Buderus GB162-65 Installation Instructions Manual Download Page 1

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Installation instructions

Pump group

Logamax plus
GB162-65/80/100

7217

100

(03

/201

For heating engineers

Please read thoroughly
before starting installation

Summary of Contents for GB162-65

Page 1: ...Installation instructions Pump group Logamax plus GB162 65 80 100 7217 5100 03 2010 GB For heating engineers Please read thoroughly before starting installation ...

Page 2: ...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 1...

Page 3: ...r 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 s...

Page 4: ...k 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 ...

Page 5: ...plied 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 1 2 Item 6 Insulation cover Item 7 Technical d...

Page 6: ...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 B...

Page 7: ...NT 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 2 1 NOTE We advise you...

Page 8: ... 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 1 UPER 25 80 UPS 25 80 pump group with pump 2 Table 1 Selecting the correct pump group DAMAGE TO THE ...

Page 9: ...ly 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 1 2 fig 6 Removing the non return valve 1 fig 7 Removing the non return valve 1 DAMAGE TO THE UNIT due to reduced flow or pipes becoming clogged up Make sure that...

Page 10: ...train 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 1 and Ø 35 mm fig 8 Fitting the pump 1 2 fig 9 Installing the isolating valves Item 1 Press...

Page 11: ...65 with pump group UPS 25 80 with non return valve 1 3000 20 Logamax plus GB162 65 with pump group UPS 25 80 without non return valve 375 3000 20 Logamax plus GB162 65 with pump group UPER 25 80 with non return valve 1 3000 20 Logamax plus GB162 65 with pump group UPER 25 80 without non return valve 375 3000 20 Logamax plus GB162 80 with pump group UPS 25 80 with non return valve 153 3600 20 Logam...

Page 12: ...pin through the valve body fig 11 Fit the compression elbow fig 12 item 1 supplied packed with the boiler using thread sealant Fit a 22 mm metal discharge pipe fig 12 item 2 fig 10 Removing the retaining pin NOTE To prevent the pressure in the heating system from becoming excessively high a pressure relief valve is required A 4 bar pressure relief valve forms part of the pump group fig 9 item 1 fi...

Page 13: ...tem 1 to the conden sate drain outlet CDO fig 13 Filling the syphon with clean water DANGER OF FATAL ACCIDENT due to poisoning If the syphon is not filled with clean water flue gas can escape and put people s lives at risk fig 14 Installing the syphon Item 1 Syphon 1 2 1 NOTE The trap is fitted with a bayonet connection After pushing 1 the trap upwards into place you have to turn it a 1 4 turn ant...

Page 14: ... to the seweage system The condensate must be able to run into a funnel or neutralisation tank without restrictions This prevents condensate from building up in the boiler The syphon in the connection kit must no be permanently connected to the condensate drain pipe The minimum distance between the syphon and the condensate drainage pipe is 2 cm fig 16 item 1 5 7 Connecting the expansion vessel ac...

Page 15: ...t every boiler is connected to the expansion vessel fig 17 Refer to the cascade system installation instructions for the installation details 5 8 Making the electrical connections to the pump Turn the vent key through a quarter rotation to undo the boiler door lock fig 18 item 1 Push the fastener down fig 18 item 2 and open the boiler door fig 18 item 3 Remove the cover shield of the pump group fi...

Page 16: ...the cover over the electrical connections and pull the cover up fig 19 Lay the pump connection cable from the boiler through the hole under the electrical connection box downwards see fig 20 item 1 and fig 21 item 1 fig 19 Pulling the cover over the electrical connections up fig 20 Laying the pump connection cable Item 1 Pump connection cable 1 ...

Page 17: ... 1 to the pump 5 9 Installing the insulation cover Feed the insulation cover with its upper edge into the groove in the lower support fig 23 fig 21 Laying the pump connection leads Item 1 Pump connection cable fig 22 Connecting the pump Item 1 Mains cable connector 1 1 fig 23 Installing the insulation cover NOTE The door over the boiler control panel must be closed ...

Page 18: ...00 Subject to modifications resulting from technical improvements 18 6 Commissioning NOTE See the Installation and servicing instructions of the boiler assembly for commissioning instructions Observe the safety instructions and take the relevant measures ...

Page 19: ...ump group without a non return valve UPS 25 80 Residual head downstream of the pump group with a non return valve UPS 25 80 fig 25 Residual head downstream of the pump group UPER 25 80 with and without a non return valve 0 100 200 300 400 500 600 700 800 900 0 500 1000 1500 2000 2500 3000 3500 4500 5000 4000 Volume flow l h Residual head mbar Residual head downstream of the pump group without a no...

Page 20: ... Orchard Dublin 10 Tel 01 6305700 Fax 01 6305706 01 6305715 www cfquadrant ie e mail sales cfquadrant ie 721 756A 0005 Buderus Cotswold Way Warndon Worcester WR4 9SW Customer service 0844 892 9700 Technical support 0844 892 3004 Fax 01905 753130 United Kingdom www buderus commercial co uk In the UK and IE Buderus is a brand name of Bosch Thermotechnology Ltd ...

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