.4 Water and Gas connection . . . . . . . . . . . . . . . . . . . . . . . 13
6.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4.2 Connecting the pressure relief valve (PRV) . . . . . . . . . 14
6.4.3 Making the gas connection . . . . . . . . . . . . . . . . . . . . . . 14
6.4.4 Installing the heating supply and return pipe . . . . . . . . 14
6.4.5 Installing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4.6 Installing the condensate trap . . . . . . . . . . . . . . . . . . . . 15
6.5 Connecting the condensate drain pipe . . . . . . . . . . . . . 16
6.5.1 Connecting the expansion vessel in a
single-boiler system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.6 Combustion Air and Ventilation Openings . . . . . . . . . . 16
6.7 Flue gas adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.8 Installation of the Exhaust and Air Intake system . . . . . 18
6.9 Multiple boiler vent terminal clearance . . . . . . . . . . . . . 23
7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1 External connection board connections . . . . . . . . . . . . 24
7.1.1 Routing the cable through the boiler . . . . . . . . . . . . . . . 24
7.1.2 Low voltage connections . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1.3 120 VAC connections . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1.4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Installing function modules (accessories) . . . . . . . . . . 26
7.2.1 Installing function modules in the boiler . . . . . . . . . . . . 26
7.2.2 Installing function modules outside the boiler . . . . . . . 28
7.3 Electrical wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . 29
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.1 BC10 basic controller . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.2 BC10 operating instructions . . . . . . . . . . . . . . . . . . . . . 31
9 Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.1 Check for gas leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.2 Fill the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.3 Fill the condensate trap with water . . . . . . . . . . . . . . . . 35
9.4 Bleed the gas supply valve . . . . . . . . . . . . . . . . . . . . . . . 35
9.5 Check the air/flue gas connection . . . . . . . . . . . . . . . . . 36
9.6 Checking the appliance configuration . . . . . . . . . . . . . 36
9.7 Measure the gas inlet pressure (working pressure) . . . 36
9.8 Carry out a leakage test in operating conditions . . . . . 38
9.9 Check and adjust the flue gases CO
emissions . . . . . 38
2
9.10 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.11 Measure the ionization current . . . . . . . . . . . . . . . . . . . 39
9.12 Test the Ignition Safety shut off device . . . . . . . . . . . . . 40
9.13 Boiler settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.13.1 Set the heating capacity . . . . . . . . . . . . . . . . . . . . . . . . 40
9.13.2 Set the space heating water temperature . . . . . . . . . . 40
9.13.3 Set the pump run-over time . . . . . . . . . . . . . . . . . . . . . . 40
9.13.4 Switch DHW mode ON/OFF . . . . . . . . . . . . . . . . . . . . . . 40
9.13.5 Set the DHW temperature . . . . . . . . . . . . . . . . . . . . . . . 40
9.14 Final activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.14.1 Close the boiler door and the control panel . . . . . . . . . 41
9.14.2 Hand over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10 Shutting down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10.1 Shut down the appliance using the basic controller . . 41
10.2 Shutting down the heating system if there is a
risk of freezing (interruption of use) . . . . . . . . . . . . . . 41
10.3 Shutting down the heating system in the event
of an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.1 Prepare the appliance for inspection . . . . . . . . . . . . . . 42
11.2 Carry out a visual check for general signs of corrosion 42
11.3 Gas valve leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.4 Measure the ionization current . . . . . . . . . . . . . . . . . . . 43
11.5 Measure the gas inlet pressure (working pressure) . . . 43
11.6 Check and adjust the flue gas CO
emissions . . . . . . . 43
2
11.7 Carry out a leakage test in operating conditions . . . . . 43
11.8 Measure the flue gases CO
emissions . . . . . . . . . . . . . 43
2
11.9 Fill the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.10 Check the air/flue gas connection . . . . . . . . . . . . . . . . . 43
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12.1 Prepare the heating system for maintenance . . . . . . . . 43
12.2 Remove the boiler door . . . . . . . . . . . . . . . . . . . . . . . . . 43
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)4
12.3 Clean the heat exchanger, burner and
condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
12.3.1 Remove the gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
12.3.2 Remove the burner cover with the fan and the
gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
12.3.3 Remove the burner and the burner seal . . . . . . . . . . . . 45
12.3.4 Checking ignition unit . . . . . . . . . . . . . . . . . . . . . . . . . . 45
12.3.5 Disconnect the condensate trap . . . . . . . . . . . . . . . . . . 46
12.3.6 Remove the condensate collector . . . . . . . . . . . . . . . . . 46
12.3.7 Clean the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . 47
12.4 Check and adjust the flue gases CO
12.5 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
emissions . . . . . 47
2
Explanation of symbols and safety information
1
1 Explanation of symbols and safety information
1.1 Guideline to symbols
Warnings
Warnings are indicated in the text by a warning triangle
and a gray background.
In case of danger from electric shock, the exclamation
point on the warning triangle is replaced with a flash.
13 Display information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
13.1 Removing the control panel . . . . . . . . . . . . . . . . . . . . . . 48
13.2 Replacing the control panel . . . . . . . . . . . . . . . . . . . . . . 48
13.3 BC10 Display readings . . . . . . . . . . . . . . . . . . . . . . . . . 48
13.4 BC10 Display settings . . . . . . . . . . . . . . . . . . . . . . . . . . 48
13.5 BC10 Display codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
14 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
14.1 Technical specifications of GB162-boilers at
low BTU (4,000-10,200 ft.) . . . . . . . . . . . . . . . . . . . . 54
15 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
15.1 Start-up report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
15.2 Inspection report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
15.3 Service report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
16 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Signal words at the beginning of a warning are used to indicate the type
and seriousness of the ensuing risk if measures for minimizing damage
are not taken.
• NOTE indicates that damage to property may occur.
• CAUTION indicates possible minor to medium personal injury.
• WARNING indicates possible severe personal injury.
• DANGER indicates a potential for loss of life.
Important Information
Important information neither indicating personal injury
nor damage to property are marked with this symbol.
They are separated by lines above and below the text.
Additional symbols
Symbol Explanation
▶ Sequence of steps
Cross-reference to other points in this document or to
other documents
• Listing/list entry
– Listing/list entry (2nd level)
Table 1
1.2 Safety instructions
Installation and service must be performed by a qualified installer,
service agency or the gas supplier.
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 5
WARNING:
A fire or explosion may result causing pr operty damage,
personal injury or death.
▶ If the information in these instructions is not followed
exactly,
DANGER:
if flammable gas explodes.
▶ Beware if you smell gas: there may be an explosion
hazard!
▶ Do not store or use gasoline or other flammable vapors and liquids in
the vicinity of this or any other boiler.
2
Regulations and guidelines
WARNING:
Dangerous flue gas can escape if the air supply is
insufficient.
▶ Make sure that air vents are not reduced in size or
obstructed.
▶ The boiler may only be operated after the defect has
been remedied.
▶ Warn the user of the system of the defect verbally
and in writing.
WARNING:
Danger of fatal accident from explosive fumes.
▶ Only carry out work on gas pipes and fittings if you
are properly registered.
General warnings
The following instructions must be observed
• The boiler must only be used for its designated purpose, observing
the Installation Instructions.
• Only use the boiler in the combinations and with the accessories and
spares listed.
• Maintenance and repairs must only be carried out by trained
professionals.
• You are only permitted to operate the condensing gas boiler with the
combustion air/flue gas system that has been specifically designed
and approved for this type of boiler.
• Please note that local approval of the flue system and the condensate
connection to the public sewer system may be required.
• If boiler installation is provided as replacement heater, do not
connect new boiler venting to an existing vent system, if it is shared
with other appliances.
• The local building regulations stipulating the installation rules at the
time of installation.
• The local building regulations concerning the air intake and outlet
systems and the chimney connection.
• The regulations for the power supply connection.
• The technical rules laid down by the gas utility company concerning
the connection of the gas burner fitting to the local gas main.
• The instructions and standards concerning the safety equipment for
the water/space heating system.
• The Installation Instructions for building heating systems.
• The boiler must be located in an area where leakage of the tank or
connections will not result in damage to the area adjacent to the
boiler or to lo wer flo ors of t he stru cture. When su ch locations cannot
be avoided, it is recommended that a suitable drain pan, adequately
drained, be installed under the boiler. The pan must not restrict
combustion air flow.
• The boiler must be installed such that the gas ignition system
components are protected from water (dripping, spraying, rain etc.)
during boiler operation and service.
• Do not restrict or seal any air intake or outlet openings.
• If you find any defects, you must inform the owner of the system of
the defect and the associated hazard in writing.
• The boiler must not be installed on carpeting.
What to do if you smell gas:
• Do not try to light any boiler.
• Do not touch any electrical switch; do not use any phone in your
building.
• Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
2 Regulations and guidelines
• The installation must conform to the requirements of the authority
having jurisdiction or, in the absence of such requirements, to the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA
B149.1, Natural Gas and Propane Installation Code.
• Where required by the authority having jurisdiction, the installation
must conform to the Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
▶ Install CO detectors per local regulations. Boiler requires yearly
maintenance chap. 12 "Maintenance", page 43.
Operating Limits of the boiler:
Max. boiler temperature: 230 °F (110 °C)
Max. operating pressure: 30 psi (2.6 bar)
- with optional pressure relief valve 50 psi (3.45 bar).
The hot water distribution system must comply with applicable codes
and regulations. When replacing an existing boiler, it is important to
check the condition of the entire hot wate r distribution system to ensure
safe operation.
2.1 Massachusetts Installations Only
(a) For all side wall side horizontally vented gas fuelled equipment
installed in every dwelling, building or structure used in whole or in part
for residential purposes, including those owned or operated by the
Commonwealth and where the side wall exhaust vent termination is less
than 7 feet above finished grade in the area of the venting, including but
not limited to decks and porches, the following requirements shall be
satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of
installation of the side wall horizontal vented gas fueled equipment,
the installing plumber or gas fitter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed.
In addition, the installing plumber or gas fitter shall observe that a
battery operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling, building or
structure served by the side wall horizontal vented gas fueled
equipment. It shall be the responsibility of the property owner to
secure the services of qualified licensed professionals for the
installation of hard wired carbon monoxide detectors
– In the event that the side wall horizontally vented gas fueled
equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may
be installed on the next adjacent floor level.
– In the event that the requirements of this subdivision can not be
met at the time of completion of installation, the owner shall have
a period of thirty (30) days to comply with the above
requirements; provided, however, that during said 30 day
period, a battery operated carbon monoxide detector with an
alarm shall be installed. alarm and battery back-up may be
installed on the next adjacent floor level.
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)6
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above
provisions shall comply with NPA 720 and be ANSI/UL 2034 listed
and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently
mounted to the exterior of the building at a minimum height of 8 ft.
above grade directly in line with the exhaust vent terminal for the
horizontally vented gas fuelled heating appliance or equipment.
The sign shall read, in print size no less than 1-½" in size, GAS VENT
DIRECTLY BELOW. “KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fuelled equipment shall not approve the
installation unless, upon inspections, the inspector observes carbon
monoxide detectors and signage installed in accordance with the
provisions of 248 CRM 5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CRM
5.08(2)(a)1 through 4:
The following equipment is exempt from 248 CRM 5.08(2)(a)1 through
4:
1. The equipment listed in Chapter 10 entitled “Equipment Not
Required To Be Vented” in the most correct edition of NFPA 54 as
adopted by the board: and
2. Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential
purposes.
(c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM REQUIRED.
When the manufacturer of Product Approved side wall horizontally
mounted gas equipment provides a venting system design or venting
system components with the equipment, the instructions provided by
the manufacturer for the installation of the equipment and venting shall
include:
1. Detailed instructions for the installation of the venting system or the
venting system components: and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED.
When the manufacturer of Product Approved side wall horizontally
vented gas fueled equipment does not provide the parts for the venting
of flue gases, but identifies “special venting systems”, the following
requirements shall be satisfied by the manufacturer:
1. The referenced “special venting systems” shall be included with the
appliance or equipment installation instructions: and
2. The “special venting systems” shall be Product Approved by the
Board, and the instructions for that system shall include a parts list
and detailed installation instructions.
(e) A copy of all instructions.
For all Product Approved side wall horizontally vented gas fueled
equipment, all venting instructions, all parts lists for venting
instructions, and/or venting design instructions shall remain with the
appliance or equipment at the completion of the installation.
General information
3
3 General information
About these instructions
These Installation Instructions contain important information for the
safe and professional installation, start-up and maintenance of the boiler
with boiler input rating of 80 kW and 100 kW.
These Installation Instructions are intended for professional installers,
who have the necessary training and experience for working on heating
and gas systems.
Cascade installation
Special cascade units (accessories) have been developed to enable this
boiler to be installed in a cascade system. Every cascade unit includes an
installation frame, horizontal headers, connection pipes for the boiler,
main gas pipe and a vertical low loss header. Cascade units are available
for installing the boilers inline or back-to-back. These cascade units
make installing a cascade system easier and less labor intensive.
Please contact Buderus for further information about cascade systems.
Updating of documentation
The following technical documentation is available for the Logamax plus
GB162-L.B. 80 kW/100 kW:
• Installation instructions,
• User’s manual,
• Service manual.
Subject to technical modifications
Slight changes may be made without prior notice to the illustrations,
process steps and technical data as a result of our policy of continuous
improvement
GB162-L.B. Natural Gas Propane Gas
80 kW 290,000 btu/hr 270,000 btu/hr
100 kW 333,000 btu/hr 315,000 btu/hr
Table 2 max. input rate
3.1 Designated use
The boiler was designed to heat water in a central heating system and
generating domestic hot water. It is suitable for connection to fully
pumped, sealed water systems only, with a maximum supply
temperature set point off 180 °F (82 °C).
The boiler can be installed either as a single system or as part of a
multiple system (cascade system).
This boiler may not be installed in places below 4,001 ft.
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 7
3
General information
3.2 Heating system water quality
The quality of the system water is very important. Poor water quality can
damage heating systems due to scale formation and corrosion.
For further details, please see the accompanying “Water quality
requirements for Logamax plus GB162-L.B. 80kW/100 kW” manual.
CAUTION:
Risk of system damage due to unsuitable heating system
water.
▶ If oxygen-permeable pipes are used, e.g. for under
floor heating systems, the systems must be
separated from one another by plate heat
exchangers. Unsuitable heating system water
promotes sludge and corrosion formation. This can
result in heat exchanger malfunction and damage.
3.3 Pump test
If the boiler has not been operational for approx. 2 days, the pump will
automatically run for 10 seconds every 24 hours. This pump test is first
carried out 24 hours after the main power has been connected to the
boiler.
3.4 Freeze protection
The boiler has integrated freeze protection that switches the boiler ON
at a space heating (CH) water temperature of 45 °F (7 °C) and switches
it OFF at a CH flow temperature of 59 °F (15 °C).
This feature does not protect the central heating system from freezing. If
there is a risk of radiators or pipe sections freezing up, we recommend
setting the pump run-over time to 24 hours ( § 13.4. page 48)
3.5 Tools, materials and further equipment
For the installation and maintenance of the boiler you will need the
standard tools for space heating, gas and water fitting. In addition, a
hand truck with a fastening belt is useful.
3.6 Disposal
▶ Dispose of the boiler packaging in an environmentally sound manner.
▶ Dispose of components of the heating system (e. g. boiler or control
device), that must be replaced in an environmentally responsible
manner.
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)8
4 Dimensions and connections
C
DFE
G
4.1” (103.5 mm)
38.58” (980 mm)
5.3” (135 mm)
1.4” (35 mm)
5.4” (138 mm)
6.4” (162 mm)
1.54” (39 mm)
5.1” (130 mm)
5.5” (140 mm)
5.1” (130 mm)
A
B
0 020.5” (520 mm)
39.5” (1003 mm)
40,55” (1030 mm)
51.6” (1310 mm)
16” (406 mm)
G
D/F
E
A/B
6” (152 mm)
18.3” (465 mm)
0.25” (6 mm)
16.5" (420 mm)
1.2” (30 mm)
24.8” (630 mm)
20.5" (520 mm)
6720645916-02.1TD
4.1 Without pump group
Dimensions and connections
4
Fig. 2 Dimensions and connections without pump group
[A] (LA) = Flue gas connection; inside diameter 4" (100 mm)
[B] (AA) = Air intake connection; inside diameter 4"(100 mm)
[C] (WB) = Wall Bracket (not shown)
[D] (VK) = Supply; G1½" union nut with female thread
[E] (GAS) = Gas connection to boiler; Rp1" female thread
[F] (RK) = Return; G1½" union nut with female thread
[G] (AKO) = Condensate outlet; Ø 32 mm (1¼")O/D
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 9
The required permanent clearances (closet) are:
in front: 1" (25 mm)
right side: 0
left side: 0
above: 6" (152 mm).
The position selected for installation MUST allow adequate space for
servicing in front of the boiler of at least 16.5" + 20.5" = 37" (940 mm).
Maintain an installation clearance from combustible construction from
hot water piping of at least 1" (25 mm).
4
G
C
DFE
4.1” (103.5 mm)
38.58” (980 mm)
5.3” (135 mm)
1.4” (35 mm)
5.4” (138 mm)
6.4” (162 mm)
1.54” (39 mm)
5.1” (130 mm)
5.5” (140 mm)
5.1” (130 mm)
A
B
0 020.5” (520 mm)
39.5” (1003 mm)
40,55” (1030 mm)
51.6” (1310 mm)
16” (406 mm)
G
D/F
E
A/B
6” (152 mm)
18.3” (465 mm) 0.25” (6 mm)
H/J
G
HI
J
1.2” (30 mm)
50.4” (1280 mm)
24.8” (630 mm)
16.5" (420 mm)
20.5" (520 mm)
6720645916-03.1TD
Dimensions and connections
4.2 With pump group
Fig. 3 Dimensions and connections with pump group
[A] (LA) = Flue gas connection; inside diameter 4" (100 mm)
[B] (AA) = Air intake with pompadour; inside diameter 4" (100 mm)
[C] (WB) = Wall Bracket (not shown)
[D] (VK) = Supply; G1½" union nut with female thread
[E] (GAS) = Gas connection to boiler; Rp1" female thread
[F] (RK) = Return; G1½" union nut with female thread
[G] (AKO) = Condensate outlet; Ø 32 mm (1¼")O/D
[H] (PF) = Pump group supply; G1½" male thread, flat seal
[I] = Gas connection to pump group; 1" NPT female thread
[J] (PR) = Pump group return; G1½" male thread, flat seal
The required permanent clearances (closet) are:
in front: 1" (25 mm)
right side: 0
left side: 0
above: 6" (152 mm).
The position selected for installation MUST allow adequate space for
servicing in front of the boiler of at least 16.5" + 20.5" = 37" (940 mm).
Maintain an installation clearance from combustible construction from
hot water piping of at least 1" (25 mm).
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)10
Packaging and transportation
6 720 646157-05.1TD
5
5 Packaging and transportation
5.1 Scope of delivery
The boiler is delivered factory-assembled.
▶ When receiving the delivery, check if the packaging is intact.
▶ Check that all items are included in the delivery.
1
2
4
8
2
1
3
0
4
9
Fig. 4 Items supplied with unit
Nr. Parts Qty. Packaging
1 Boiler with casing 1 1 box
2Wall bracket 1
3 Condensate trap with hose 1
4 Technical documents set 1
5 Supply and return union nuts with sealing
rings
6 Screws and plugs for wall bracket 2
7 Union nut for gas connection 1
8 DHW sensor 1
9 Pump group 1 1 box
Table 3 Items supplied with GB162-L.B. 80 kW/100 kW
3
5
6
7
7746800103-01.1TD
1
1 2
7746800103-02.1TD
Fig. 5 Additional accessories
[1] Low loss header (single installation only)
[2] AM10 modulating outdoor reset control
5.2 Transporting the boiler
CAUTION: The boiler may be damaged when it is
improperly secured.
▶ Only transport the boiler using the right
transportation equipment, such as a hand truck with
a fastening belt or special equipment for
maneuvering steps.
▶ During transportation the boiler must be secured on
the transportation equipment to prevent it from
falling off.
▶ Protect all parts against impacts if they are to be
transported.
▶ Observe the transportation markings on the
packaging.
CAUTION: The unpacked boiler may be damaged when
not protected against contamination.
▶ Leave the protective covers on the connections.
▶ Cover the flue gas connections at the top of the boiler
with plastic film.
▶ Always lift and carry the boiler with 2 people as shown in fig. 6, or use
a hand truck or special equipment.
Additional required accessories (not in delivery content)
A single boiler must be installed with the Buderus low loss header (LLH)
to regulate the flow. The low loss header must be ordered separately.
The low loss header delivery comes also with the AM10 modulating
outdoor reset control.
Multiple boiler cascade installations can use the Buderus cascade frame
accessories. Please contact Buderus for further informations.
▶ When receiving the delivery, check if the packaging is intact.
▶ Check that all items are included in the delivery ( fig. 5).
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 11
Fig. 6 Lift and carry the boiler correctly
6
6 720 646157-06.1TD
Installation
CAUTION: Damage to the unit by lifting or carrying
incorrectly.
▶ Do not hold the boiler by the door covering the
control panel ( fig. 7).
Fig. 7 Incorrect way of lifting and carrying the boiler
▶ When using oxygen-permeable pipes (plastic), e.g. for floor heating
systems, you must separate the system using secondary heat
exchangers.
6.3 Installing the boiler
Observe the installation distances of the combustion air/flue gas
system.
▶ Before starting installation check that the carrying capacity of the
wall is sufficient for the boiler weight.
NOTICE
▶ To protect the connection orifice you must not
remove the styrofoam bottom panel.
▶ Do not lift the boiler by the door covering the control
panel ( chap. 5.2 "Transporting the boiler",
page 11).
▶ Protect the boiler and the combustion
air/flue gas orifice against pollution during
installation.
▶ Remove the packaging and dispose of it in an environmentally
manner.
▶ Measure the installation height ( chap. 4 "Dimensions and
connections", page 9).
▶ Mark both holes with the wall bracket ( fig. 8) using a spirit level.
▶ Install the wall bracket with 2 screws ( fig. 8).
6 Installation
6.1 Requirements for the installation room
DANGER:
▶ Install the heating system in a frost-free room.
▶ If the boiler is operated dependent on room air, the
installation room must have the required air vents.
Do not obstruct these vents. The air vents must
always be free.
▶ When installed in a room with thin walls or a thin
floor, resonating noise may occur. Install noise
reducing parts if required.
▶ Do not store any flammable materials or liquids in the
immediate vicinity of the boiler.
▶ Never use any chlorinated detergents or halogenated
hydrocarbons (e. g. in spray cans, solvents and
detergents, paints, adhesives).
▶ Do not allow too much dust to collect on the boiler.
6.2 Requirements for the heating system
▶ Installing a dirt trap like a y-strainer and a desludging device is
required. This must be installed in the heating system in the
immediate vicinity of the boiler, in an easily accessible position
between the boiler and the lowest point in the return of the system.
▶ Clean the dirt trap at every annual service.
▶ Never use salt bedding type exchangers (ion exchangers) to soften
the water.
▶ The low loss header and boiler connection set must be installed
(supplied with the boiler).
A
B
C
D
6 720 646157-07.1TD
Fig. 8 Installing the wall bracket
▶ With 2 people, lift the boiler by holding it by its back and by the
transport rail at its bottom and install it on the wall bracket ( fig. 6,
page 11).
▶ The boiler can be moved sideways to get the correct position.
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)12
▶ Level the boiler with the set screw and a spirit level ( fig. 9).
6 720 646157-08.1T
6 720 646157-09.1TD
1
2
3
4
5
6
7
6 720 646157-10.1TD
6 720 646157-11.1TD
1
Fig. 9 Aligning the boiler with the set screw
▶ Remove the protective covers from the bottom of the boiler
( fig. 10).
Fig. 11 Pump group
[1] pressure relief valve
[2] supply water valve
[3] manual gas shutoff valve
[4] circulation pump
[5] gas inlet
[6] return water valve
[7] pump group cover
Installation
6
NOTICE
▶ If you do not use the included pump group, you have to
install a separate circulation pump under the boiler.
This pump must be selected so that the volume flow
through the boiler is sufficient to handle the maximum
boiler input rating ( § 6.4.5, page 15).
▶ Install the pump group on the boiler in accordance with the pump
group installation instructions.
A single boiler must be installed with the low loss header to regulate the
flow.
Fig. 10 Removing the covers - boiler bottom
▶ Install the low loss header [1].
NOTICE
▶ Some residual water from final testing may leak
away.
6.4 Water and Gas connection
6.4.1 General
The water and gas connections to the boiler are made using the pump
group ( fig. 4, page 11). This pump group includes the circulation
pump and a pressure relief valve.
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 13
Fig. 12 Low loss header
6
7746800103-03.1TD
12
6
3
5
3
894
13
11
10
12
7
33
Installation
NOTICE
▶ Avoid installing the boiler above radiation levels.
If the boiler is installed above radiation sections, a
low water cutoff shall be installed and wired to the
boiler. Follow local code or in case of use of a low
water cutoff, be aware to use an air vent, in order to
prevent the boiler from shutting down unnecessarily
6.4.2 Connecting the pressure relief valve (PRV)
The pressure relief valve is a part of the supplied pump group ( fig. 11,
[1]). A listed ASME pressure relief valve supplied with the boiler must be
installed at the time of installation. No valve is to be placed between the
PRV and the boiler.
No reducing coupling or other restriction may be installed in the
discharge line. The discharge line must be within 12" (305 mm) with a
minimum of 4" (100 mm) above a drain and installed such that it allows
complete drainage of both the PRV and the line. The location of the PRV
must be readily accessible for servicing or replacement and be mounted
as close to the boiler as possible. To install the PRV, a suitable fitting
connected to an extension on a “T” fitting can be sweated to the hot
water line. Support all piping.
Maintain an installation clearance from combustible construction of at
least 1" (25 mm) from the hot water piping.
6.4.3 Making the gas connection
DANGER:
▶ Only carry out work on gas lines if you are a qualified
gas fitter
Equivalent length for Pipe Fittings in feet (m)
Type of pipe fitting
Steel pipe
diameter in
inches (mm)
¾ (19) 2.1 (0.64) 4.1 (1.25) 0.5 (0.15) 1.25 (0.38)
1 (25) 2.6 (0.79) 5.2 (1.59) 0.6 (0.18) 1.60 (0.49)
1¼ (32) 3.5 (1.07) 6.9 (2.11) 0.8 (0.24) 2.15 (0.66)
1½ (38) 4.0 (1.22) 8.0 (2.44) 0.9 (0.27) 2.50 (0.76)
Table 5 Equivalent length for pipe fittings in feet
6.4.4 Installing the heating supply and return pipe
90º-Elbow
Tee flow th ru
branch
Equivalent length in feet (m)
Gate valve Gas cocks
▶ The manual gas shutoff valve is part of the pump group, and is
installed in accordance with the pump group installation
instructions.
▶ Determine proper size gas pipe for the installation using table 4 and
table 5. Do not forget the pipe fitting losses and observe proper size
of the fittings.
▶ Connect the gas supply pipe to the manual gas shutoff valve, so that
it is free from any strain.
Length of pipe in
feet (m)
10 (3.05) 278 520 1,060 1,600
20 (6.1) 190 350 730 1,100
30 (9.15) 152 285 590 890
40 (12.2) 130 245 500 760
50 (15.25) 115 215 440 670
75 (22.88) 93 175 360 545
100 (30.5) 79 160 305 480
150 (47.25) 64 120 250 380
Table 4 Gas pipe capacity for different pipe sizes
1) Maximum pipe capacity in ft.3/hr, based on a specific gravity of 60 (42 mbar)
and a inlet gas pressure of 14" W.C. (35 mbar) or less and a pressure drop of 3"
W.C. (20 mbar)
Gas volume Capacity in ft.3/hr
¾" 1" 1¼" 1½"
1)
Fig. 13 Connecting the boiler supply and return
[1] Supply
[2] Return
[3] Isolating valves
[4] Drain cock
[5] Gas valve
[6] Pressure relief valve
[7] Condensate trap
[8] Pump
[9] Non-return valve
[10] Dirt filter (for example scale cartridge or y-strainer)
[11] Gas supply
[12] Air gap > 1" (25.4 mm)
[13] Low loss header (single boiler installation)
NOTICE
▶ When using plastic pipes, observe the supplier’s
instructions - especially those referring to
recommended jointing techniques and the notes
relating to the heating system water on page 8.
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)14
Installation
6 720 646157-014.1TD
1
1
3
2
6 720 646157-15.1TD
6
NOTICE
▶ To prevent contamination in the heating system we
recommend you integrate a dirt filter ( fig. 13,
[10]) in the return pipe, near the boiler. In an old
system it is a requirement to install a dirt filter. Also
install shutoff valves to enable filter cleaning
immediately upstream and downstream of the dirt
filter (scale cartridge or y-strainer)
▶ Connect the supply pipe with a flat rubber seal installed to the Supply
connection ( fig. 13, [1]) making sure it is not under stress. Use a
supply pipe with a minimum diameter of 1½" (38 mm).
▶ Connect the return pipe with a flat rubber seal installed to the Return
connection ( fig. 13, [2]) making sure it is not under stress. Use a
return pipe with a minimum diameter of 1½" (38 mm).
6.4.5 Installing the pump
Always use the supplied Buderus pump group and the low loss header
when installing a single boiler so correct flows are guaranteed. It is not
necessary to install a low loss header for cascade systems.
▶ Install the pump ( fig. 13, [8]) in the return circuit ( fig. 13,
[2]).
6.4.6 Installing the condensate trap
WARNING:
Danger of fatal accident due to poisoning
▶ If the condensate trap is not filled with water, flue gas
can escape and put people's lives at risk.
▶ Connect the condensate trap [1] to the condensate outlet.
The condensate trap has a bayonet connector, insert and turn
¼ rotation clockwise to click into position.
Fig. 15 Installing the condensate trap
▶ Connect the condensate trap hose [3] and the rubber sleeve [2] to
the condensate trap [1].
▶ Fill the condensate trap (supplied with the boiler) with water
( fig. 14).
6 720 646157-13.1TD
Fig. 14 Filling the condensate trap with water
Fig. 16 Installing the condensate trap hose
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 15
6
7746800103-62.1TD
1
2
> 1” (25.4 mm)
6 720 645916-017
7746800103-04.1TD
2
3
1
Installation
6.5 Connecting the condensate drain pipe
NOTICE
▶ The condensate must be drained from the boiler in
accordance with local, state or federal rules and
regulations.
NOTICE
▶ Use materials approved by the authority having
jurisdiction. In the absence of such authority, PVC
and CPVC pipe must comply with ASTM D1785,
F441 or D2665. Cement and primer must comply
with ASTM D2564 or F493. For Canada, use ULC
certified PVC or CPVC pipe, fittings and cement.
6.5.1 Connecting the expansion vessel in a single-boiler system
CAUTION:
Damage to the installation due to faulty pressure relief
valve.
▶ The expansion vessel must be of sufficient capacity.
▶ Connect the expansion tank to the boiler return. If a check valve is
available: connect the expansion vessel to the CH-side of the check
valve in the return circuit [1].
Fig. 19 Connecting the expansion vessel in a single-boiler system
[1] Expansion vessel
[2] Gas supply
[3] Air gap < 1" (25.4 mm)
Fig. 17 Connecting the condensate trap
[1] Condensate trap
[2] Air gap > 1" (25.4 mm)
6.6 Combustion Air and Ventilation Openings
Provisions for combustion and ventilation air must be made in
accordance with section 5.3, Air for Combustion and Ventilation, of the
National Flue Gas Code, ANSI Z223.1/NFPA 54, or Sections 7.2, 7.3 or
7.4 of CAN/CGA B149, Installation Codes, or applicable provisions of
the local building codes.
DANGER:
Fire danger due to flammable materials or liquids.
▶ Do not store flammable materials and liquids in the
immediate vicinity of the boiler.
WARNING:
Boiler Damage.
Fig. 18 Condensate drainage pipe
▶ Install the condensate drain pipe taking the following into account:
– An air gap of at least 1" (25.4 mm) must be maintained between
the boiler condensate trap hose and the condensate pipe work
( fig. 17 and fig. 18).
– If the condensate outlet of the boiler is lower than the drain, a
condensate pump must be used.
– The condensate produced by the boiler has a pH value between
3 and 4.
▶ Install a neutralization unit if required by the local code.
▶ Boiler must be clear and free from combustible
materials, gasoline and other flammable vapors and
liquids, and corrosive liquids and vapors.
Never use chlorine and hydrocarbon containing
chemicals (such as spray chemicals, solution and
cleaning agents, paints, glues etc.) in the vicinity of
the boiler
▶ Do not store and use these chemicals in the boiler
room.
▶ Avoid excessive dust formation and build-up.
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)16
Installation
2
1
1
6 720 645916-19.1N
7 746 800 103-09.1D
1
6
CAUTION:
Boiler damage and operational failures!
Due to insufficient or improper ope nings for combustion
air and/or ventilation of the boiler room.
Provisions for combustion air and ventilation are always
required, regardless whether the combustion air is
taken from the outside (sealed combustion) or inside
(room air for combustion).
Insufficient ventilation of the boiler room can lead to
high air temperatures. This can result in boiler damage.
▶ Make sure that intake and exhaust openings are
6.7 Flue gas adapter
CAUTION:
Risk of boiler damage due to excessive dust and airborne
debris levels.
▶ Do not operate the boiler when there is a lot of dust in
the boiler room, e.g. due to building work.
▶ An air filter must be fitted if the supply of combustion
air contains large quantities of dust (e.g. from unpaved roads and tracks or dusty workplaces such as
quarries, mines, etc.) or airborne seeds from plants.
sufficiently sized and no reduction or closure of
openings takes place.
▶ When the problem is not resolved, do not operate the
boiler.
CAUTION:
▶ Do not use lubricants to avoid degradation of the lip
rings.
▶ Please note these restrictions and its dangers to the
operator of the boiler.
▶ When installing PVC vent pipes remove the upper lip ring and insert
[1].
NOTICE
▶ When one expects contaminated combustion air
(near swimming pools, chemical cleaning operations
and hair salons), sealed combustion operation is
▶ In case of open venting, use basket [2] on the air intake.
▶ When installing parallel PP venting material remove upper lip ring and
insert [1] and use PVC/PP PolyPro adapter offered by your local vent
supplier.
recommended.
All Air form inside the Building (non sealed combustion)
The closet shall be provided with 2 permanent openings communicatin g
directly with an additional room(s). The total input of all gas utilization
equipment installed in the combined space shall be considered in
making this determination. Each ope ning shall have a minimum free area
of 12" per 1,000 btu/h of total input rating of all gas utilization
equipment in the confined space, but no less than 1.002". One opening
shall commence within 12" (305 mm) of the top, and one opening shall
commence within 12" (305 mm) of the bottom of the enclosure.
The minimum dimension of air openings shall be not less than 4"
(101.6 mm).
1. Where directly communicating with the outdoors, each opening shall
have a minimum free area of 12" per 4,000 Btu/hr of total input
rating of all equipment in the enclosure.
2. Where communicating with the outdoors through vertical ducts,
each opening shall have a minimum free area of 12" per 4,000
Btu/hr of total input rating of all equipment in the enclosure.
Fig. 20 Connecting the flue gas adapter (parallel)
▶ When installing concentric PP venting material remove upper lip ring
and insert ( fig. 20, [1]) and place air intake cap [1].
3. Where communicating with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 12" per 2,000
Btu/hr of total input rating of all equipment in the enclosure.
4. Where ducts are used, they shall be of the same cross-sectional area
as the free area of the opening to which they connect.
All Air from Outdoor (sealed combustion)
The closet shall be provided with two permanent openings, one
commencing within 12" (305 mm) from the top, and one commencing
within 12" (305 mm) from the bottom of the enclosure. The openings
shall communicate directly, or by ducts, with the outdoors or spaces
(crawl or attic) that freely communicate with the outdoors. The minimum
dimension of air openings shall be no less than 4" (101.6 mm).
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 17
Fig. 21 Placing air intake cap
6
6 720 645916-20.1N
1
2
12" (305 mm)
minimum
12" (305 mm)
minimum
12" (305 mm)
minimum
INTAKE
EXHAUST
12" (305 mm)
minimum
12" (305 mm)
minimum
6 720 646916-21.1N
Installation
6.8 Installation of the Exhaust and Air Intake system
NOTICE
▶ Consult local and state codes pertaining to special
building code and fire department requirements.
Adhere to national code requirements.
▶ Observe the listed maximum lengths of vent system,
which are boiler model dependent. The maximum
permissible lengths are listed in table 8, page 22.
Optional vent kits are:
1. Parallel or concentric, horizontal (with approved wall terminal) or
vertical
Fig. 22 Vent pipes
The termination shall be at least 4 ft. (1,220 mm) for the U.S. and 6 ft.
(1,830 mm) for Canada away from a gas utility meter, service regulator
or the like (for room air applications only).
The termination shall terminate at least 4 ft. (1,220 mm) below, 4 ft.
(1,220 mm) horizontally from, or 1 ft. (305 mm) above any door,
window, or gravity air inlet into any building.
Vent must be at least 12" (305 mm) above grade, anticipated snow line
or roof surface (Canada 18" (457 mm) minimum) ( fig. 23).
Vent termination must be at least 7 ft. (2,135 mm) above a public
walkway ( fig. 24).
Vent must be 3 ft. (915 mm) above any forced air intake within 10 ft.
(3,050 mm) ( fig. 24). Do not extend exposed vent pipe outside the
building beyond recommended distance. Condensate could freeze and
block vent pipe.Vent should terminate at least 3 ft. (915 mm) away from
adjacent walls, inside corners and 5 ft. (1,525 mm) below roof
overhang ( fig. 24). It is not recommended to terminate vent above
any door or window, condensate can freeze causing ice formations.
Do not use chimney as a raceway if another boiler or fireplace is vented
into or through chimney.
All PVC and CPVC vent pipes must be glued, except for the flue gas
adapter. Installed you can slide the pipe onto the adapter, properly
supported and the exhaust pipe must be pitched a minimum of a ¼"
(6.35 mm) per foot back to the boiler. This allows the condensate to
drain away.
All non-steel combustion air and vent pipe materials and fittings must
comply with the following and must be UL approved venting material:
Item Material United States Canada
4" (100 mm)
Intake/combustion
air pipe and fitting
PVC schedule
ANSI/ASTM D1785 BH gas
40, 80
PVC-DWV ANSI/ASTM D2665
CPVC schedule
ANSI/ASTM F441
40, 80
PP
M&G Duravent
PolyPro and
ANSI Cat IV,
approved
Polypropylene
Centrotherm
InnoFlue SW
PP-Flex
M&G Duravent
PolyPro Flex and
ANSI Cat IV,
approved
Polypropylene
venting
systems,
ULC
1)
S636
Class IIA -
PVC,
Class IIB -
CPVC,
Class IIC -
Polypro-
pylene
,
Centrotherm
InnoFlue SW Flex
4"/6" (100/150
mm) concentric
Intake/combustion
PP Bosch
Concentric
ANSI Cat IV,
approved
Polypropylene
air pipe and fitting
Pipe cement /
primer
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
Table 6 Approved venting air pipe material
1) For installations in Canada, field supplied plastic vent piping must comply with
CAN/CGA B149.1 (latest edition) and be certified to the Standard for Type BH
Gas Venting systems. ULC S636 Components of this listed system shall not be
interchanged with other vent systems or unlisted pipe/fittings. All plastic
components and specified primers and glues of certified vent systems must be
from a single manufacturer and not mixed with other system manufacturer's vent
system parts. The supplied vent connector and separate available wall
termination kits are certified as part of the GB162 Boiler.
Fig. 23 Vent and air pipe position (1) of a sealed combustion system
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)18
Installation
1'
3'
3'
1'
4'
4'
7'
4'
1'
3'
5'
(2135 mm)
(305 mm)
(1220 mm)
(1525 mm)
(1220 mm)
(915 mm)
(915 mm)
(305 mm)
(305 mm)
(1220 mm)
(1220 mm)
6 720 645916-22.1N
1
2
3
4
6
Approved vent terminations and flue material:
Roof terminals
4"/6"
(100/150 mm)
4"/6"
(100/150 mm)
(PP)
Flue System
(trade name)
Concentric PVC IPEX System 636 no.
M&G Duravent PolyPro
concentric and
Centrotherm Innoflue SW
Vent / air intake
terminal(s)
CVK
M&G Duravent Order
No. 4PPS-VK (-TC) or
Centrotherm ICRT4679
concentric
4" (100 mm)
(PP)
M&G Duravent - PolyPro
Flex Chimney Cap
Centrotherm - Innoflue
M&G Duravent order No.
4PPS FCT or
Centrotherm ISCP04
SW Flex Chimney Cap
Wall terminals Flue System
(trade name)
4" (100 mm) PVC/parallel stainless
steel
4" (100 mm) PolyPro Twin pipe
termination (PP)
4" (100 mm) Parallel PVC to
Vent / air intake
terminal(s)
ANSI/ASTM D1785 or
Field Controls
M&G Duravent Order
No. 4PPS-HTP
IPEX no. CVK
ANSI/ASTM D1785
Table 7 Approved vent terminations and flue material
Roof terminals
4"/6" (100/150
mm)
Flue System
(trade name)
Concentric PP
M&G Duravent PolyPro
Vent / air intake
terminal(s)
Bosch Order No.
7738004825
concentric
90°-elbow with
inlet screen
90°-elbow with
inlet screen
PVC/stainless steel ANSI/ASTM D1785 or
Z-Flex/Heat Fab
PP M&G Duravent PolyPro
or Centrotherm Innoflue
SW
Table 7 Approved vent terminations and flue material
NOTICE
▶ Use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel® (polyphenolsulfone) in venting
systems shall be prohibited.
▶ Covering non-metallic vent pipe and fittings with
thermal insulation shall be prohibited.
▶ A minimum clearance of 4 ft. (1,220 mm)
horizontally from and in no case above and below,
unless a 4 ft. (1,220 mm) horizontal distance is
maintained, from electric meters, gas meters,
regulators and relief equipment
Fig. 24 Vent and air pipe position (2) of a system with combustion air supply from the room (non-sealed)
[1] Height at Least 1ft (305 mm) above grade and snow line
[2] Exhaust terminal must be at least 3 ft. (915 mm) above forced air
inlet within 10 ft. (3,050 mm)
[3] Forced Air Inlet
[4] Gravity Air Inlet
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 19
6
6720645916-23.1TD
1
2
7746800103-05.1TD
3
1
2
6 720 645 916-29.2TD
2
1
Installation
Below are approved examples of vertical and horizontal venting
installation
NOTICE
▶ Place pipe supports every 5 ft. (1,525 mm) of
horizontal and vertical run, beginning with support
near boiler.
▶ The condensate must be drained in accordance with
the applicable rules ( § 6.5, page 16).
▶ Periodic cleaning of the vent terminal and air-intake
screens is mandatory.
▶ Avoid locating vent terminals near equipment or
construction which can be subject to degradation
from exhaust gases.
Fig. 25 Horizontal venting system (sealed combustion)
[1] exhaust 4" (100 mm)
[2] intake 4" (100 mm)
Fig. 26 Concentric horizontal venting system (sealed combustion)
[1] concentric adaptor 4" (100 mm) / 6" (150 mm)
[2] exhaust 4" (100 mm) / intake 6" (150 mm)
[3] place the air intake cap
Fig. 27 Horizontal venting system (sealed combustion)
[1] exhaust 4" (100 mm)
[2] intake 4" (100 mm)
Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)20
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