Buderus Logamax plus GB142-24 User manual

Please read these instructions carefully
Service kit instructions, condensate trap and condensate bypass pipe
Condensing gas boiler
Logamax plus
WARNING!
This service kit shall be installed by a qualified service
agency in accordance with the manufacturer‘s instruc-
tions 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 prop-
erty damage, personal injury or death. The qualified ser-
vice agency is responsible for the proper installation of
this kit.
The installation is not proper and complete until the oper-
ation of the repaired appliance is checked as specified in
the manufacturer‘s instructions supplied with the kit.
CAUTION!
Shut off the gas supply prior to disconnecting the electri-
cal power, before starting.
Notice! Save these instructions for later use.
GB142-24/30/45/60
6 720 810 045 (12/2013) US/CA

2| Contents
Logamax plus GB142-24/30/45/606 720 810 045 (2013/12)
Contents
1 Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Application purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Explanation of Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Additional symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Observe the following warnings . . . . . . . . . . . . . . . . . . . 2
2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Shutting down the appliance . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Removing the condensate trap . . . . . . . . . . . . . . . . . . . . 3
3.3 Removing the heat exchanger . . . . . . . . . . . . . . . . . . . . . 4
3.4 Mounting the new condensate trap and flue gas
adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Testing for gas leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Filling the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Start up the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Safety considerations
The conversion shall be carried out by a manufacturer’s authorized
representative, in accordance with the requirements of the
manufacturer, provincial or territorial authorities having jurisdiction and
in accordance with the requirements of the CAN/CGA-B149.1 or
CAN/CGA-B149.2 installation codes.
For use in Canada the conversion shall be carried out in accordance with
the requirements of the provincial authorities having jurisdiction and in
accordance with the requirements of the CAN/CGA-B149.1 and
CAN/CGA-B149.2 Installation Code. See also E.I.V.
Please observe the following safety instructions.
1.1 Application purpose
This kit and these instructions are to provide the Logamax plus
GB142-24/30/45/60 with an internal condensate bypass.
1.2 Explanation of Symbols
Warning symbols
Signal words indicate the seriousness of the hazard in terms of the
consequences of not following the safety instructions.
•NOTICE indicates possible damage to property or equipment, but
where there is no risk of injury.
•CAUTION indicates possible injury.
•WARNING indicates possible severe injury.
•DANGER indicates possible risk to life.
Important information
1.3 Additional symbols
1.4 Observe the following warnings
2 Scope of delivery
Fig. 1 Service kit with condensate trap, condensate bypass pipe and
flue gas adapter
This service kit contains the following parts:
[1] Flue gas adapter
[2] condensate trap
[3] condensate bypass pipe
[4] gas ring
[5] instructions
Safety instructions in this document are framed and
identified by a warning triangle which is printed on a
grey background.
Electrical hazards are identified by a lightning symbol
surrounded by a warning triangle.
Notes contain important information in cases where
there is no risk of personal injury or material losses and
are identified by the symbol shown on the left. They are
bordered by horizontal lines above and below the text.
Symbol Meaning
▶ a step in an action sequence
a reference to a related part in the document or to other
related documents
• a list entry
–a list entry (second level)
Table 1
DANGER: gas explosion.
▶ Work only on gas components when you have a
license to do so.
▶ 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 technician.
DANGER: electrical shock.
▶ Prior to doing any work on the heating system,
disconnect all electrical powerto the appliance at the
emergency switch. It is not sufficient to shut off only
the appliance control.
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6 720 810 045 (2013/12)Logamax plus GB142-24/30/45/60
3Installation
To install the parts of the service kit in the appliance, the following
instructions must be adhered to.
3.1 Shutting down the appliance
▶ Close the gas shut-off valve.
Fig. 2 Gas shut-off valve closed
▶ Press the control panel cover to open.
Fig. 3 Control panel cover
▶ Switch off the appliance by setting the mains switch [1] to position
“0”.
Fig. 4 Mains switch to “OFF”
▶ Disconnect the electrical power to the appliance.
▶ Set the thermostat or other operating control to the lowest setting.
▶ Use the radiator key to unlock the two latches a quarter turn [1.].
▶ Open the latches [2.].
▶ Remove the casing by lifting it upwards and then pulling it forwards
[3.].
Fig. 5 Removing the casing
3.2 Removing the condensate trap
▶ Pull the condensate trap from the condensate collector [1].
▶ Loosen the condensate trap from the connection [2] and remove it.
Fig. 6 Removing the condensate trap
NOTICE: appliance damage due to incorrect lifting.
▶ Do not hold the casing by the latches.
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Logamax plus GB142-24/30/45/606 720 810 045 (2013/12)
3.3 Removing the heat exchanger
▶ Close the maintenance shut-off valves [1] and drain [2] of the
Logamax plus GB142.
Fig. 7 Maintenance shut-off valves
▶ Remove the cable plug from the gas control valve.
Fig. 8 Removing the gas control valve cable plug
▶ Remove both cable plugs [1] from the fan unit.
Fig. 9 Removing the fan unit cable plugs
▶ Pull both retaining clips [1] on the burner cover to open them and
remove the burner cover with the fan unit and the gas control valve.
Fig. 10 Loosening the retaining clips
▶ Remove the burner [1].
Fig. 11 Removing the burner
▶ Disconnect the supply [1], return [2] and safety [3] sensors.
Fig. 12 Disconnecting the supply sensor
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CAUTION: electrical short circuit.
To prevent mix-ups, the supply sensor is marked by a
red sleeve on the side of the cable harness.
1.
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6 720 810 045 (2013/12)Logamax plus GB142-24/30/45/60
Fig. 13 Disconnecting the return sensor
Fig. 14 Disconnecting the safety sensor
▶ Disconnect the hot surface ignitor and ionization electrode plugs.
▶ Pull the ground cable from the hot surface ignitor [2].
Fig. 15 Dismantling the hot surface ignitor
▶ Open all latches [1] of the condensate collector.
Fig. 16 Opening the latches of the condensate collector
▶ Remove the condensate collector.
▶ Dismantle the tension spring [1] between the supply pipe and the
heat exchanger.
Fig. 17 Dismantling the tension spring
▶ Loosening with one turn the nut between the supply connection and
three way valve connection AB [1].
▶ Pull the supply pipe out of the heat exchanger [2].
▶ Loosen the return pipe of the heat exchanger [3].
Fig. 18 Removing the supply pipe
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6| Installation
Logamax plus GB142-24/30/45/606 720 810 045 (2013/12)
▶ Pull the combustion air supply and flue gas exhaust connections on
top of the appliance upwards to remove them.
▶ Loosen all fastening screws of the flue gas adapter.
▶ Remove the flue gas adapter [1] from the top of the appliance.
Fig. 19 Removing the flue gas adapter
▶ Remove the heat exchanger by grabbing its bottom end and pulling
forward and then pushing it upwards.
Fig. 20 Removing the heat exchanger
▶ Install the gas ring on the flue gas collector.
Fig. 21 Installing the gas ring
▶ Fit the condensate bypass pipe on the gas ring.
Fig. 22 Fitting the condensate bypass pipe
▶ Put the heat exchanger back in the appliance and assemble it in
reverse order.
▶ Open the maintenance shut-off valves (fig. 7, [1]) and drain
(fig. 7, [2]) of the Logamax plus GB142.
3.4 Mounting the new condensate trap and flue gas
adapter
▶ Fill the new condensate trap (fig. 1, [4]) with water before re-
installing it. This is to prevent exhaust gases from entering the room.
▶ Reassemble the new condensate trap to the appliance
▶ Connect the new condensate bypass pipe.
Fig. 23 Connect condensate bypass pipe
▶ Screw the new flue gas adapter on the appliance.
3.5 Testing for gas leaks
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6 720 641 697-034.1TD
6720801158-21.1TD
NOTICE: electrical short circuit.
Leaks may be caused to pipes and screw connections
during servicing activities.
▶ Carry out a proper leak test.
▶ Cover damageable parts before leak testing.
▶ Only use approved leak detection agents.
▶ Do not spray the leak testing agent onto cables, plugs
or electrical connection lines. Do not allow it to drip
onto them either.
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6 720 810 045 (2013/12)Logamax plus GB142-24/30/45/60
▶ Open the gas shut-off valve.
Fig. 24 Gas shut-off valve open
▶ Check all joints and gaskets affected by the replacement activities for
gas leaks.
▶ In case of a gas leak, close the gas shut-off valve (fig. 2) and take
the safety precautions mentioned above.
▶ Check again all joints and gaskets and repair the leakage.
▶ Open the gas shut-off valve (fig. 24) and check again for gas leaks.
3.6 Filling the appliance
▶ Switch on the heating system by setting the mains switch [1] to
position “1”. It is possible that P0.0 appears in the display of the
control panel telling you that the system pressure is to low at.
Fig. 25 Mains switch to “ON”
▶ Fill the heating system to a pressure of around 20 psi (1.5 bar).
▶ Observe the pressure on the control panel or the P/T gauge in the
pump manifold (if equipped) for the heating circuit. The fill pressure
of the system should be at least the required inlet pressure for the
expansion tank plus 7.2 psi (0.5 bar). The minimum pressure is
15 psi (1.0 bar) (on a cold system). The maximum pressure is 44 psi
(3.0 bar) (if the heating medium temperature is at its highest
possible level). If this pressure is exceeded, the pressure relief valve
will open.
3.7 Start up the appliance
For your safety, read before lighting.
A) This appliance does not have a pilot. It is equipped with an ignition
device which automatically lights the burner. Do not try to light the
burner by hand.
B) BEFORE OPERATING smell all around the appliance area for gas. Be
sure to smell next to the floor because some gas is heavier than air and
will settle on the floor.
C) Use only your hand to push in or turn the gas control knob. Never use
tools. If the knob will not push in or turn by hand, don't try to repair it, call
a qualified service technician. Force or attempted repair may result in a
fire or explosion.
D) Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the appliance
and to replace any part of the control system and any gas control which
has been under water.
▶ Wait 5 minutes to clear out any gas. Then smell for gas, including near
the floor. If you smell gas, STOP! Follow “B” in the safety information
above. If you do not smell gas, go to the next step.
▶ Install the casing again.
Fig. 26 Installing the casing
▶ Set the thermostat or other operation control to the desired setting.
▶ Connect the appliance to the power supply.
▶ Switch on the appliance using the mains switch (fig. 25).
▶ Check all gas fittings and water fittings for leaks.
DANGER: gas explosion.
What to do if you smell gas:
▶ No open fire. Do not smoke.
▶ Avoid formation of sparks. Do not touch any electric
switch, phone, electric plug or bell.
▶ Shut off the main gas supply.
▶ Open windows and doors.
▶ Notify all occupants.
▶ Leave the building.
▶ Immediately call your gas supplier, heating
contractor or fire department from a phone outside
the building.
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DANGER: due to not following these instructions.
▶ If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or loss of life.
▶ Follow these operating instructions.
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