Buderus GB162-80 kW User manual

For the contractor
Please read these instruc-
tions carefully
Propane Conversion kit
instructions
Condensing gas boiler
Logamax plus
Required Input Rates
Logamax plus GB162-80 kW Logamx plus GB162-100 kW
270,000 btu/hr 315,000 btu/hr
This kit and instructions are for converting the GB162 model
boilers from Natural Gas to Liquid Propane.
WARNING!
This conversion kit shall be installed by a qualified service agency
in accordance with the manufacturer‘s instructions and all
applicable codes and requirements of the authority having
jurisdiction.
The information in these instructions must be followed to
minimize the risk of fire or explosion or to prevent property
damage, personal injury or death. The qualified service agency
is responsible for the proper installation of this kit.
The installation is not proper and complete until the operation of
the converted boiler is checked as specified in the manufacturer‘s
instructions supplied with the kit.
CAUTION!
The gas supply shall be shut off prior to disconnecting the
electrical power, before proceeding with the conversion.
Notice! Save these instructions for later use.
6720615152-001.1TD
GB162-80 kW
GB162-100 kW
6 720 615 033 (04/2010) US/CA

Contents
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!
2
Contents
1 Safety considerations 3
1.1 Application purpose 3
1.2 Hazard definitions 3
1.3 Observe the following symbols 3
2 Parts list for converting the boiler to propane 4
3 Liquid Propane conversion 5
3.1 Shut down the boiler 5
3.2 Changing the gas valve assembly 5
3.3 Testing for gas leaks 7
3.4 Inlet gas pressure 7
3.5 Checking and adjusting the gas/air ratio 8
3.6 Carrying out a tightness test in operating conditions 9
3.7 Measuring the CO content 9
3.8 Lighting Instructions 10
4 Operating Instructions 11

1
Safety considerations
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 3
1 Safety considerations
For use in Canada the conversion kit shall be carried out
in accordance with the requirements of the provincial
authorities having jurisdiction and in accordance with the
requirements of the CAN-B149.1 and CAN1-B149.2
Installation Code. See also E.I.V.
Please observe the following safety instructions.
1.1 Application purpose
This kit and instructions are for converting the Logamax
plus GB162-80 kW/100 kW from Natural gas to Liquid
Propane.
1.2 Hazard definitions
The following defined terms are used throughout the
documentation to bring attention to the presence of
hazards of various risk levels. Notices give important
information concerning the operation of the product.
1.3 Observe the following symbols
DANGER:
Indicates the presence of hazards that will
cause severe personal injury, death or
substantial property damage.
WARNING:
Indicates the presence of hazards that can
cause severe personal injury, death or
substantial property damage.
CAUTION:
Indicates presence of hazards that will out
cause minor personal injury or property
damage.
CAUTION:
Indicates presence of hazards due to electric
shock.
Indicates special instructions on installation,
operation or maintenance that are important
but not related to personal injury or property
damage.
DANGER:
due to explosion of gas.
BWork only on gas components when you
have a license to do so.
BNote that the assembly of gas and vent
connections, the initial start-up, the
electrical connections, the maintenance
and service can only be performed by a
licensed service contractor or technican.
DANGER: Electric shock.
Live components are present inside the
boiler.
BIsolate the electrical mains supply before
working on the boiler.
BLock-out the mains supplies to prevent
accidental activation.

2Parts list for converting the boiler to propane
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!
4
2 Parts list for converting the boiler to propane
Conversion kit propane for the GB162-80 kW/100 kW
# 7746900499 includes:
• assembly # 774601703A 1 ×
– gas valve propane
– venturi
– orifice # 774600958A
• these instructions 1 ×
•label80kW 1×
• label 100 kW 1 ×
• O-ring fan-venturi 1 ×
• sealing gas pipe 1 ×
• sealing gas flange 1 ×
•TorxkeyTx25 1×
•TorxkeyTx30 1×
•Torxscrew 3×
• Screw M5x12 thread 4 ×

3
Liquid Propane conversion
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 5
3 Liquid Propane conversion
To convert the boiler to liquid propane, the following
instructions must be adhered to:
3.1 Shut down the boiler
BTurn off the gas supply underneath the boiler.
BSwitch off the boiler using the main switch (Æfig. 1,
[1]).
BDisconnect the electrical power to the boiler.
BSet the thermostat or other operating control to lowest
setting.
Fig. 1 Mains switch
BOpen the boiler door by turning the vent key through
¼ rotation anti-clockwise(Æfig. 2).
Fig. 2 Opening the boiler door
3.2 Changing the gas valve assembly
BLoosen the screw connection on the gas valve
(Æfig. 3, [1]) and pull the plugs (Æfig. 3, [2]) from the
gas valve.
Fig. 3 Undoing the connections to the gas valve
BPull both plugs from the fan unit (Æfig. 4, [1]).
Fig. 4 Removing the connectors from the fan
BPull the air suction tube from the fan (Æfig. 5).
Fig. 5 Pulling the air suction tube from the fan
BLoosen both retaining clips on the burner cover
(Æfig. 6).
DANGER: Risk of explosion.
BWork on gas appliances must be carried
out by competent registered personnel.
Reset
01
140
130
120
90
100
110
Aut
0
Eco
190
170
150
130
90
110
Aut
0
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1.
2.
3.
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3Liquid Propane conversion
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!
6
Fig. 6 Opening the retaining clips
BRemove the burner cover together with the fan unit and
the gas valve (Æfig. 7).
Fig. 7 Removing the burner cover with the gas/air unit
BUndo the 3 screws (Æfig. 8, [1]) and remove the gas
valve with the venturi from the fan unit (Æfig. 8, [2]).
BTake the gas valve and venturi from the conversion kit
# 7746900499.
Fig. 8 Removing the screws and gas valve with venturi
BInstall the venturi and gas valve of the conversion kit on
the fan unit using a new O-ring (Æfig. 9) and follow the
instructions above in reverse order.
Fig. 9 Placing a new O-ring on the fan unit
BInstall the gas flange from the natural gas assembly on
the new gas valve (Æfig. 10, [1]).
Fig. 10 Installing the gas flange
Thermal
power
gas
boiler
Type
of gas
supply
Altitude
[ft (m)]
Gas orifice
diameter
[inch
(mm)]
Venturi
article
number
GB162-
80 kW/
100 kW
Natural
gas
0-4,000
(0-1,220)
0.331(8.40) 73983
LPG P 0-4,000
(0-1,220)
4.70(0.193) 73983
Tab. 1 Gas orifice diameter
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2
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1 2

3
Liquid Propane conversion
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 7
BReplace the seal under the gas flange with a new seal
(Æfig. 10,[2]).
Fig. 11 Installing a new seal on the gas pipe
BReplace the seal from the gas pipe with a new seal
(Æfig. 11).
BRefit all parts in reverse order. When re-installing the
burner plate, make sure that the notch is on the
right-hand side (Æfig. 12).
Fig. 12 Re-installing the burner plate
BCarry out the start-up activities and complete a new
start-up report.
BCheck all joints and gaskets affected by the installation
activities while carrying out the tightness test in
operating conditions.
BPlace a new sticker underneath the existing rating plate
sticker indicating the type of gas supply installed.
BFill out the required information on the conversion label.
BClose the boiler door and lock the fastener by turning
the vent key through ¼ rotation in a clockwise
direction.
3.3 Testing for gas leaks
Prior to start-up of the boiler you must check the external
tightness of the gas supply valve and confirm this in the
start-up report.
BDisconnect the boiler from the power supply.
BCheck the exterior tightness of new conduit sections
up to and including the direct sealing point on the gas
burner fitting. The maximum test pressure allowed on
the input of the gas burner fitting is 60 inch W.C.
(150 mbar).
BCheck the input rates after converting the boiler to LPG
to the values on the front page.
3.4 Inlet gas pressure
BOpen at least 1thermostatic radiator valve if present to
allow water to flow through the boiler. Do not switch on
the boiler.
BClose the gas shut-off valve. Loosen the screw plug on
the inlet gas pressure testing nipple by 2 turns
(Æfig. 13, [1]).
BConnect the pressure gauge connection hose to the
testing nipple (Æfig. 13, [2]).
BSlowly open the gas shut-off valve.
The boiler and its individual shutoff valve must be
disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in
excess of 60 inch W.C. (150 mbar).
The boiler must be isolated from the gas supply piping
system by closing its individual manual shutoff valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 60 inch
W.C. (150 mbar).
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DANGER: Risk of explosion
BCheck for leaks before working on gas-
carrying components.
CAUTION:
due to a short circuit.
BCover damageable parts before leak
testing.
BDo not spray the leak detection agent onto
cables, plugs or electrical connection
lines. Do not allow it to drip onto them
either.

3Liquid Propane conversion
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!
8
Fig. 13 Measuring the gas supply pressure
BPress on the control panel cover to open it.
Fig. 14 Opening the control panel
BSwitch on the boiler by setting the main switch to
position “1” (Æfig. 1, page 5).
BPress the “Chimney Sweep” d button and hold it for
approx. 2 seconds until the display shows a decimal
point.
BMeasure the gas connection pressure as soon as the
“Burner” LED lights and enter this value in the start-up
report.
The inlet gas pressure must be:
• for natural gas - min. 7.0 to 10.5 inch W.C. (17.4 to
26.1 mbar), nominal supply pressure 8.0 inch W.C.
(19.9 mbar)
• for LPG - min. 8.0 to 13.0 inch W.C. (19.9 to
32.3 mbar), nominal supply pressure 11.0 inch W.C.
(27.4 mbar).
BPress repeatedly the “Service” ebutton until the
temperature indication is displayed.
BPress the “Chimney Sweep” dbutton to end the
measurement procedure.
BClose the gas shut-off valve.
BRemove the connection hose again and tighten the
screw plug on the testing nipple.
BOpen the gas shut-off valve again.
3.5 Checking and adjusting the gas/air
ratio
BSwitch off the boiler using the main switch.
BLoosen the screw plug on the measuring nipple for the
burner pressure by 2 rotations (Æfig. 15, [1]).
BSet the pressure gauge to 0.
BUse a hose to connect the plus terminal of the pressure
gauge to the burner pressure measuring nipple
(Æfig. 15, [2]).
Fig. 15 Checking the gas/air ratio
BSwitch on the boiler using the main switch.
BPress the “Chimney Sweep” d button and hold it for
approx. 2 seconds until the display shows the decimal
point.
BPress and hold the “Chimney Sweep” d and “Service”
e button, for approx. 5 seconds, until the display
shows “Lxx” (e. g. L80).
BSet the boiler to partial load “L25” for the 80 kW or
“L20” for the 100 kW boiler.
BPressing the “Chimney Sweep” d button for higher
values or the “Reset” c button for lower values.
BRead out the differential pressure.
The differential pressure (pGas– pAir) must be
-0.02 inch W.C. (-5 Pa) (±0.02 inch W.C. = ± 5 Pa)
(read-out on pressure gauge: -0.04 – 0 inch W.C. =
-10–0Pa).
BEnter the value measured in the start-up report.
1
2
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BContact the relevant gas utility company if
the required inlet gas pressure is not
available.
BInstall a gas pressure regulator before the
gas burner fitting if the supply pressure is
too high.
1
2
6720615033-019.1TD

3
Liquid Propane conversion
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 9
BAdjust the gas/air ratio, if not correct, using the
adjustment screw (Æfig. 16, [1]). The adjustment
screw is located behind the cover screw.
Fig. 16 Setting the gas/air ratio
BPress repeatedly the “Service” e button until the
temperature indication is displayed.
BPress the “Chimney Sweep” d button until the
decimal point is cleared from the display.
BSwitch off the boiler using the main switch.
BRemove the measurement set-up, tighten the screw in
the burner pressure measuring nipple.
BSwitch on the boiler using the main switch.
3.6 Carrying out a tightness test in
operating conditions
BCheck all gaskets and joints in the burner gas circuit for
leaks while the burner is operational, using a leak
detection agent.
3.7 Measuring the CO content
BMeasure the CO content on the flue gas sampling
point (Æfig. 17, [1]).
The CO values in an air-free condition must be below
400 ppm or 0.04 vol. %.
Values of 400 ppm and up indicate that the burner
adjustment may be wrong, the gas burner fitting or the
heat exchanger are dirty or that there may be burner faults.
BEstablish and resolve the cause.
The boiler must be operational when you do this.
Fig. 17 Measuring the CO content
CAUTION:
due to a short circuit.
BCover damageable parts before leak
testing.
BDo not spray the leak detection agent onto
cables, plugs or electrical connection
lines. Do not allow it to drip onto them
either.
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1

3Liquid Propane conversion
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!
10
3.8 Lighting Instructions
For your safety, read before lighting.
This boiler is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot by
hand.
Check for smell of gas around the boiler area.
Be sure to smell next to the floor because some gas is
heavier than air and will settle on the floor.
Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to inspect
the boiler and to replace any part of the control system
and any gas control which has been under water.
DANGER:
What to do if you smell gas:
BNo open fire! Do not smoke!
BAvoid formation of sparks! Do not touch
any electric switch, phone, electric plug or
bell!
BShut off main gas supply.
BOpen windows and doors!
BNotify all occupants!
BLeave the building!
BImmediately call your gas supplier, heating
contractor or fire department from a
phone outside the building!
WARNING:
due to not following these instructions.
BIf you do not follow these instructions
exactly, a fire or explosion may result
causing property damage, personal injury
or loss of life.
BFollow these operating instructions.

4
Operating Instructions
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 11
4 Operating Instructions
Start up the boiler
STOP!
Read the safety precautions on page 10 of this manual.
BWait 5 minutes to clear out any gas. Then smell for gas,
including near the floor. If you smell gas, STOP! and
see the safety information on page 10. If you do not
smell gas, go to the next step.
BInstall the casing again.
BOpen the gas shut-off valve.
BSet the thermostat or other operation control to desired
setting.
BConnect the boiler to the power supply.
BSwitch on the boiler using the main switch (Æfig. 18).
Fig. 18
Reset
01
140
130
120
90
100
110
Aut
0
Eco
190
170
150
130
90
110
Aut
0
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