Buderus GB162-65 User manual

Installation instructions Pump group
Logamax plus
GB162-65/80/100
7217 5100 (03/2010) GB
For heating engineers
Please read thoroughly
before starting installation

pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!
2
1 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 About these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Items supplied with pump group . . . . . . . . . . . . . . . . . . . . . . 5
4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Regulations 1
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 3
1 Regulations
1.1 About these instructions
These installation instructions contain important
information about the safe and proper installation of the
Logamax plus GB162-65/80/100 pump group.
These installation instructions are for 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 standards and
guidelines and the technical documents
pertaining to the boiler must be observed
for the installation and operation of the
heating system!

Safety2
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!
4
2 Safety
Please observe these instructions for your own safety.
You can find a detailed explanation of the format of
these instructions in the Installation and Servicing
Instructions of the Logamax plus GB162-65/80/100.
Observe the following instructions when installing and
operating the pump group:
DANGER OF FATAL ACCIDENT
by unprofessional repair.
Do not repair parts with safety functions.
DANGER OF FATAL ACCIDENT
due to electric shock.
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 the main gas supply!
Open doors and windows.
Warn the residents but do not sound the
doorbells!
Contact the gas supplier from a tele-
phone located outside the building!
If you can hear gas leaking, evacuate the
building immediately, prevent other
people from entering, and notify the
police and fire service immediately (from
a telephone OUTSIDE the building).

Items supplied with pump group 3
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 5
3 Items supplied with pump group
Check that the packaging is intact upon delivery.
Check that all items have been supplied with the unit.
fig. 1 Items supplied 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 1½’’ (2×)
Item 6: Insulation cover
Item 7: Technical documents
1
6
4
7
5
2
3
NOTE
Please contact your supplier if anything
is damaged or missing.

Dimensions4
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!
6
4 Dimensions
AIC
FGC
AIC
FGC
CDO
CDO
Gas P
Gas P
Gas B Gas B
CHF/CHR
CHRCHF
PF/PR PF PR
CS
fig. 2 Dimensions and connections (dimensions in mm)
1 DO NOT remove the cap CS (not used in UK)
2 The pump group is accessory and can be ordered separately.
This figure shows 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 = Boiler flow; G1½’’ union nut with female thread
CHR = Boiler return; G1½’’ union nut with female thread
PF = Pump group flow; G1½’’ male thread, flat seal
PR = Pump group return; G1½’’ male thread, flat seal

Installation 5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 7
5 Installation
General installation instructions
Connect all pipes without forcing them into place.
Make sure that the connections are tight and carry
out a gas and water tightness test after completing
the connection work (also see the boiler installation
and servicing instructions).
5.1 Making the gas connection
Install the gas valve (fig. 4, item 1) onto the gas pipe
(GAS) in the boiler.
Connect the main gas supply to the gas isolating
valve (fig. 4, item 2) free of strain.
fig. 3 Rubber seal
DANGER OF FATAL ACCIDENT
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 to integrate a gas filter in the
gas line.
Make the gas connection according to
the country-specific standards and regu-
lations.
Carry out gas leak test on gas connec-
tion using leak detection spray
DANGER OF FATAL ACCIDENT
from explosive fumes.
Pipes and screw connections may leak after
commissioning and maintenance activities
have been carried out.
Carry out a leakage test.
Only use approved detection products to
locate leaks.

Installation5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!
8
5.2 Removing the non-return valve (if necessary)
If the system pressure is not sufficient according to
table 3, page 11, you can remove the integrated non-
return valve from single-boiler systems.
Selecting the correct pump group
Select the correct pump group using table 1.
1) Only remove the non-return valve from the pump group (beneath
the pump) when installing single-boiler systems
2) Do not use a pump group or switch, but select a separate pump
using the installation and servicing instructions with the boiler.
Logamax plus
GB162-65
Logamax plus
GB162-80
Logamax plus
GB162-100
Multi-boiler
system
(cascade
system)
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 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 UNIT
in cascade systems or in single-boiler
systems with a switch due to the heating
medium flowing back.
Only remove the non-return valve from
the pump group of a single-boiler system
if the residual head (see table 3, page 11
is not sufficient.
Logamax plus
GB162-65
Logamax plus
GB162-80
Logamax plus
GB162-100
Multi-boiler
system (cascade
system)
not allowed not allowed not allowed
Single-boiler
system with
Buderus diverter
valve
not allowed not allowed not allowed
Single-boiler
system without
diverter valve
Check the
residual head
Check the
residual head
not effective,
use pump
Table 2 Removing the non-return valve

Installation 5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 9
Removing the non-return valve
Remove the non-return valve before installing the
heating flow and return circuits otherwise it cannot be
fully 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 no fragments of the non-
return valve stay behind in the pipe.

Installation5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!
10
Then fit back the flat rubber seal (fig. 8, item 2) and
the pump (fig. 8, item 1).
5.3 Installing the heating flow and return
Install the blue and red isolating valve (fig. 9, item 3
and item 4) with the flat rubber seals in place on the
CHR and CHF (boiler return and flow) connections.
Connect the flow pipe to the red isolating valve (fig. 9,
item 5) free of strain. If necessary, use the screw
fitting (accessory, fig. 9, item 7).
Connect the return pipe to the blue isolating valve
(fig. 9, item 6) free of strain. 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 1½’’ and Ø 35 mm.
fig. 8 Fitting the pump
1
2
fig. 9 Installing the isolating valves
Item 1: Pressure relief valve
Item 2: Pump
Item 3: Isolating valve, blue
Item 4: Isolating valve, red
Item 5: Flow connection
Item 6: Return connection
Item 7: Screw fitting 1’’ female thread (accessory)
2
3
1
4
6
7
5
NOTE
To prevent pollution in the heating system
we advise you to integrate a dirt filter in the
return circuit. When connecting the heating
boiler to an existing heating system, this dirt
filter must be installed.

Installation 5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 11
Install a shut-off valve for filter cleaning immediately
upstream and downstream of the dirt filter.
Installing the differential pressure controller
In situations where there is no low less header, installing
a by-pass valve with a differential pressure controller
would be required.
If a low less header is present, it may be required -
depending on the situation - to install a differential
pressure controller to the secondary side of the open
manifold. This serves to protect the secondary pump
against overheating as a result of insufficient flow.
Installing the drain cock
Since the isolating valve for the return circuit already has
an integrated filling and drain valve, fitting a drain valve
is not necessary.
Installing the non-return valve
Since the isolating valve for the return circuit (blue)
already has an integrated non-return valve, fitting a
non-return valve in the return circuit is not necessary.
Residual head [mbar] with minimum required volume flow [l/h] with T [K]
Logamax plus GB162-65 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
Logamax plus GB162-80 with pump group
UPS 25-80 without non-return valve
259 3600 20
Logamax plus GB162-80 with pump group
UPER 25-80 with non-return valve
1) 3600 20
Logamax plus GB162-80 with pump group
UPER 25-80 without non-return valve
219 3600 20
Logamax plus GB162-100 with pump group
UPS 25-80 with non-return valve
1) 4300 20
Logamax plus GB162-100 with pump group
UPS 25-80 without non-return valve
1) 4300 20
Logamax plus GB162-100 with pump group
UPER 25-80 with non-return valve
1) 4300 20
Logamax plus GB162-100 with pump group
UPER 25-80 without non-return valve
1) 4300 20
Table 3 Residual head downstream of pump group with a single-boiler system
1) Switch required
NOTE
When using plastic pipework in the heating
system, e.g. for underfloor heating, it has to
be oxygen diffusion tight. If this pipework
does not comply with the relevant
standards, a heat exchanger must be
integrated to separate the systems.

Installation5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!
12
5.4 Rotating the pressure relief valve
Remove the retaining pin from the pressure relief
valve body (fig. 10, step 1).
Rotate the valve body (fig. 10, step 2).
Re-fit the retaining 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).
fig. 11 Re-fitting the retaining pin
fig. 12 Fitting the compression elbow with discharge pipe
1
2

Installation 5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 13
5.5 Installing the syphon
Fill the syphon (supplied with the boiler) with clean
water (fig. 13).
Connect the syphon (fig. 14, item 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
anticlockwise [2.] until it locks into position.

Installation5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!
14
Connect the syphon hose (fig. 15, item 3) and the
rubber sleeve (fig. 15, item 2) to the syphon (fig. 15,
item 1).
5.6 Connecting the condensate drain pipe
Connect the condensate drain pipe to the syphon.
Observe the following regulations:
–The waste water disposal regulations.
–Plastic pipework must be used to drain the
condensate, at least until it is delivered 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 (accessory)
fig. 15 Installing the syphon hose
Item 1: Syphon
Item 2: Rubber sleeve
Item 3: Syphon hose
1
2
3
fig. 16 Condensate drain pipe
Item 1: Condensate drain pipe
1
DAMAGE TO THE UNIT
due to faulty pressure relief valve.
The expansion vessel must be of suffi-
cient capacity.

Installation 5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 15
Connecting the expansion vessel in a multi-boiler
configuration (cascade configuration)
In cascade systems only one expansion vessel is
required for the heating system.
Connect the expansion vessel to the secondary side
of the header in the return circuit (fig. 17), so that
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 (fig. 18,
item 4).
fig. 17 Connecting the expansion vessel in a multi-boiler
configuration (cascade configuration)
Item 1: Expansion vessel
VK RK
GAS
VK RK
GAS
1
fig. 18 Opening the boiler door
1
2
3
4

Installation5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements!
16
Undo 1 screw to release 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

Installation 5
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 17
Connect the mains cable connector (fig. 22, item 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.

Commissioning6
pump group Logamax plus GB162-65/80/100 - 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.

Technical specifications 7
pump group Logamax plus GB162-65/80/100 - Subject to modifications resulting from technical improvements! 19
7 Technical specifications
fig. 24 Residual head downstream of the pump group (UPS 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 4000 4500 5000
Volume flow (l/h)
Residual head (mbar)
Residual head downstream of the pump 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 non-return valve (UPER 25-80) - full load
Residual head downstream of the pump group with a
non-return valve (UPER 25-80) - full load
Residual head downstream of the pump group with a
non-return valve (UPER 25-80) - partial load

Bosch Thermotechnik GmbH
Sophienstrasse 30-32
D-35576 Wetzlar
www.buderus.de
[email protected]
C & F Quadrant Ltd.
Unit L40 Cherry Orchard Industrial Estate
Cherry Orchard, Dublin 10
Tel.: [phone]
Fax: [phone]
www.cfquadrant.ie
e-mail: [email protected]
721.756A 0005
Buderus
Cotswold Way, Warndon, Worcester WR4 9SW,
Customer service: 0844 892 9700
Technical support: 0844 892 3004
Fax: [phone]
United Kingdom
www.buderus-commercial.co.uk
In the UK and IE, Buderus is a brand name of
Bosch Thermotechnology Ltd.