Buderus Logamax plus GB162 User manual

For heating contractors
Please read carefully prior to
commissioning and servicing
Record book Condensing gas boiler
Water quality requirements for
Logamax plus GB162-80 kW/100 kW
6 720 641 552 (2011/05) US

Contents
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!
2
Contents
1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Requirements 4
2.1 System requirements 4
2.2 Cleaning of the heating system 4
2.3 Checking the water quality 4
2.4 pH-value 4
2.5 Prevention of damage by corrosion 5
2.6 Use of anti-freeze 5
2.7 Use of inhibitors 5
3 Operator's log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1
About this document
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 3
1 About this document
This document contains important information regarding
the quality of water for boilers containing aluminium
materials and shows you how to keep a log of the water
quality.
An operator's log (Æchapter 3, page 6) is included at the
end of this document.
This operator's log is intended for qualified heating
engineers, who – as a result of their training and
experience – are skilled in dealing with heating systems.
Warranty claims with respect to Logamax plus
GB162-80 kW/100 kW boilers are only valid in
conjunction with the requirements specified herein and
properly completed annual service records in the
operator's log and the servicing and maintenance log
(part of the installation and service manual).
Additional symbols
Symbol Explanation
BSequence of steps
ÆCross-reference to other points in this
document or to other documents
• Listing/list entry
–Listing/list entry (2nd level)
Table 1

2Requirements
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!
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2 Requirements
The quality of the system water is very important. Poor
water quality can damage heating systems due to scale
formation and corrosion.
2.1 System requirements
• 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).
• When using oxygen-permeable pipes (plastic), e.g. for
floor heating systems, you must separate the system
using secondary heat exchangers.
2.2 Cleaning of the heating system
• Flushing ensures trouble free operation of your boiler.
Thoroughly flush (30 minutes to 1 hour) the heating
system (not including the boiler) with mains water prior
to filling. The boiler must be isolated from the heating
system.
• Close the shutoff-valves underneath the boiler so dirt
and the cleaner is not flushed through the boiler.
The following cleaners can be used:
– Fernox F3 cleaner;
– Rhomar hydro-solv 9100 cleanser;
– Sentinel X300 cleaner.
• Install dielectric unions at the boiler supply line and
return nearest the boiler or the low loss header to
electrically separate the water heater from the
household piping.
• It is not permitted to use well water to fill or replenish
your system.
•Do not use inhibitors or other additives unless
approved by Buderus for that purpose.
• The maximum permissable flow rate for this boiler type
is 22 USgpm (83 l/min.).
2.3 Checking the water quality
The quality of water, especially when mixed with an anti-
freeze (glycol), can have an enormous impact on the
system performance. Marginal water quality can lead to
the precipitation of scale, sediment deposits, or the
accumulation of sludge in the heat exchanger, which
reduces heat transfer efficiency. Poor water quality can
damage the system by depleting the corrosion inhibitor
and promoting a number of corrosions including general
and acidic attack corrosion.
Therefore you must ensure the water complies to the
following parameters:
Good quality water without anti-freeze contains:
• less than 300 ppm (17.5 gr/gall US) of total hardness;
• less than 100 ppm (5.8 gr/gall US) of chloride;
• less than 100 ppm (5.8 gr/gall US) of sulfate.
Good quality water with anti-freeze contains:
• less than 100 ppm (5.8 gr/gall US) of total hardness;
• less than 25 ppm (1.5 gr/gall US) of chloride;
• less than 25 ppm (1.5 gr/gall US) of sulfate.
In those cases where mains water does not meet the
standards of good quality, use demineralized water that
has been distilled, deionized, or passed through a reverse
osmosis process to remove harmful minerals and salts or
separate the system with secondary heat exchangers.
2.4 pH-value
The pH-value must comply to values as stated in table 2
and must be checked once a year. If the pH-value isn‘t
between the specified values then this must be corrected.
Follow the instructions of the anti-freeze manufacturer to
correct the pH-value.
Record the findings in the operator's log on page 6.
Use a suitable and calibrated pH-measuring instrument
with an accuracy of less than 0.1.
In order to obtain a correct reading of the pH-value, turn
on the boiler for 15 minutes, then measure the pH-value
and adjust if necessary. Contact Buderus if you have any
water quality issues or questions.
NOTE:
If the appliance is installed in an existing
heating system, dirt may accumulate in the
boiler.
BLeading to localized overheating,
corrosion and noise.
NOTE:
Use the proper equipment to determine the
water quality.
BOr have the water quality analized.

2
Requirements
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 5
2.5 Prevention of damage by corrosion
Corrosion damage occurs if oxygen constantly enters the
heating water due, for example, to:
• undersized expansion vessels (changing pressure can
accelerate corrosion);
• faulty expansion vessels.
2.6 Use of anti-freeze
Only the following, by Buderus approved, anti-freeze
fluids and concentrations may be used:
• Noble Company Noburst AL
• Interstate Intercool Biogreen 50 AA
• Interstate Intercool NFP-50 AA
Follow the instructions of the anti-freeze manufacturer,
with regard to regular annual checking of the
concentration and for proper disposal of anti-freeze.
2.7 Use of inhibitors
The following inhibitors are approved:
• Sentinel X100 at a concentration of 2%
• Fernox F1 protectorat a concentration of 0.5%.
pH-value
without anti-freeze 7.0 - 8.5
with anti-freeze 8.0 - 8.5
Table 2
NOTE:
The water quality is an important factor in
increasing the economy, operating safety,
service life and operational readiness of a
heating system.
BRecord the values required to confirm the
water quality in the operator's log on
page 6.
WARNING:
When using anti-freeze in the primary circuit
of the boiler.
BDo not use PVC flue material. Only use
CPVC or stainless steel!
WARNING:
Contamination of potable water.
BTake measures, such as disconnecting
the filling loop or by installing a safety
valve, to ensure that cross contamination
with potable water is not possible.
NOTE:
Any additives introduced into the heating
system water
Bmust be approved by the boiler
manufacturer for use with aluminum
boilers
NOTE:
The boiler manufacturer only responsible for
the boiler.
BNot for the heating system.
NOTE:
The use of anti-freeze has a great effect on
the heat transfer to the radiators. Keep this in
mind while designing your heating system.
BFor example:
When using a concentration of 30% anti-
freeze in your heating system, you need to
increase your radiator surface with 15%
compared to the radiator surface if no anti-
freeze is added to the heating system.
NOTE:
We advise not to exceed the anti-freeze
concentration of 40%.
BTo determine the anti-freeze
concentrationuse a measuring instrument
with an accuracy of at least 1%
WARNING:
Boiler damage!
BThe anti-freeze concentration must not
exceed 50%, this voids warranty on the
boiler.

3Operator's log
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications!
6
3 Operator's log
No. of installed GB162 boilers: _____________ Total combined output: ____________________ kW (btu)
Date commissioned: ______________________________________________________________________________
Anti-freeze product used (max. 50% concentration)? ________________________________________________
Table 3
Date
Water quality check (enclose
the analysis results to this
operator's log)
Type of fill water
(mains water/distilled water)
Added water volume
[gal (l)]
Total water volume
[gal (l)]
Added anti-freeze volume
[gal (l)]
Concentration of anti-freeze
in the system [%]
pH-value
Primary flow over the boiler 1)
[USgpm (l/min)]
1) Can be determined from the ΔT while the boiler is operating at full load
Company (stamp) / signature
Table 4 Operator's log

3
Operator's log
Logamax plus GB162-80 kW/100 kW - We reserve the right to make any changes due to technical modifications! 7
No. of installed GB162 boilers: _____________ Total combined output: ____________________ kW (btu)
Date commissioned: ______________________________________________________________________________
Anti-freeze product used (max. 50% concentration)? ________________________________________________
Table 5
Date
Water quality check (enclose
the analysis results to this
operator's log)
Type of fill water
(mains water/distilled water)
Added water volume
[gal (l)]
Total water volume
[gal (l)]
Added anti-freeze volume
[gal (l)]
Concentration of anti-freeze
in the system [%]
pH-value
Primary flow over the boiler 1)
[USgpm (l/min)]
1) Can be determined from the ΔT while the boiler is operating at full load
Company (stamp) / signature
Table 6 Operator's log

6720641552 0003