GB142 Application Manual
Contents
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9. 4 4 gt 12 12 minimum minimum Page 7 DIRECT VENT SEALED COMBUSTION amp DIRECT VENT NON SEALED COMBUSTION TERMINATION GUIDELINES WARNING Follow these instructions when determining vent termination location to avoid possibility of severe personal injury death substantial property damage or cross contamination of combustion air Gas vent extending through an exterior wall shall not terminate adjacent to the wall or below building extensions such as eaves parapets balconies or decks Failure to comply could result in severe personal injury death or substantial property damage Locate the concentric vent air termination using the following guidelines e The total length of piping for vent or combustion air should not exceed the limits in Table 6 for maximum output One must consider the immediate environment when locating the vent air termination Gases will form a white plume in winter Plume could obstruct window view Prevailing winds could freeze condensate and cause water ice buildup on building plants or roof Do not terminate vent in window well stairwell alcove courtyard or other recessed areas e Maintain Minimum Clearances below to prevent potential problems 1 Vent must terminate at least 12 inches above grade anticipated snow line roof surface Canada 18 minimum Vent termination must
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12. Taco B amp G Grundfos Taco B amp G S120 UP14 42 3 007 NRF22 UP26 64 0012 PL30 57150 UP26 64 0011 PL30 UP26 64 0013 PL35 ST200 UP26 64 0014 PL30 UP26 64 0011 PL45 ST300 UP26 64 0014 PL30 UP26 64 0011 PL30 ST400 NR 0011 PL45 NR NR NR SU500 UP26 64 0014 PL30 UP26 64 0011 PL45 Refers to Grundfos UP15 42 w built in flow check and speed setting Refers to Taco 007 without built in flow check combination not recommended Page 2 Table 3 Indirect Pump Recommendations for GB142 45 and 60 models GB142 45 GB142 60 Tank Model Grundfos B amp G Grundfos Taco B amp G S120 UP26 64 0014 PL36 UP26 64 0011 PL30 ST150 UP26 99 NR PL36 NR 0013 PL36 ST200 UP26 99 NR PL36 NR 0013 PL36 ST300 UP26 99 0013 PL36 UP26 99 0013 PL36 ST400 UP26 99 NR NR UP26 99 NR NR SU500 NR NR PL36 NR NR NR SU750 UP26 64 0011 PL30 NR 0011 PL36 01000 UP26 64 0012 PL30 UP26 64 0012 PL30 Refers to Grundfos UP15 42 w built in flow check and speed setting Refers to Taco 007 without built in flow check 50750 and SU1000 tanks are non stock Allow 6 to 8 weeks for delivery NR combination not recommended Tables 4 and 5 show pump recommendations for 2 and 3 tank systems operating off a single GB142 heater Tank pumps are placed in parallel with each tank having its own pump The GB142 DHW sensor is placed in one tank a high limit aquastat is to be ins
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16. be at least 7 feet above a public walkway Vent must be 3 feet above any forced air intake within 10 feet Vent must terminate at least 3 feet horizontally from electric meters gas meters regulators relief valves and other equipment and in no case above or below unless a 3 feet horizontal distance is maintained Do not extend exposed vent pipe outside the building beyond recommended distance Condensate could freeze and block vent pipe Vent should terminate at least 3 feet away from adjacent walls inside corners and below roof overhang It is not recommended to terminate vent above any door or window condensate can freeze causing ice formations Do not use chimney as a raceway if another appliance or fireplace is vented into or through chimney The exhaust vent must be pitched up toward the termination a minimum of 4 in per foot Condensate must flow back to the Boiler freely without accumulating in the vent 10 Multiple boiler vent terminations See Venting application Page 8 EXHAUST AND INTAKE AIR PLACEMENT THROUGH THE ROOF PENETRATION CONCENTRIC 1 2 3 Determine best location for vent air termination using previous guidelines Cut a 5 hole to accommodate the 42 diameter PVC pipe Cement termination concentric Y to 4 2 diameter PVC pipe then pass through roof penetration and field supplied roof boot flashing Secure assembly to roof structure with field supplied metal strapping or equivalent
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18. inches from the building based on minimum 12 inch required separation between intake and exhaust Exhaust vent vertical rise shall not extend beyond 39 from building penetration to termination elbow Condensate could freeze and block vent pipe Operate heater through one complete cycle and check for flue gas leakage Exterior wall FT a Perak NPT Ft Ter tipa Er Biaderiiz Logamax plus GB142 Multiple Heater installation Terminate all exhaust vents at the same height and all combustion air inlets at the same height while maintaining the minimum 12 inches vertical height clearance from between exhaust and combustion air inlet Exhaust vent termination edge shall be at least 12 inches laterally from the edge of the air inlet pipe of an adjacent heater The combustion air inlet is part of the direct vent system and not classified as a forced air inlet Page 15 CONDENSATE PIPING Figure 7 shows a typical sealed combustion installation e The furnished 3 x 34 socket female vent condensate drain must be installed as close as possible to the exhaust connection with the 34 branch pointing down to drain condensate e Install furnished 1 1 2 x 34 coupling under GB142 condensate drain install a 34 PVC tee and bring in upper vent drain with a trap into this tee Pour 1 qt of water in exhaust pipe and make sure to fill the external trap and internal trap of the GB142 e Incase of vertical venting install a short horiz
19. support material Insert smaller 2 PVC vent exhaust pipe into larger 4 diameter combustion air pipe ensuring PVC exhaust vent pipe is properly cement into concentric Y Cement vent exhaust pipe and air inlet pipe onto concentric vent termination Concentric vent termination cannot be extended beyond manufactured length Concentric vent termination may be cut to desired length Concentric vent shall terminate at least 12 inches above snow line but not more 24 inches above roof surface see FIG 4 and FIG 5 for details Operate heater through one complete cycle and check for flue gas leakage Refer to fig 6 for multiple Through the roof installations and maintain a 12 center to center distance Buderus Part Number BRYKGAVT0602CVT abaya reat Mino or snow bne Maximum of 24 Biang ny Oo nol screw ar de imo any gat of terminason oc pipe sr by Page 9 Through roof Penetration concentric 12 Center 15 camer Center to camer 12 min above rool snow Ine 24 Page 10 SIDE WALL PENETRATION CONCENTRIC 1 Determine best location for vent air termination using previous guidelines FIG amp 7 Cut a 5 hole to accommodate the 4 diameter PVC pipe Cement termination concentric to 412 diameter PVC pipe then pass through wall penetration and field supplied flashing if required Insert
20. Buderus Applications Manual for Buderus GB142 Wall Hung Heaters Table of Contents EB Introduction 1 E Description of Main Components Pre piped Manifold and Pump Settings 2 Pump Sizing for Buderus Indirect Tanks 2 BC10 Controller 4 RC10 Room Controller 4 Space Heating Options 4 DHW Heating Operation 4 Description of Operation Dimensions and Connections Space Heating 6 Domestic Hot Water Heating 6 Venting Guidelines Horizontal Venting 8 Vertical Venting 9 Condensate Piping 16 Piping and Wiring Applications Mechanical Electrical Symbols 17 GB142 with DHW zone and indoor reset 18 GB142 with DHW zone and on off heating zone 20 GB142 with DHW zone Comfort Zone and zone valves 22 GB142 with DHW zone Indoor reset Buderus Pumping Station and 24 zone valves GB142 with DHW zone single temperature of radiant No Mixing Valve 26 required GB142 with DHW zone motorize mixing valve zone thermostatic 28 mixing valves zone and high temperature zone GB142 with DHW zone and high temperature on off zones 30 GB142 with DHW zones constant circulation w Comfort zone control 32 GB142 with DHW zone amp the Buderus Quick Fit Modular Piping 34 systems Near GB142 Piping with Multiple GB142 s 36 Multiple GB142 Units with DWH zone piping diagrams 40 RC10 Error Codes 41 2 DESCRIPTION OF MAIN COMPONENTS This GB142 Applications Manual is intended to present some of the most common applications ofthe wall hung Bu
21. PVC DWV or ABS DWV Schedule 40 Cement and primer must comply with ASTM D2564 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement Foam core PVC pipe can not be used Note Installation must comply with local requirements codes National Fuel Gas Code ANSI Z223 1 USA installations CSA B149 1 or B149 2 Canadian installations In Canada venting must comply with ULC S636 Note Installing contractor must install condensate tee supplied by Buderus immediately after the first 90 degree flue elbow Condensate must be drained into a condensate pump or appropriate drain The GB142 is approved for both Direct Vent sealed combustion see FIG 3A for termination location as well as Direct Exhaust non sealed combustion see FIG 3B for termination location operation in both a horizontal and vertical vent arrangement For room air applications follow National Fuel Gas Code to ensure ample combustion air All PVC venting material is approved for 0 clearance to combustibles for venting of the GB142 boiler Table 6 Maximum Equivalent Vent Lengths Model Max Intake Length ft Eq Exhaust Length ft GB142 24 30 44 100 100 GB142 60 60 60 Table 7 Friction Loss Equivalent for Fittings Fittings or Piping Equivalent Length ft 45 Elbow 3 90 Elbow 5 Optional Concentric Vent Kit 3 Page 6 Fig 12 minimum
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24. derus GB142 heater for use in hot water space heating applications Applications are shown with both piping and corresponding electrical schematics Auxiliary equipment depicted does not necessarily represent any one particular manufacturer or specific model number There are a wide variety of techniques practices and piping strategies possible with hydronic heating systems and it is the responsibility of the installing contractor to determine the most suitable arrangement for his application In an effort to simplify piping and electrical diagrams only Diagrams 1P and 1E depict the complete details with respect to piping and wiring of an indirect hot water tank This part is left off all subsequent drawings for clarity purposes Basic information regarding vent installation clearances condensate piping and termination locations are included as well Although this manual covers many common applications for our equipment system possibilities are virtually endless Should you encounter an application that is not covered in this manual or have any questions regarding any of its content we encourage you to contact your local sales rep or us directly at Bosch Thermotechnology Corp Page 1 PRE PIPED MANIFOLD AND PUMP SETTINGS All GB142 are standard supplied with a pre piped and wired heater manifold with pump to easily facilitate required primary secondary piping for the installing contractor Shut offs relief valve pressure and temperature gau
25. ent pipe when passing through floors ceilings and roofs Install a field supplied roof penetration boot flashing 24 minimum Minumum of 12 above roof line snow line Minimum 12 Maximum 24 TERMINATION AND FITTING 1 Prepare the vent termination coupling and the air termination elbow by inserting the bird screens provided with boiler into the three inch fittings 2 The combustion air inlet shall terminate at least 12 inches above maximum snow line or 24 inches above roof surface which ever is greater 3 The combustion air inlet pipe must terminate in a downward position using two 90 degree elbows The combustion air inlet pipe shall terminate at least two feet horizontally from the center line of the exhaust vent this is to prevent cross contamination of flue gases into the combustion air stream 4 The exhaust vent must terminate vertically upward with a coupling and bird screen The top of the coupling shall termination at least 12 inches above the bottom of the down turned 90 elbow but no more than 24 inches MULTIPLE HEATER INSTALLATION Terminate all exhaust vents at the same height and all combustion air inlets at the same height while maintaining the minimum 12 to a maximum of 24 height clearance from the exhaust to the down turned 90 degree elbow and combustion air inlet Exhaust vent termination edge shall be at least 12 from the edge of the air inlet pipe of an ad
26. fort and efficiency from the product Suggested timings of the post purge for the boiler pump PK are shown on each wiring diagram Note Never connect a RC10 control and a thermostat or end switch at the same time SPACE HEATING OPERATION The PK boiler pump operates and the burner fires on a call for heat from the T T terminal or from the 10 controller Use only T T connections or RC terminals but do NOT use both at the same installation Once the call for heat is satisfied the PK pump continues to operate through an adjustable programmable post purge cycle before shutting down The PK pump can also set to operate continuously for up to 24 hours after the last call for heat DHW HEATING OPERATION A call for heat from the FW DHW sensor brings the control into DHW priority shutting off the PK pump firing the boiler to maximum temperature and operating the PS pump Internal logic includes an anticipative DHW heating cycle with automatically adjusting post purge feature and reduces burner modulation rate Page 4 3 DIMENSIONS CONNECTIONS and CLEARANCES nt 5 ox 2 2 2 2 Y E 1 A 257 17 2 2 4 7 7 Fig 2 Dimensions and Connections for GB142 45 and 60 Page 5 4 VENTING GUIDELINES VENTING GUIDELINES The GB142 is suitable for side wall as well as vertical venting using field supplied 3 PVC or CPVC pipe in compliance with ANSI ASTM D1785 schedule 40 PVC F441 D2665
27. ge purge station on the supply leg and built in flow check and a Grundfos UPS15 58 3 speed heater pump are included on the return side of the manifold Refer to Diagram 1P Table 1 show AT values for different speed settings on the UPS15 58 pump for each GB142 model Table 1 Max Heater AT F Values for UPS 15 58 Manifold Pump Heater Model Speed 1 Speed 2 Speed 3 GB142 24 26 N A N A GB142 30 33 N A N A GB142 45 N A 32 28 GB142 60 N A 43 32 Integrated heater controls will automatically reduce the heater input once the heater AT exceeds 45 F regardless of feedback signal from the RC10 control Complete burner shut down will always take place before AT exceeds 99 F The maximum flow rates are as follows GB142 24 or 30 11 GPM model 45 15 GPM model 60 20 GPM PUMP SIZING FOR BUDERUS INDIRECT TANKS heating zones are piped directly off the supply left side of the heater manifold with heating returns combined on the return right side Piping connections for an indirect tank charging pump PS are included on the heater manifold Refer to Tables 2 and 3 for tank pump recommendations for different Buderus indirect tanks All piping to and from the indirect needs to be at least 1 Use a minimum number of elbows and keep piping lengths to a minimum Table 2 Indirect Pump Recommendations for GB142 24 and 30 models GB142 24 GB142 30 Tank Model Grundfos
28. jacent heater Exhaust vent terminations may be place next to each other as practical like wise air intake terminations may also be placed next to each other The combustion air inlet is part of the direct vent system and not classified as a forced air inlet see FIG 9A and 9B Minimum 12 Maximum 24 Minimum 24 from center to center 12 Minimum Page 13 12 minimum Minimum 24 Maximum 30 SIDE WALL PENETRATION NON CONCENTRIC 1 11 14 Determine best location for vent air termination using previous guidelines Cut a 4 hole to accommodate the 32 diameter PVC pipe Through the wall penetration may be sealed with a field provided flashing if required Insert bird screens provided with heater into both exhaust and combustion air field supplied elbows Combustion air inlet elbow should always be positioned downward The exhaust outlet or elbow shall always be positioned pointing away from the building Combustion air inlet elbow must terminate at least 12 below exhaust elbow or outlet but not exceed 15 maximum separation Combustion air inlet must maintain at least 12 above grade and or snow line Combustion air inlet may be extended vertically upward a maximum of 24 from the building penetration see FIG 10 Do not extend exposed exhaust vent pipe outside the building beyond recommendations Horizontal termination shall not extend beyond 18
29. lied with GB142 2 FA optional outdoor sensor terminals blue color connections requires RC34 controller available Fall 2005 3 WA T T terminals light green color connections for optional conventional thermostat 4 FW DHW tank sensor terminals light gray color for sensing tank water temperature Tank sensor standard supplied with GB142 5 EV terminals red color for connecting of an optional safety such as LWCO manual reset high limit or any other type of external limit circuit BC10 CONTROLLER A BC10 control panel is installed in every GB142 which includes a diagnostic display status indicator lights dials for DHW and maximum heater temperature as well as programming and diagnostic access buttons detailed description of all diagnostic and status codes is provided with the GB142 Installation and Service Manual RC10 ROOM CONTROLLER A RC10 room controller is provided with every GB142 to provide indoor reset and pin point precision control back to the BC10 The 10 must be installed in a reference location for indoor feedback to the GB142 The RC10 will control the modulation and heater water temperature based on maintaining desired indoor comfort levels The RC10 is typically placed in the main living area for optimum comfort and accurate temperature control Give careful consideration to the placement of the RC10 sensor The use of the RC10 indoor room controller is shown in a number of diagrams to achieve maximum com
30. ontal run to install the vent condensate drain Page 16 5 DRAWINGS 24 wc hard anne Mechanical Electrical Symbols Grund connection mien breaker Wire cnnraactiaa 24 Vac Trek Est voter Gees Fira rer Water Feed Chuck Frum Ignem 7 Wiley Maing adm rii cori for meag valen Zona Zonas Thames Tempeegkure aed Pressure Dorian Zone Casal RC sepia wilh Etir Wal Expats Fed caer Themes nra Low Loss Header Page 17 CAES OF 0U que Deus pu ssanpacead ume mug gc smog Assnpu pelea jo sep menbape eun pepe er j Posey pare Ep murs inj s sk papaeu aq Argis JOUR Ajajes RUPE Sigma puna Ayajes Jo UD Sep ssmippe cq uodand pou sop pur sumeu uj jenidesuns si sk nq paunbeu sing BuO WHO EPL BEN Sue dep bad Bureta Page 18 eje s jou si DORIA suagedydidie pue ssunpaoexd e joy Aasnpui pajdacar jo menbupe amey
31. sep seb ygn eae dai sali Y39843 seb 0 poys 10 1048 YAN 2919 YAN PUISSIM WA HD pue ygn Uaamyaq ouf 53019 PEY usep v6 Buissiur aduunf pa e1sut uado 1215 AB ope pajoauuoasip saia 10 si Pas 0 aaueldde van eaejdei Paap vgn yg useu 1 Jeyoqjeserisnp sum uy uo pue go _ _______simpepiamad aol use 5 JeMSUP uiejqo4d ejqissoa 19591 joeye ejdsip Page 42 Buderus Bosch Thermotechnology Corp 50 Wentworth Avenue Londonderry NH 03053 Tel 1 800 BUDERUS Fax 1 603 584 1681 www buderus net Bosch Thermotechnology Corp reserves the right to make changes without notice due to continuing engineering and technological advances
32. smaller 2 PVC vent exhaust pipe into larger 442 diameter combustion air pipe ensuring PVC exhaust vent pipe is properly cement into concentric Y Cement vent exhaust pipe and air inlet pipe onto concentric vent termination Concentric vent termination cannot be extended beyond manufactured length Concentric vent termination may be cut to desired length Operate heater through one complete cycle and check for flue gas leakage Allow 8 center to center horizontal distance between concentric vent terminations with multiple heater installations Extenor wall PVC Pipe When uzing Room Fem metal ait of ar intake dipe mat aeedect Y x v Fenaa HP T PVC Ter audierne T Logamax plus GB142 PVC oF copper pino Suppi Ratum v 15 3 Enterta iran by Guerin Fa Inatapac Oerviensate Drain Page 11 THROUGH THE PENETRATION NON CONCENTRIC 1 2 12 Determine best location for vent air termination using previous guidelines Air pipe penetration Cut a hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter Vent pipe penetration Cut a hole for the vent pipe Size the vent pipe hole as close as desired to the vent pipe outside diameter Space the air and vent holes to provide the minimum spacing see FIC 8 Follow all local codes for isolation of v
33. talled in other tanks and wired in series with the pump power to prevent over heating Domestic water must be drawn equally from the tanks Table 4 Two Tank Systems GB142 30 GB142 45 GB142 60 Tank B amp G Grundfos Taco B amp G Grundfos Taco B amp G Grundfos Taco ST150 PL50 15 42 009 PL30 26 64 0014 PL30 26 64 0011 ST200 PL50 15 42 009 PL30 26 64 0014 PL30 26 64 0011 ST300 PL50 15 42 009 PL30 26 64 0014 PL30 26 64 0011 ST400 PL50 15 42 009 PL30 26 64 0014 PL30 26 64 0011 Table 5 Three Tank Systems GB142 30 GB142 45 GB142 60 Tank B amp G Grundfos Taco B amp G Grundfos Taco B amp G Grundfos Taco ST150 NRF22 15 42 008 PL30 26 64 009 PL50 26 64 0014 ST200 22 15 42 008 PL30 26 64 009 PL30 26 64 0014 ST300 2 15 42 008 PL30 26 64 009 PL30 26 64 0014 ST400 NRF22 15 42 008 PL30 26 64 009 PL30 26 64 0014 Electrically the GB142 has 120 V connections for the heater manifold pump PK 4 Amp max indirect tank charging pump PS and DHW recirculation pump PZ Max Amp draw of 5 Amp for PS and PZ combined Page 3 The low voltage side is equipped with the following terminals 1 RC terminals orange color for an indoor room sensor for firing and modulating the burner RC10 control standard supp
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