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Installation instructions

1. Description Product No 1 Door USA L B 8718600326 2 Sealing door 73912 3 Doorlock 73911 4 Hinge door 73990 5 Wall mounting bracket 73965 6 Bracket left 73962 7 Bracket right 73963 8 Adjusting foot 73949 9 Transport slide L R 73951 10 Drawer modules 73964 11 Screw 4 2x8 5x 10 pc 73988 12 Condensate collector 73930 13 Seal condensate collector 7746900152 14 Seal 3 2 80 mm 73931 15 Upper side condensate collectors 73934 16 Mounting flue gas pipe 73907 17 Exhaust pipe 73935 20 Condensate collector 73933 21 Seal condensate collector 73463 22 Drain pipe 73932 23 Sealing bush white 73449 24 Condensate drain pipe 73995 25 Fan 7746900382 26 Seal fan 73920 27 O ring 70x3 2 pc 73983 28 Venturi 73978 29 Seal 2 4 60 mm 73563 30 Gas valve natural gas 8718600323 31 Seal 33 x 24 x 8 5 10 pc 73479s 32 Gas pipe 7746900397 33 Flange gas valve 8718600286 34 O ring 10 pc 73982 36 Screw M5 x 20 10 pc 73572s 37 Screw M5 x 16 10 pc 73970 38 Screw M6 x 20 10 pc 73971 39 Air inlet pipe 73926 40 Sealing 10 pc 73969 41 Air vent revision set 73916 42 Clip 73973 43 Sensor NTC 7746900391 44 Clip 3 x 2 pc 78156s 45 O ring 9 19 x 2 62 10 pc 78175s 46 Pressure sensor 7391
2. Display codes Main Sub display display Key to display code Other effects code code Locking fault RI I HOG The contacts to the outdoor temperature sensor have shorted or are Minimum outdoor temperature is assumed interrupted the sensor has been connected incorrectly or is defective Locking fault AG I HOG The contacts to the DHW temperature sensor have shorted or are No DHW is heated any more interrupted the sensor has been connected incorrectly or is defective Locking fault AG I HH The contacts to DHW temperature sensor to have shorted or are No DHW is heated any more interrupted the sensor has been connected incorrectly or is defective Locking fault No DHW available but there is heating RH 1 Bi The boiler water does not warm up Sensor lead broken or shorted operation The DHW priority is cancelled sensor connected incorrectly or defective filling pump connected when the fault message appears Switch incorrectly or defective permanent tapping or leak the boiler off and on to reset the boiler Locking fault Thermal disinfection has failed Outlet flow during disinfection period Hi 6d Th disinfecti int ted AO Bl too high sensor lead broken or shorted sensor connected incorrectly Eee Mass se or defective filling pump defec
3. Tab 22 BC10 Display settings 13 5 BC10 Display codes The following table contains all codes that can show on the BC10 display To show the current display code and or sub code press the amp key repeatedly There are 3 main code groups Operating codes this code gives the status of the boiler No action is necessary Locking faults the boiler resumes normal operation when the fault has cleared Blocking faults the boiler is locked and will only restart after a manual reset The pump will operate continuously for frost protection If a blinking code is displayed together with other codes all displayed codes will blink A locking code will always show on the first screen of the BC10 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Buderus 59 E Display information Display codes Main Sub display display Key to display code Other effects code code Operating phase Communication test while starting up This display code flashes 5 times i I within 5 seconds while starting up to indicate that the communication between the UBA 3 and the BC10 basic controller is being tested If a new UBA 3 or a new KIM was fitted this code will flash for max 10 seconds r Blocking fault a If this code continues to flash on the display there is a fault in the No heating operation and no DHW communication bet
4. 6 720 646157 11 1TD Fig 11 Low loss header Determine proper size gas pipe for the installation using table 4 and table 5 Do not forget the pipe fitting losses and observe proper size of the fittings Connectthe gas supply pipe to the manual gas shutoff valve so that it is free from any strain NOTICE i Avoid installing the boiler above radiation levels If the boiler is installed above radiation sections a low water cutoff shall be installed and wired to the boiler Follow local code or in case of use of a low water cutoff be aware to use an air vent in order to prevent the boiler from shutting down unnecessarily Length of Gas volume Capacity in ft3 nr pipe in feet m 34 1 114 115 10 3 05 278 520 1 060 1 600 20 6 1 190 350 730 1 100 30 9 15 152 285 590 890 40 12 2 130 245 500 760 50 15 25 115 215 440 670 75 22 88 93 175 360 545 100 30 5 79 160 305 480 150 47 25 64 120 250 380 Tab 4 Gas pipe capacity for different pipe sizes 1 Maximum pipe capacity in ft S hr based on a specific gravity of 60 42 mbar and a inlet gas pressure of 14 W C 35 mbar or less and a pressure drop of 3 W C 20 mbar 6 4 20 Connecting the pressure relief valve PRV The pressure relief valve is a part of the supplied pump group fig 10 1 A listed ASME pressure relief valve supplied with the boiler must be instal
5. 00000 52 11 9 Check the air flue gas connection 52 12 Maintenance seeeeeern nnn nnn nn 53 12 1 Prepare the heating system for maintenance 53 12 2 Remove the boiler door 000000 53 12 3 Clean the heat exchanger burner and condensate trap sees 53 12 3 1 Remove the gas valve cece 53 12 3 2 Remove the burner cover with the fan and the gas valve iocos ret ame dew 54 12 3 3 Remove the burner and the burner seal 54 12 3 4 Checking ignition unit 0 55 12 3 5 Disconnect the condensate trap 55 12 3 6 Remove the condensate collector 56 12 3 7 Clean the heat exchanger 57 12 4 Check and adjust the gas air ratio flue gases CO emissions 05 57 12 5 Function check suis eus bes per dei ate oat 57 13 Display information esee 58 13 1 Removing the control panel 58 13 2 Replacing the control panel 58 19 8 BC10 Display readings 58 13 4 BC10 Display settings 59 13 5 BC10 Display codes 59 14 Technical specifications 66 14 1 Technical specifications of GB162 boilers low BTU 4 001 10 200 ft 0 eee eae 66 15 Reporls 5 5 i a chao rrr y htm me 68 151 Start up report 0 68 15 2 Inspectionireport oo ccc scta ss nmn 69 15 3 Service repo
6. 7 1 External connection board connections WARNING N Danger of fatal accident due to electric shock 120 VAC connections may be present elec on the external connection board when xiii power is supplied to the boiler Open the boiler door Remove the screw to release the cover over the electrical connections and pull the cover upwards fig 32 El ZA 1 3 6 720 646157 33 1 Fig 33 Routing the cable 7 1 2 Low voltage connections T n I RC FA WA FW lag TETETEEI UERE ES 123 4 5 7 8 9 10 6 720 646157 34 1N Fig 34 External connection board connections no abbr color component 1 RC orange Room controller RC and EMS bus 2 FA blue Outdoor temperature sensor 6 720 646157 32 1 Fig 32 Removing the cover 3 WA green Potential free On off thermostat 4 FW grey DHW temperature sensor 7 1 4 Routing the cable through the boiler 5 EV red External switch contact potential free e g Route the cable for the low voltage connections through the opening on the left fig 33 1 for floor heating safety e Route the cable for the 120 VAC connections through ANE E the opening on the left fig 33 2 7 PK green External heating pump 120 VAC for use with Route and attach the cable for the 120 VAC REG even IUD connections using the strain relief clamps fig
7. 48 9 13 MBoilersettings seese enu 48 9 13 1 Set the heating capacity 48 9 13 2 Set the space heating water temperature 48 9 13 3 Set the pump run over time 49 9 13 4 Switch DHW mode ON OFF 49 9 13 5 Set the DHW temperature 49 9 14 Final activities sse eee 49 9 14 1 Close the boiler door and the control panel 49 9 14 2 Hand Over e em Ru 49 10 Shutting down the system sies 50 10 1 Shut down the appliance using the basic controller siriar op Eoi bn Ree 50 10 2 Shutting down the heating system if there is a risk of freezing interruption of use 50 10 8 Shutting down the heating system in the event of an emergency vcre a wank wd oed eve dau 50 11 Inspection is hah mit Ram Roa 51 11 1 Prepare the appliance for inspection 51 11 2 Carry out a visual check for general signs of GOITOSIOIY iiezeccueirssveser4eigcueied4 nee 52 11 8 Gas valve leakage test 0 52 11 4 Measure the ionization current 52 11 5 Measure the gas inlet pressure working pressure 52 11 6 Check and adjust the flue gases CO emissions icu s a Renate ate lee son ao Bon Rd 52 11 7 Carry out a leakage test in operating conditions Pa a E E thori bd 52 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 11 8 Fill the heating system
8. Subject to modifications resulting from technical improvements 13 6 Installation 6 Installation 6 1 Requirements for the installation room DANGER N Install the heating system in a frost free room gt If the boiler is operated dependent on room air the installation room must have the required air vents DO NOT obstruct these vents The air vents must always be free When installed in a room with thin walls or a thin floor resonating noise may occur Install noise reducing parts if required gt Do not store any flammable materials or liquids in the immediate vicinity of the boiler Neveruse any chlorinated detergents or halogenated hydrocarbons e g in spray cans solvents and detergents paints adhesives Do not allow too much dust to collect on the boiler Li NOTICE To protect the connection orifice you must not remove the styrofoam bottom panel Donotlift the boiler by the door covering the control panel chapter 5 2 Transporting the boiler page 12 Protect the boiler and the combustion air flue gas orifice against pollution during installation Remove the packaging and dispose of it in an environmentally manner Measure the installation height gt chapter 4 Dimensions and connections page 10 6 2 Requirements for the heating system Installing a dirt trap like a y strainer and a desludging device is required This must be installed
9. The hot water distribution system must comply with applicable codes and regulations When replacing an existing boiler it is important to check the condition of the entire hot water distribution system to ensure safe operation 2 4 Massachusetts Installations Only a For all side wall side horizontally vented gas fuelled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wire
10. sees 9 3 1 Designated USC 0 0 cece nnn 9 3 2 Heating system water quality 9 33 Pumpitest iieri Dx eE Nes uae diem 9 39 4 Freeze protection ccc esee 9 3 5 Tools materials and further equipment 9 3 6 Disposal con sous ue Rede lee 9 4 Dimensions and connections 10 4 1 Without pump group 0 cece II 10 4 2 With pump group ccssec sese ck nan ae 11 5 Packaging and transportation 12 5 1 Scope of delivery llsseeeeseesss 12 5 2 Transporting the boiler 00 12 6 Installation eere 14 6 1 Requirements for the installation room 14 6 2 Requirements for the heating system 14 6 3 Installing the boiler isis 14 6 4 Water and Gas connection 15 6 41 General nn irren ERIS 15 6 4 2 Connecting the pressure relief valve PRV 16 6 4 3 Making the gas connection 16 6 4 4 Installing the heating supply and return pipe 17 6 4 5 Installing the pump 0 cece eee 17 6 4 6 Installing the condensate trap 17 6 5 Connecting the condensate drain pipe 18 6 5 1 Connecting the expansion vessel in a single boiler SYSIGM i mia sacs Xen do moma E iE E 19 6 6 Combustion Air and Ventilation Openings 19 6 7 Flue gas adapter eee ee 20 6 8 Installation of the Exhaust and Air Intake system 20 6 9 Multiple boiler vent terminal clear
11. 33 3 8 PS grey DHW tank pump 120 VAC Only the 120 V electrical connections require a B PZ lilac DHW recirculation pump 120 VAC 14 gauge wire 10 Netz white Main power connection 120 VAC Tab 9 External connection board connections Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 27 Electrical connections WARNING due to electric shock Make sure no power is supplied to the boiler when making connections Connect all components to the relevant terminals RC Terminal Room Controller Connect a Room or Cascade controller to the orange RC terminal fig 34 paragraph 7 1 4 Controller page 28 FA Terminal Outdoor temperature sensor If outdoor temperature dependant control operation is used an outdoor temperature sensor must be connected Connect the outdoor temperature sensor to the blue FA terminal fig 34 WA Terminal Potential free heat demand With this connection the room temperature based modulating function of the boiler is not used This has a negative effect on comfort and energy consumption The boiler will now only modulate up to the preset space heating water temperature Connect the potential free heat demand contact On Off thermostat or relay panel end switch to the green WA terminal fig 34 The maximum allowed resistance of this circuit is 100 Q NOTICE i The RC and W
12. 46 to get access to the BC10 basic controller fig 47 10 9 ei 100 120 90 N 430 oo Eco 140 HHH m 0 NA aut 2 ce 6720645916 47 1N Fig 47 BC10 basic controller Main power switch Reset button Chimney sweep button Service button Service Tool Connector LED Burner operation LED Central heat demand Space heating water temperature knob Display 0 DHW temperature knob 1 LED DHW demand 20o0 o0gi amp oWwuz The BC10 basic controller has the following components Main power switch fig 47 1 The main power switch is used to switch the boiler ON and OFF Buderus Reset button fig 47 2 If a fault has occurred you may have to restart the boiler by pressing the Reset button This is only required in the event of a locking fault Blocking faults are reset automatically as soon as their cause has been corrected The display shows r E during the reset operation CAUTION N Limitthe space heating water temperature to the maximum flow temperature of the floor heating circuit gt A power interruption discontinues manual operation Frost damage may occur e Chimney sweep button fig 47 3 The Chimney sweep button is used to put the boiler into flue gas test service or manual operation mode The BC10 maximum heating water temperature setting applies The flue gas test enables the boi
13. f TBI Yau t fast 3H 334 Blocking fault No heating operation and no There was a momentary interruption of power DHW vat eB Ri No heating operation and no DHW Ta Ys BB Blocking fault T The UBA 3 is defect 242 Operating phase l B4 1 The external switch contact is open No heating operation Start up phase AAA The boiler starts up after activation of the mains power supply or completion of a system reset This code is displayed for a maximum of 4 minutes Yi Y Blocking fault 73A 2350 The UBA 3 or the KIM is defective No heating operation and no DHW Yi Blocking fault TAA e dP The UBA 3 or the KIM is defective No heating operation and no DHW Yi Blocking fault JIH jeie The UBA 3 or the KIM is defective No heating operation and no DHW Yi Blocking fault j3 can The contacts for the gas valve have been broken No heating gperation andino DEIW yg i Ya 3B Blocking fault LM The UBA 3 or the KIM is defective Yi X Blocking fault j3P giH The UBA 3 or the KIM is defective No heating operation and no DHW Y Y Blocking fault Vt 13U 12340 The UBA 3 or the KIM is defective No heating operatiotiana no DHW Tab 23 Display codes Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Buderus 63 E Display information
14. fig 92 d UT AC E bo LIT 5 x ELIT N CT j m TRI N aan 6720645916 93 1 Fig 92 Cleaning the heat exchanger Maintenance ES Refit the condensate collector and make sure that the 2 retaining clips close smoothly If this is not the case the seal between the condensate collector and the flue pipe at the rear side of the heat exchanger may be leaking Connect the flexible condensate drain hose to the condensate collector Re install the condensate trap Rinse the heat exchanger with clean water Reassemble all boiler components in reverse order Burner with burner seal Burner cover with fan and gas valve Gas valve Glow ignitor and ionization electrode e Start up the boiler gt chapter 9 Start up procedure page 40 12 4 Check and adjust the gas air ratio flue gases CO emissions paragraph 9 9 Check and adjust the flue gases CO2 emissions page 45 12 5 Function check Slowly open the gas valve by pushing on the gas valve and turning it 1 4 rotation in an counterclockwise direction Switch ON the appliance by pressing the main switch on the BC10 basic controller fig 93 1 Setthe space heating water temperature knob fig 93 8 and the DHW temperature knob fig 93 10 to the maximum temperatures Enteraheat demand via the control unit and check that the boiler starts the heating mode Open a hot water tap and ch
15. is more than 122 F 50 C gH Locking fault The pump has stopped or is running without water gH cg Locking fault No feedback from the pump 3R Ee BH Locking fault The tacho signal from the fan has failed during the operating phase Tab 23 Display codes Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 61 E Display information Display codes Main Sub display display Key to display code Other effects code code 3t Ys 4f Blocking fault No heating operation and no DHW 5 0 No current of air after a certain time Operating phase The appliance has been switched off for a couple of dF 2 14 seconds because it had been running without any interruption for 24 hours This is a safety check B be Blocking fault No heating operation and no DHW JL g Mr The tacho signal from the fan is not present during the pre operative or operating phase le p T3 E Blocking fault No heating operation and no DHW J5 The fan is running too slowly T3 T ya 5 Blocking fault No heating operation and no DHW 15 The fan i
16. less than 12 psi 0 8 bar a a aa Operating phase l pe The system pressure is too high higher than 58 psi 4 0 bar Noel operahan and no DER Locking fault rE Reset is carried out This code appears after the Reset button on the No heating operation and no DHW Tab 23 Display codes Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 65 ES Technical specifications 14 Technical specifications 14 1 Technical specifications of GB162 boilers low BTU 4 001 10 200 ft General specifications unit GB162 L B 80 NG GB162 L B 80 LP GB162 L B 100 NG GB162 L B 100 LP Gas category Natural gas Propane Natural gas Propane Rated thermal load btu h 100 000 290 000 90 000 270 000 100 000 333 000 90 000 315 000 aon ene Pe E btu h 89 000 255 200 76 700 237 600 89 000 293 000 76 700 277 200 iene veda Fe pid YES btu h 99 000 281 300 85 300 261 900 99 000 326 300 85 300 308 700 Boiler efficiency at max capacity 88 88 heating curve 176 140 F 80 60 C Boiler efficiency at max capacity 97 98 heating curve 122 86 F 50 30 C CSA Output btu h 261 000 243 000 295 000 279 000 De ration altitudes 4 001 6 000 ft 1 000 ft 2 3 2 3 1 4 2 0 De ration altitudes 6 000 8 000 ft 1 000
17. pressure relief valve The expansion vessel must be of sufficient capacity 6 720 645916 18 1N Fig 18 Connecting the expansion vessel in a single boiler system Expansion vessel Gas supply Air gap lt 1 25 4 mm Qn Connect the expansion tank to the boiler return If a check valve is available connect the expansion vessel to the CH side of the check valve in the return circuit fig 18 1 6 6 Combustion Air and Ventilation Openings Provisions for combustion and ventilation air must be made in accordance with section 5 3 Air for Combustion and Ventilation of the National Flue Gas Code ANSI Z223 1 NFPA 54 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 Installation Codes or applicable provisions of the local building codes DANGER N Fire danger due to flammable materials or liquids Do not store flammable materials and liquids in the immediate vicinity of the boiler Installation 6 WARNING Boiler Damage gt Boiler must be clear and free from combustible materials gasoline and other flammable vapors and liquids and corrosive liquids and vapors Never use chlorine and hydrocarbon containing chemicals such as spray chemicals solution and cleaning agents paints glues etc in the vicinity of the boiler gt Do not store and use these chemicals in the boiler room Avoid excessive dust formation and build up CAUTION N Boiler damage an
18. ted i 65 O sey 1 66 OE grey Pi H H ei oO Patilla externe pour l enterprise c d entretien sp cialiste ES mw m PS PZ Netz 63 2 2 T t3 4 PSTN Te orange aie green grey um naranja azul verde gris rojo turquesa orange bleu vert gris rouge turquoise 18 19 20 21 22 3 d E lilac white verde gris lila blanco vert gris lilas blanc 4 85 26 a7 green yellow blue brown green yellow 6 720 646157 45 1N Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Fig 45 Electrical wiring diagram 1 81 pole connector AC 0 10 24 and 230 V 2 16 pole connector AC 120 V 3 Connection for pump in connection kit accessory 4 Fan 5 Gas valve 6 Transformer 7 Glow ignitor 8 Earth 9 lonization 10 Pressure sensor 11 Return sensor 12 Safety temperature sensor 13 Supply sensor 14 Flue gas sensor 15 Fuse 5 amp FAST sand filled 16 BUS function modules 17 Connector for BC10 Basic Controller 18 Room controller RC and EMS bus 19 Outdoor temperature sensor 20 On off temperature controller potential free 21 DHW sensor 22 External switch contact potential free e g floor heating 23 External 3 way valve 24 Boiler pump 120 VAC max 100 W 25 DHW pump pump 120 VAC max 100 W 26 DHW re circulation pump pump 120 VAC max 100 W 27 Main power connection 120 V 60 Hz max
19. 2 seconds Step5 L Display shows the maximum capacity setting during heating mode in gt paragraph 13 4 BC10 Display settings page 59 In this case L 100 Service mode has been activated You can now adjust the boiler performance to partial load i e to check the gas air ratio or the ionization current Step 6 Press and hold the 3 button until the display shows L 35 Display setting with a 80 kW boiler and L 30 with a 100 kW boiler Minimum capacity setting during heating mode in 96 gt paragraph 13 4 BC10 Display settings page 59 The boiler will reduce its performance to 36 or 30 respectively within a couple of seconds The space heating water temperature set on the BC10 basic controller control panel applies now Check the gas air ratio or the ionization current and if necessary set the gas air ratio according to paragraph 9 9 or paragraph 9 1 1 Step 7 Press the button Step 8 F 5 This parameter shows the pump run over time in minutes that starts when the heating mode has ended gt paragraph 13 4 BC10 Display settings page 59 Step 9 Press the button Step 10 E This parameter indicates the DHW mode status setting gt paragraph 13 4 BC10 Display settings page 59 Step 11 Press the button Step 12 20 Shows currently measured space heating water temperature in F gt paragraph 13 3 BC10 Display readings page 58 Step 13 Press the button Step 14 P 22 Shows curr
20. 80 100 kW Subject to modifications resulting from technical improvements 9 1 Check for gas leaks Prior to the initial start up check that the gas flow pipe work is gas tight this must be confirmed in the start up report Start up procedure Ss 9 2 Fill the heating system To ensure a trouble free operation of the boiler read the accompanying instructions about water quality before filling the heating system WARNING N The boiler and its manual gas shutoff valve must be isolated from the gas supply piping system during any pressure testing of that system exceeding 0 5 psi 34 5 mbar The maximum test pressure allowed at the manual gas shutoff valve inlet is 0 5 psi 34 5 mbar Cover endangered positions before leak testing Do not spray the leak testing agent onto cables plugs or electrical connection lines Do not allow it to drip onto them either DANGER N Leaks may be caused to pipes and screw connections during commissioning and maintenance activities Carry out a proper leak test Only use approved leak detection agents for leak detection gt If 0 5 psi 34 45 mbar or less slowly open the gas valve by pushing on the gas valve and turning it 1 4 rotation in a counter clockwise direction fig 49 The gas valve is open when it is in the vertical position Shut off the appliance from the power supply Checkthe new conduit section up to and including
21. 8718600323 the instruction Conversion to another type of LB gas 1 220 3 048 gos supply 80 kW 4 001 8 000 Information on gas type instruction plate tookw LPG 1 220 2 408 4 70 0 185 7746900499 Set to gas category Propane Tab 26 Factory setting of the gas control valve LPG 2 bru 5 00 0 197 7746900499 Hn 7 pei The gas orifice diameter is marked on the gas orifice Tab 25 Gas orifice diameter in mm Hydraulic resistance of the boiler 7 25 500 6 53 450 5 80 400 5 08 350 100 kw 4 35 300 H 3 63 2504 2 90 200 80 ATETEA REIP l l 2 48 150 l l 145 100 l l 073 50 l I l 0 0 j j j a l l 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 L h 2 2 2 4 4 6 6 8 8 11 0 13 2 15 4 17 6 19 8 22 0 GPM 6720645916 98 1N Fig 97 Boiler resistance curve 1 Volume flow 2 Pressure drop Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 67 ES Reports 15 Reports 15 1 Start up report Enter your signature and the date after completing the start up activities Start up activities Page Measurement results Remarks 1 Check for gas leaks 41 2 Fill the heating system 41 C Pre pressure expansion vessel refer to the installation instructions for the expansion vessel psi Heatin
22. and shut down procedures Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 49 EI Shutting down the system 10 Shutting down the system 10 2 Shutting down the heating system if CAUTION s 5 T there is a risk of freezing The heating system may freeze if it is not int ti f operational in times of freezing interruption of use If conditions are such that the heating system has to be shut down for a long period while there is a risk of freezing the water must be drained from the heating Protect the heating system against freezing if there is a danger of frost affecting the system Drain the heating System system water from the lowest point of the heating system The vent screw at the Push on the control panel to open it highest point of the heating system must Switch off OFF appliance by pressing the main switch then be open of the BC10 fig 71 1 Close the main gas supply or the gas valve fig 72 10 1 Shut down the appliance using the Drain the heating water at the lowest point of the heating system using the drain cock or the heating body fig 73 The automatic air vent at the highest point of the heating system radiator must be open basic controller Shut down your appliance by means of the Logamatic BC10 basic controller When the system is shut down the burner is automatically switched off Further informat
23. boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no restriction leakage corrosion and other deficiencies which could cause unsafe condition c Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously d Test for spillage at the draft hood relief opening after 5 minutes of burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe e Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code 6 9 Multiple boiler vent terminal clearance Vertical terminations The combustion air inlet pipe must terminate in a down war
24. fig 82 The retaining clips may be under tension Remove the retaining clips Fig 82 Opening the retaining clips Remove the burner cover with the gas air unit fig 83 x po ra 12 3 3 Remove the burner and the burner seal Remove the burner seal fig 84 1 and replace it if necessary Remove the burner plate fig 84 2 and clean it on all sides using compressed air or a soft brush When re installing the burner plate make sure that the notch is on the right hand side fig 84 detailed picture 54 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Maintenance ES 6720645916 85 1N Fig 84 Removing the burner plate and the burner seal 12 3 4 Checking ignition unit DANGER N Close the gas valve prior to working on components in contact with gas Checkfor gas tightness after carrying out work on components in contact with gas NOTICE i The glow ignitor is fragile Handle with care NOTICE If the seat of the cover plate leaks the seal can burn away gt Check the cover plate for tightness e Check the individual components of the ignition unit fig 86 for wear or contamination fig 85 e If required replace the ionizatio
25. ft 2 3 2 1 1 5 1 9 De ration altitudes 8 000 10 200 ft 1 000 ft 2 2 1 5 1 9 1 8 AFUE at 80 180 F 27 82 C 93 8 93 9 n a n a BTS 2000 at 80 180 F 27 82 C part load n a n a 96 1 96 1 BTS 2000 at 80 180 F 27 82 C full load n a n a 90 8 90 8 Heating Maximum flow temperature F C 180 82 Maximum working pressure boiler psi bar 50 3 6 Minimum water circulation volume Gal h l h 0 Flow temperature F C 86 180 30 82 can be set on the BC10 basic controller Resistance at AT 20 K psi bar 3 26 225 4 57 315 Heating circuit volume of heat exchanger Gal L 1 3 5 0 Pipe connections boiler without pump group Gas connection in Rp1 Heating water connection in G1 union nut with female thread enclosed Condensate connection in mm 11 4 32 Flue gas values Condensate quantity at 104 86 F 40 30 C Gal h L h 2 4 9 0 2 85 10 8 pH value of condensate pH approx 4 1 Flue gas mass flow rate full load g s 35 3 44 9 e ue ide UAT as F C 153 67 149 65 169 76 165 63 Bep rok aUe IUE F C 144 62 136 58 144 62 136 58 Flue gas temperature 122 86 F NUR 50 30 C full load F C 118 48 114 46 124 51 120 49 Flue gas temperature 122 86 F ELE 50 30 C partial load F C 96 36 88 31 96 36 88 31 CO content at full load 9 3 0 2 9 6 9 3 0 2 9 7 Free fan feed pressure w c Pa 0 602 150 0 883 220 Flue gas connection Flue gas system room air de
26. full load measured value 9 3 9 3 1 8 3 and 9 3 1 5 7 8 So when the CO percentage at full load is 9 3 the partial load CO percentage value has to be between 8 3 and 7 8 If necessary adjust the CO Percentage to the calculated value by means of the air gas ratio adjustment screw fig 65 1 The adjustment screw is located behind the screw plug Open the screw plug Turn adjustment screw to the left for a lower CO percentage Turn adjustment screw to the right for a higher CO percentage After adjusting close the screw plug Note the set value in table 15 1 Start up report page 68 46 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Start up procedure Ss 6720645916 6720645916 47 1N Fig 65 Adjusting gas air ratio at minimum load Switch OFF the appliance by pressing the main switch of the BC10 basic controller fig 62 1 Remove the flue gas analyzer and fit the cover back onto the flue gas measuring point fig 63 1 Switch ON the appliance by pressing the main switch of the BC10 basic controller fig 62 1 Press on the control panel to close it 9 10 Function test During initial start up and annual inspection and or needs oriented servicing make sure that all control regulating and safety devices are in full wor
27. heating system so that the heating water temperature will not become too high etc When the external switch contact is opened the boiler will be switched off for heating operation and for domestic hot water operation The pump continues to run for the run over time set on the boiler Remove the cable from the EV terminal fig 34 7 1 4 Controller Buderus WARNING Connecting incoming power Ground the boiler electrically in accordance with local codes or in absence of local codes with the National Electrical Code ANSI INFPA 70 and or the CSA C22 1 Electrical Code Install a 120 VAC cable to the boiler mains connection 28 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements NOTICE gt Itis not possible to connect more than 1 room controller The following controls can be connected to the boiler Logamatic RC35 room controller Logamatic 4323 controls Control with contact for potential free heat demand Error reporting module EM10 0 10 V input can be used to convert a O 10 V signal to a modulating signal MOM boiler cascade module up to 16 boilers To install additional modules in the boiler gt paragraph 7 2 Installing function modules accessories on page 29 Installing an RC35 controller as an outdoor reset control in the boiler OOo wot f
28. it is improperly secured gt Only transport the boiler using the right transportation equipment such as a hand truck with a fastening belt or special equipment for maneuvering steps During transportation the boiler must be securedon the transportation equipment to prevent it from falling off Protect all parts against impacts if they are to be transported Observe the transportation markings on the packaging CAUTION The unpacked boiler may be N damaged when not protected against contamination Leave the protective covers on the connections gt Cover the flue gas connections at the top of the boiler with plastic film Always lift and carry the boiler with 2 people as shown in fig 5 or use a hand truck or special equipment 6 720 646157 05 1TD 10 Low loss header single installation only 1 box Fig 5 Lift and carry the boiler correctly Tab 3 Items supplied with Buderus 12 GB162 L B 80 kW 100 kW CAUTION Damage to the unit by lifting or N carrying incorrectly Do not hold the boiler by the door covering the control panel fig 6 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Packaging and transportation 5 6 720 646157 06 1TD Fig 6 Incorrect way of lifting and carrying the boiler Buderus Logamax plus GB162 L B 80 100 kW
29. lights when there is a heat demand and is extinguished when the heat demand is no longer present Space heating water temperature knob fig 47 8 The Space heating water temperature knob is used to set the upper space heating water temperature limit The unit is F Display fig 47 9 The appliance display values display settings and display codes can be read out from the display If a fault occurs the display will immediately show the accompanying fault code The fault code flashes if a locking fault has occurred DHW temperature knob fig 47 10 The DHW temperature knob is used to select the required temperature of the hot water in the hot water Operation ES cylinder The unit is F gt table 20 Setting of the DHW temperature page 49 LED DHW demand fig 47 11 The LED DHW status lights when there is a DHW request and is extinguished when the DHW demand is no longer present 8 2 BC10 operating instructions You can navigate through the menu structure of the boiler on the BC10 using the Reset button the Chimney sweep button the Service button fig 47 2 3 and 4 and the display fig 47 9 The menu structure consists of 5 menus Normal Operation menu table 11 Flue Gas Test menu table 12 Service Mode menu gt table 13 Manual Operation menu gt table 14 Settings menu table 15 Normal Operation menu Step 1 15 Shows currently measured space he
30. observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CRM 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CRM 5 08 2 a 1 through 4 The following equipment is exempt from 248 CRM 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most correct edition of NFPA 54 as adopted by the board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURERS REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM REQUIRED When the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for the installation of the equipment and venting shall include 1 Detailed instructions for the installation of the venting system or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURERS REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for the venting of flue gases but identifies special venting systems th
31. with the Service mode menu gt table 13 Service mode page 37 Set the capacity to minimum part load according to the Service mode menu gt table 13 Service mode page 37 After the LED Burner operation fig 66 6 has lit wait for 1 minute until the boiler is burning at part load Measure the ionization current The ionization current must be gt 5 pA DC at part load operation Enter the result in the start up report gt paragraph 15 1 Start up report page 68 If the result is not as it should be check the flue gases CO emissions paragraph 9 9 Check and adjust the flue gases CO2 emissions page 45 or check the ionization electrode paragraph 12 3 4 Checking ignition unit page 55 Press and hold the Chimney sweep button fig 66 3 approx 2 seconds until the dot in the right hand bottom corner of the display fig 66 9 appears gt table 12 Flue gas test page 36 Switch OFF the appliance by pressing the main switch of the BC10 basic controller fig 66 1 Remove the multi meter and reconnect the monitoring cable Switch ON the appliance by pressing the main switch of the BC10 basic controller fig 66 1 Check that the boiler performance is still at the required value table 13 Service mode page 37 9 12 Testthe Ignition Safety shut off Buderus 48 device Switch OFF the appliance by pressing the main switch of the BC10 basic controller fig 66 1
32. with the set screw and a spirit level fig 8 page 15 6 720 646157 09 1TD Fig 9 Removing the covers boiler bottom Remove the protective covers from the bottom of the boiler fig 9 page 15 NOTICE Hi Some residual water from final testing may leak away 6 4 Water and Gas connection 6 4 1 General The water and gas connections to the boiler are made using the pump group gt fig 4 page 12 This pump group includes the circulation pump and a pressure relief valve Installation 6 6 720 646157 10 1TD Fig 10 Pump group pressure relief valve supply water valve manual gas shutoff valve circulation pump gas inlet return water valve pump group cover NOTICE If you do not use the included pump group you have to install a separate circulation pump under the boiler This pump must be selected so that the volume flow through the boiler is sufficient to handle the maximum boiler input rating paragraph 6 4 5 Installing the pump page 17 Noohonbd Install the pump group on the boiler in accordance with the pump group installation instructions A single boiler must be installed with the included low loss header to regulate the flow Install the low loss header fig 11 1 Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 15
33. 0 mm for the U S and 6 ft 1 830 mm for Canada away from a gas utility meter service regulator or the like for room air applications only The termination shall terminate at least 4 ft 1 220 mm below 4 ft 1 220 mm horizontally from or 1 ft 305 mm above any door window or gravity air inlet into any building Vent must be at least 12 305 mm above grade antici pated snow line or roof surface Canada 18 457 mm minimum gt fig 21 Vent termination must be at least 7 ft 2 135 mm above a public walkway gt fig 22 12 305 mm T minimum 12 305 mm minimum EXHAU SN EJ INTAKE 12 305 mm lt lt 12 305 mm minimum 12 305 mm minimum Fig 21 Vent and air pipe position 1 of a sealed combustion system 6 720 646916 21 1N Vent must be 3 ft 915 mm above any forced air intake within 10 ft 3 050 mm gt fig 22 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 ft 915 mm away from adjacent walls inside corners and 5 ft 1525 mm below roof overhang gt fig 22 It is not recommended to terminate vent above any door or window condensate can freeze causing ice forma tions Do not use chimney as a raceway if another boiler
34. 06 Air release tap 7746900403 107 Connection pressure gauge 73081 108 Drain pipe 7101410 109 Valve housing supply 7746900406 110 Adapter parallel 4 7746900384 111 Adapter insert 4 7746900385 112 Open venting insert 7746900386 113 Lip ring 114 7746900387 114 Lip ring 103 7746900388 117 Strain relief bracket 7746900398 118 Safety valve ASME 7746900405 119 Low loss header 7746900400 120 plug protector 73948 HOM 1231 100 kW 4 001 10 200 ft 8718600324 HCM 1232 80 kW 4 001 10 200 ft 8718600325 Screw 6 3 x 19 10 pc 73986 Tab 30 Spare parts Buderus 71 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 6720645916 99 1N Fig 98 Exploded view Logamax plus GB162 L B 80 kW 100 kW Buderus 72 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Spare parts E WS NS 6720645916 100 1N Fig 99 Exploded view pump group Logamax plus GB162 L B 80 kW 100 kW Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 73 Index A log DOOK ica rere bp tret mie 41 appliance configuration 0 0 cece eee eee 45 M B Main power switch iiis 35 basic cont
35. 2 J 6 720 646157 36 1N Fig 36 Remove the cover install the room controller Open the control panel cover Remove the cover fig 36 1 Install the RC35 in the slot fig 36 2 7 2 Installing function modules accessories NOTICE gt Refer to the installation instructions of the relevant function modules for information about installation and combination possibilities The following function modules accessories can be connected to the boiler Heat demand 0 10 V module EM10 Error reporting module EM10 Switch module WM10 Mixing module MM10 The function modules accessories can be installed in 2 ways e in the boiler max 2 gt 7 2 1 Electrical connections outside the boiler see paragraph 7 2 2 7 2 1 Installing function modules in the boiler i i B 1 6 720 646157 37 1N Fig 37 Opening the drawer Loosen the screw fig 37 step 1 Pull open the drawer fig 37 step 2 6 720 646157 38 1N Fig 38 Installing the wall bracket Install the wall bracket in the relevant slots in the drawer fig 38 6 720 646157 39 1N Fig 39 Clicking the function module into position Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 29 EA Electrical connections Click the function module s into po
36. 5 47 O ring 14 x 1 78 10 pc 78234s 48 Return supply pipe 73950 49 Connection nipple CH 73080 50 Clip 73974 51 O ring 10 pc 73972 52 Flue gas sensor 7746700420 56 Mounting set with sight glass 8718600172 with glow ignitor with ionization electrode 60 Heat exchanger 7746900383 61 Cover controller BC10 73698 62 Burner 73917 63 Seal Burner 73918 65 Burner box 73919 66 Front connection board 7101490 67 BC10 USA 78186 68 On off switch 73660 69 Knob BC10 38724 Tab 30 Spare parts Description Product No 70 Draw connection board 7101480 71 Cover control box 73977 72 Cover connection board 120 VAC 73815 73 Transformer 78191 74 UBA 3 8718600083 75 Fuse 5AF 10 pc 73904s 76 Connection board 73814 77 Electronic connection red 73776 78 Electronic connection grey 73774 79 Electronic connection grey 73773 80 Electronic connection blue 73775 81 Electronic connection orange 73777 83 Flue gas adapter 73936 84 Measure nipple cap 73937 86 Cable harness low voltage 7746900392 87 Cable harness high voltage 7746900393 88 Cable harness on off switch 73946 89 Cable harness earth 73947 91 Union nut 11 2 5 pc 73481s 92 Sealing 5 pc 7746700417 93 Nut 1 73675 95 Gas valve 7746900401 96 Pump UP26 99U 7746900402 98 Level ball valve blue 7746700421 99 Level ball valve red 7746700422 100 Casing 73961 101 Thermometer 7746900404 102 Manometer 73958 105 Valve housing return 74549 1
37. 9 3 Fill the condensate trap with water Fill the condensate trap with water fig 55 For disconnecting the condensate trap gt paragraph 12 3 5 Disconnect the condensate trap page 55 42 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Start up procedure 90 C 6720645916 55 1N Fig 55 Filling the condensate trap with water WARNING Danger of fatal accident due to poisoning gt Ifthe condensate trap is not filled with water flue gas can escape and put people s lives at risk High temperature applications e Top off with vegetable oil in case of high temperature systems and non condensing applications 9 4 Bleed the gas supply valve e Close the gas valve fig 56 6720645916 56 1N Fig 56 Closing the gas valve Open the screw plug on the testing nipple of the gas supply pressure and for purging fig 57 1 by 2 turns and install a hose ZO BRA 6720645916 57 1N Fig 57 Bleeding the gas flow pipe Slowly open the gas valve by pushing on the gas valve and turning it counterclockwise through 1 rotation fig 58 The gas valve is open when it is in the vertical position Purge the gas supply into a well ventilated area Closethe gas shutoff valve when no more air is present fig 56 Remove the hose and tighten th
38. 9 9 Check and adjust the flue gases CO emissions CAUTION N Take adequate time to properly measure the CO values Changes will only be measurable after about 1 minute gt Let the CO value stabilize for about 30 seconds before reading and or readjusting Openatleast 2 radiator valves if present Do not switch ON the boiler Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 45 Ea Start up procedure e Push on the control panel to open it Switch OFF the appliance by pressing the main switch of the BC10 basic controller fig 62 1 Remove the cover from the flue gas measuring point fig 63 1 Connect the flue gas analyzer to the left hand measuring point insert it roughly 2 fig 63 Switch ON the appliance by pressing the main switch of the BC10 basic controller Press and hold the button fig 62 3 approx 2 seconds until the dot in the right hand bottom corner of the display fig 62 9 appears gt table 12 Flue gas test page 36 After the LED Burner operation fig 62 6 has lit wait for 1 minute until the boiler is burning at full load Measure in the flue gas measuring port with closed boiler door the CO percentage The value has to be 9 3 0 2 6720645916 63 Fig 63 Measuring the
39. A terminals cannot be used simultaneously FW Terminal DHW temperature sensor Connect the external DHW temperature sensor to the grey FW terminal using the harness enclosed with the DHW temperature sensor NOTICE gt It is not possible to connect more than 1 DHW temperature sensor in the boiler Connect a DHW temperature sensor suitable for this particular boiler Connect the external switch contact to the red EV terminal fig 34 DWV Terminal 3 way valve Do not use this connection 7 1 3 120 VAC connections NOTICE Use the 120 VAC connections for specific hydraulic configurations and a corresponding controller 6 720 646157 35 1N Fig 35 120 VAC Connections PK PS PZ 120 VAC kON PK Terminal External pump Connect the external heating or system pump for situations where the pump of the Buderus pump group is not used to the green PK terminal fig 35 The maximum allowed connected load of the pump 250 Watts PS Terminal DHW pump Connect the DHW pump to the grey PS terminal fig 35 The maximum allowed connected load of the pump 250 Watts PZ Terminal DHW circulation pump Connect the DHW circulation pump to the lilac PZ terminal fig 35 The maximum allowed connected load of the pump 250 Watts Mains connector EV Terminal External switching contact An external switch contact can be used i e to safeguard a floor
40. Condensate outlet 32 mm 114 O D Pump group supply G1 male thread flat seal Gas connection to pump group 1 NPT female thread Pump group return G1 malethread flat seal The required permanent clearances closet are in front 1 25 mm right side O left side 0 above 6 152 mm The position selected for installation MUST allow adequate space for servicing in front of the boiler of at least 16 5 20 5 37 940 mm Maintain an installation clearance from combustible construction from hot water piping of at least 1 25 mm Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 11 Fa Packaging and transportation 5 5 1 Packaging and transportation Scope of delivery The boiler is delivered factory assembled e When receiving the delivery check if the packaging is intact e Check that all items are included in the delivery 6720645916 04 1TD Fig 4 Items supplied with unit Nr Parts Packaging Boiler with casing 1 box Wall bracket Condensate trap with hose Technical documents set Supply and return union nuts with sealing rings Screws and plugs for wall bracket Union nut for gas connection DHW sensor 9 Pump group 1 box 5 2 Transporting the boiler CAUTION The boiler may be damaged N when
41. Disconnect the plug and socket connection of the monitoring cable Switch ON the appliance by pressing the main switch of the BC10 basic controller fig 66 1 Press the Chimney Sweep button and hold it for approx 2 seconds until the display shows the decimal point Check if the boiler does 1 start up attempt and 3 restart attempts After each start up attempt the boiler will signal a start up failure A 6A code can be seen in the display After the last start up attempt the boiler will lock out The 6A code is blinking in the display Connect the plug and socket connection of the monitoring cable Press the reset button Check if the boiler starts up Press the Chimney Sweep button return to normal operating conditions 9 13 Boiler settings 9 13 1 Set the heating capacity Set the required heating capacity on the BC10 according to the Settings menu gt table 18 when making these settings Rated heating capacity 3 596 Display based on natural gas low BTU T GB162 L B 80kW GB162 L B 100kW kW btu h kW btu h Lad 29 9 97 900 LH 32 9 104 400 39 9 130 500 L50 41 5 130 500 49 8 163 200 LED 50 1 156 600 59 8 195 800 LU 58 7 182 700 69 7 228 400 LAG 67 3 208 800 79 6 261 000 Lad 75 9 234 900 89 6 293 700 LL 84 5 261 000 99 5 326 300 Tab 18 Heating capacity as a percentage low BTU 4 001 10 200 ft 9 13 2 Set the space heating wa
42. Display readings page 58 Step 6 Press the button Step 7 H 4 Display code Operating phase gt paragraph 13 5 BC10 Display codes page 59 The boiler is in manual operation mode During manual operation the Settings menu table 15 from step 2 can be used to temporarily change the target boiler performance NOTE If the boiler output has been changed temporarily this must be set again after ending manual operation according to the Settings menu table 15 Step 8 Press the button Step 9 t2 I1 Shows currently measured space heating water temperature in F gt paragraph 13 3 BC10 Display readings page 58 Step 10 After a power interruption manual operation ends automatically To end manually press and hold the amp button for more than 2 seconds until the dot disappears Tab 14 Manual operation Buderus 38 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Operation ES Settings menu Step 1 20 Shows currently measured space heating water temperature in F gt paragraph 13 3 BC10 Display readings page 58 Step 2 To open the Settings menu Press and hold the buttons for more th
43. HA e W eee 1 2 3 6720645916 47 1N maximum DHW temperature is 140 F 60 C Fig 69 BC10 basic controller 9 13 3 Set the pump run over time Setthe pump run over time according to the Settings menu gt table 15 Settings page 39 If the heating system is room temperature controlled and not controlled parts of the heating system risk freeze damage e g radiators in the garage set the pump run over time to 24 hours 9 13 4 Switch DHW mode ON OFF Setthe DHW mode according to the Settings menu gt table 15 Settings page 39 When DHW mode is switched OFF E DI the freeze protection for the hot water cylinder if present is switched OFF 9 13 5 Set the DHW temperature Set the DHW temperature knob fig 69 10 to the required temperature of the hot water in the hot water cylinder gt table 20 Tab 20 Setting of the DHW temperature 9 14 Final activities 9 14 1 Close the boiler door and the control panel Close the boiler door fig 70 and lock the fastener by turning the vent screw through 1 rotation in a clockwise direction e Push on the control panel to close it 6720645916 71 1N Fig 70 Closing the boiler door 9 14 2 Hand over Hand over all relevant documentation to the end user and explain his her responsibilities under the relevant national and regional regulations Explain and demonstrate the start up
44. Installation instructions Condensing gas boiler CAUTION Before putting the boiler into operation read this manual carefully WARNING Improper installation adjustment alteration service or maintenance can cause injury loss of life or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier CAUTION The operating manual is part of the documentation that is delivered to the installation s operator Go through the information in this manual with the owner operator and make sure that he or she is familiar with all the necessary operating instructions NOTICE In the Commonwealth of Massachusetts this boiler must be installed by a licensed Plumber or Gas Fitter Warning If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance What to do if you smell gas Do not try to light any boiler Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department Installation and service must be performed by a quali fied installer service
45. System trade name Supplier 4 100 mm PVC parallel stainless steel Flex L SJTK_DVG 4 6 100 150 mm concentric PVC IPEX 90 elbow with inlet screen PVC stainless steel Z Flex Heat Fab Tab 7 Approved flue material NOTICE DO NOT use cellular core pipe gt Aminimum clearance of 4 ft 1 220 mm horizontally from and in no case above and below unless a 4 ft 1 220 mm horizontal distance is maintained from electric meters gas meters regulators and relief equipment 7 2135 mm 5 1525 mm 1220 mm 1220 mm 1220 mm 3 915 mm 4 6 720 645916 22 1N Fig 22 Vent and air pipe position 2 of a system with combustion air supply from the room non sealed 1 Height at Least 1ft 305 mm above grade and snow line 2 Exhaust terminal must be at least 3 ft 915 mm above forced air inlet within 10 ft 8 050 mm 3 Forced Air Inlet 4 Gravity Air Inlet Below are approved examples of vertical and horizontal venting installation Buderus 22 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Installation ky NOTICE i Place pipe supports every 5 ft 1 525 mm of horizontal and vertical run beginning with support near boiler The condensate must be drained in l accordance with the applicable rules 2 paragraph 6 5 C
46. ace for servicing in front of the boiler of at least 16 5 20 5 37 940 mm Maintain an installation clearance from combustible construction from hot water piping of at least 1 25 mm G AKO Condensate outlet 32 mm 114 O D Buderus 10 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 4 2 With pump group Dimensions and connections noy 16 5 420 mm 205 520mm 6 152 mm 24 8 630 mm 18 3 465 mm 0 25 6 mm 0 20 5 520 mm 0 E AJB mN eo S gt 4 1 103 5 mm Lat ty a id C MA 1 E 16 406 mm i e NEN z ES EE eo ale SB El is d 15 ouo E 98g SE S Tie d D x 2 z B ip J PE F OO a ee tg WP 32 i Q g WA WU ui UN Y 1 4 35 mm 154 329mm TE 5 4 138 mm 5 4 130 mm 5 1 130 mm Z 6 4 162 mm epe a d E HI J i s MEET wow 5 5 140 mm 6720645916 03 1TD Fig 3 A LA B AA C WB D VK E GAS F RK G AKO H PF I J PR Dimensions and connections with pump group Flue gas connection inside diameter 4 100 mm Air intake with pompadour inside diameter 4 100 mm Wall Bracket not shown Supply G12 union nut with female thread Gas connection to boiler Rp1 female thread Return G1 union nut with female thread
47. ackaging in an environmentally sound manner Dispose of components of the heating system e g boiler or control device that must be replaced in an environmentally responsible manner Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 9 4 Dimensions and connections 4 4 1 Without pump group Dimensions and connections 16 5 420 mm 20 5 520 mm 24 8 630 mm 18 3 465 mm 0 25 6 mm 0 20 5 520 mm 0 a 152 mm I j 4 1 103 5 mm 7 r1 C E __16 406 mm 4 c f ae r A abe E y E y 3 B A P z NE y f y IBN Z 1 4 35 mm 154 G9 mm 1 7 54 100mm 7 7 5 130 mm 138 mm 5 4 6 4 162 mm Fig 2 Dimensions and connections without pump The required permanent clearances closet are group in front 1 25 mm A LA Flue gas connection inside diameter 4 100 mm non id 0 B AA Air intake connection inside diameter 4 100 mm eft side o C WB Wall Bracket not shown above 6 152 mm D VK Supply G1 uni ienas The position selected for installation MUST allow Supply 2 union nut with female threa E GAS Gas connection to boiler Rp1 female thread F RK Return G11 union nut with female thread adequate sp
48. agency or the gas supplier Notice lt j i E i Arata reat This manual is available E the English and French language This manual must be retained for future reference Logamax plus For the registered installer Please read these GB162 L B 80 kW instructions carefully GB162 L B 100 kW before starting the operation 6 720 645 916 2010 10 US 6720645916 000 1N Buderus 6720645916 01 TD Fig 1 Logamax plus GB162 L B with pump group Buderus 2 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements ONO khOND e 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 BC10 basic controller receptacle Installation option for room controller e g RC35 Cover with user manual compartment BC10 basic controller can be expanded e g by the RC35 room controller Connection box low voltage and 120 VAC connections Fan harness and mains lead of the pump Condensate drain outlet Condensate collector Boiler front door Automatic air vent Retaining clips Air intake for the fan Gas pipe Flue gas pipe Door lock Flue gas sensor Flue measuring point Measuring point for air intake Flue gas connection Air intake connection Fan Gas va
49. al improvements 31 Electrical connections red black Q Buderus 32 Logamax plus GB162 80 kW 100 kW 120 VAC brown blue green yellow NS qu 0 O14 PE D 19 External connection for professional use Conexi n para expertos t ci connexion externe pour l enter 1 45 Q orange white blue 9 N H 17 1 white H O green yellow O11 PE H T oj um brown 120 VAC O10 L i 16 C 2239 grey 1 71 ee vac orange e H 72 Q white i 27 OR AN white black H 52 Qs orange white bl i 25 Q 24 VAC pack inn 120 VAG 4 N i 81 Oe is e blue brown 120 VAC Os 4 H 80 Q red H 1 230 VAC H 28 H white i e 230 VAC Mel Lees 120 VAC Os H i blue DEG i 55 Q i black i i 2 oi red Cem ce Ces 4 2 i 9 black negro noir X c Pin bue azul blue H WENN eee Patilla brown marr n brun 62 9 1 orange white 0O Broche N 19 green verde vert i 61 E brown a grey gris gris 1 70 O grey orange naranja orange i 1 red rojo rouge i UE e white blanco blanc 1 voco blue yellow amarillo jaune i 38 orange 15 i 39 S orange 1 13 O red H 144 O
50. an 2 seconds Step 3 This shows the Settings menu is open You can adjust the setting of this parameter Step 4 Target output Adjust as follows or go to step 5 Lower Decrease the modulation rate with the button The minimum setting for boilers with low BTU L 35 36 with an 80 kW boiler and L 30 30 with a 100 kW boiler Higher Increase the modulation rate with the button The maximum setting is L 100 This is equal to the factory setting Step 5 Press the button Step 6 F 5 Pump run over time in minutes starts when the heating mode has ended Adjust as follows or go to step 7 Lower Decrease the time with the button The minimum setting is F O minutes The factory default setting is 5 minutes CAUTION Do not set the post purge time to less than 5 minutes Higher Increase the time with the button The maximum setting is F 0 60 minutes or F d 24 hours Step 7 Press the button Step 8 DHW mode status setting Adjust as follows or go to step 9 DHW mode can be switched OFF or ON This setting has priority over other DHW mode settings such as those made on the room thermostat Set the DHW mode with the or buttons L means ON E O means OFF NOTE Setting E also switches OFF the hot water cylinder frost protection Step 9 After 5 seconds or after a power interruption the settings menu ends automatically To end manually press the button Any adjust
51. ance 25 7 Electrical connections Lese 27 7 1 External connection board connections 27 7 1 1 Routing the cable through the boiler 27 7 1 2 Low voltage connections 0008 27 7 1 3 120 VAC connections 0 28 CUA Goritroller 2 pep px ERE eee RR 29 7 2 Installing function modules accessories 29 Buderus 4 7 2 1 Installing function modules in the boiler 29 7 2 2 Installing function modules outside the boiler 30 7 3 Electrical wiring diagram sess 31 8 Operation o ore em ur saknas Reina mn 34 8 1 BC10 basic controller 34 8 2 BC10 operating instructions 35 9 Start up procedure essen 40 9 1 Check for gas leaks 000 41 9 2 Fillthe heating system 0004 41 9 3 Fill the condensate trap with water 42 9 4 Bleed the gas supply valve 008 43 9 5 Check the air flue gas connection 43 9 6 Checking the appliance configuration 44 9 7 Measure the gas inlet pressure working pressure 44 9 8 Carry out a leakage test in operating conditions EEE EE s rae AUR Re SS mek LAGE N 45 9 9 Check and adjust the flue gases CO2 emissions debi E E N E E Dodd dite 45 910 Function test 2 o eeu ek meds 47 9 11 Measure the ionization current 47 9 12 Test the Ignition Safety shut off device
52. ating water temperature in F gt paragraph 13 3 BC10 Display readings page 58 Step 2 Press the button Step 3 Pgg Shows currently measured system pressure in psi gt paragraph 13 3 BC10 Display readings page 58 Step 4 Press the button Step 5 H Current display code In this case Operating phase Boiler in heating mode gt paragraph 13 5 BC10 Display codes page 59 Step 6 After 5 seconds the display returns to step 1 or Step 7 Press the button Tab 11 Normal operation Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 35 8 Operation Flue Gas Test menu Step 1 20 Shows currently measured space heating water temperature in F gt paragraph 13 3 BC10 Display readings page 58 Step 2 To activate the flue gas test Press and hold the d button for more than 2 but not longer than 5 seconds Step 3 20 The non flashing dot in the right hand bottom corner of the display shows the flue gas test has been activated the boiler is in heating mode at a capacity of 100 for a maximum of 30 minutes Space heating water temperature is as set on the BC10 basic controller DHW mode is not possible Step 4 Press the button Step 5 P22 Shows currently measure
53. bber sleeve fig 15 2 to the condensate trap fig 15 1 6 5 Connecting the condensate drain pipe NOTICE The condensate must be drained from the boiler in accordance with local state or federal rules and regulations Buderus NOTICE Use materials approved by the authority having jurisdiction In the absence of such authority PVC and CPVC pipe must comply with ASTM D1785 F441 or D2665 Cement and primer must comply with ASTM D2564 or F493 For Canada use ULC certified PVC or CPVC pipe fittings and cement 6 720 645916 16 1N Fig 16 Connecting the condensate trap 1 Condensate trap 2 Air gap gt 1 25 4 mm EZ 6 720 645916 017 Fig 17 Condensate drainage pipe nstall the condensate drain pipe taking the following into account An air gap of at least 1 25 4 mm must be maintained between the boiler condensate trap hose and the condensate pipe work fig 16 and fig 17 If the condensate outlet of the boiler is lower than the drain a condensate pump must be used The condensate produced by the boiler has a pH value between 3 and 4 Install a neutralization unit if required by the local code 18 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 6 5 1 Connecting the expansion vessel in a single boiler system CAUTION N Damage to the installation due to faulty
54. d any gas control which has been under water CAUTION N Insufficient or improper cleaning and maintenance can cause damage to the installation Inspect and clean the appliance once a year Carry out maintenance as required Immediately remedy faults This will avoid further damage to the system CAUTION N Risk of electric shock Before opening the appliance disconnect the appliance from the power supply using the appliance emergency OFF button or disconnect the relevant circuit breaker of the house from the power grid Secure the appliance against accidental restarting Periodically examine the venting systems and cleaning of the screens in the vent terminal Also periodically inspect the low water cutoffs including flushing of float types and clean the condensate collections and disposal system 11 1 Prepare the appliance for inspection Switch OFF the appliance by pressing the main switch of the BC10 Inspection ae gt If gas pipes have to be disconnected from the gas burner fitting the burner cover must only be opened by a specialized professional m INSTRUCTION FOR THE INSTALLER Close the gas valve fig 74 1 Close the isolating valves fig 74 2 Ig ee 6720645916 75 1N Fig 74 Closing the valves here in closed position Open the boiler door Turn the vent key through a quarter rotation to und
55. d carbon monoxide detectors n the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level n the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 80 days to comply with the above requirements provided however that during said 30 day period a battery operated carbon monoxide detector with an alarm shall be installed alarm and battery back up may be installed on the next adjacent floor level Buderus 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of 8 ft above grade directly in line with the exhaust vent terminal for the horizontally vented gas fuelled heating appliance or equipment The sign shall read in print size no less than 1 2 in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fuelled equipment shall not approve the installation unless upon inspections the inspector
56. d operational failures Due to insufficient or improper openings for combustion air and or ventilation of the boiler room Provisions for combustion air and ventilation are always required regardless whether the combustion air is taken from the outside sealed combustion or inside room air for combustion Insufficient ventilation of the boiler room can lead to high air temperatures This can result in boiler damage Make sure that intake and exhaust openings are sufficiently sized and no reduction or closure of openings takes place When the problem is not resolved do not operate the boiler Please note these restrictions and its dangers to the operator of the boiler NOTICE When one expects contaminated combustion air near swimming pools chemical cleaning operations and hair salons sealed combustion operation is recommended All Air form inside the Building non sealed combustion The closet shall be provided with 2 permanent openings communicating directly with an additional room s The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of 1 per 1 000 btu h of total input rating of all gas utilization equipment in the confined space but no less than 1002 One opening shall commence within 12 Buderus Logamax plus GB162 L B 80 100 kW Subject to modi
57. d position using 2 x 90 elbows The combustion air inlet pipe shall terminate at least 3 ft 914 mm horizon tally from the center line of the exhaust vent this is to prevent cross contamination of flue gases into the combustion air stream Terminate all exhaust vents at the same height and all combustion air inlets at the same height while maintaining the minimum 36 914 mm height clearance from the exhaust to the down turned 90 elbow and combustion air inlet Exhaust vent termination edge shall be at least 24 610 mm from the edge of the air inlet pipe of an adjacent heater Exhaust vent terminations shall be placed at a minimum of 12 305 mm center to center gt fig 30 amp fig 31 Air intake terminations may be placed adjacent to each other The combustion air inlet is part of the direct vent system and not classified as a forced air inlet Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 25 6 720 645 916 030 1N Fig 30 Vertical terminations minimum 12 305 mm minimum 36 914 mm minimum 36 914 mm minimum 12 805 mm 6 720 645 916 031 1N minimum 36 915 mm Fig 31 Horizontal terminations minimum 24 610 mm oahanhs minimum 12 305 mm maximum 15 381 mm maximum 18 457 mm minimum 12 305 mm minimum 12 305 mm maximum 39 991 mm Horizontal terminations Combustion air inlet e
58. d system pressure in psi gt paragraph 13 3 BC10 Display readings page 58 Step 6 Press the button Step 7 A_ Display code Operating phase The boiler is in flue gas test mode gt paragraph 13 5 BC10 Display codes page 59 Step 8 Press the button Step 9 20 Shows currently measured space heating water temperature in F gt paragraph 13 3 BC10 Display readings page 58 Step 10 After 30 minutes or after a power interruption the flue gas test ends automatically To end manually press and hold the amp button for more than 2 seconds until the dot disappears Tab 12 Flue gas test Buderus 36 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Operation ES Service Mode menu Step 1 120 Shows currently measured space heating water temperature in F gt paragraph 13 3 BC10 Display readings page 58 Step 2 To activate service mode 1 step Press and hold the amp button for more than 2 but not longer than 5 seconds Step 3 20 The non flashing dot is shown in the right hand bottom corner of the display shows the boiler is now in Flue gas test mode Step 4 To activate service mode 2 step Simultaneously press and hold the buttons for more than
59. e following requirements shall be satisfied by the manufacturer 1 The referenced special venting systems shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all instructions For all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or venting design instructions shall remain with the appliance or equipment at the completion of the installation 8 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 3 General information About these instructions These Installation Instructions contain important information for the safe and professional installation start up and maintenance of the boiler with boiler input rating of 80 kW and 100 kW These Installation Instructions are intended for professional installers who have the necessary training and experience for working on heating and gas systems Cascade installation Special cascade units accessories have been developed to enable this boiler to be installed in a cascade system Every cascade unit includes an installation frame horizontal headers connection pipes for the boiler main gas pipe and a vertical low l
60. e screw plug on the testing nipple again lee 6720645916 58 1N Fig 58 Opening the gas valve NOTICE Testthe tightness of the used measuring nipple s 9 5 Check the air flue gas connection Check the following points sthe prescribed flue gas system used gt paragraph 6 8 Installation of the Exhaust and Air Intake system page 20 Have the configuration instructions from the relevant flue gas system installation instructions been observed Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 438 Ea Start up procedure 9 6 Checking the appliance configuration NOTICE The burner must only be put into use with the correct orifice gt table 16 gt Consult the relevant gas utility company for the type of gas supply Check that the actual gas supply is in accordance with the type of gas supply specified on the gas classification label fig 59 6720645916 59 1N Fig 59 Checking the gas classification label Gas orifice Boiler me Sioa a i diameter in PPly inch mm GB162 Natural gas 4 001 10 200 0 370 L B 80kW 1 220 3 111 9 40 100kW LPG 4 001 8 000 0 185 1 220 2 625 4 70 LPG 8 000 10 200 0 197 2 625 3 111 5 00 Tab 16 Gas orifice diameter 9 7 Measure the gas inlet pressure worki
61. ease see the accompanying Water quality requirements for Logamax plus GB162 L B 80kW 100 kW manual CAUTION N Risk of system damage due to unsuitable heating system water gt If oxygen permeable pipes are used e g for under floor heating systems the systems must be separated from one another by plate heat exchangers Unsuitable heating system water promotes sludge and corrosion formation This can result in heat exchanger malfunction and damage 3 3 Pump test If the boiler has not been operational for approx 2 days the pump will automatically run for 10 seconds every 24 hours This pump test is first carried out 24 hours after the main power has been connected to the boiler 3 4 Freeze protection The boiler has integrated freeze protection that switches the boiler ON at a space heating CH water temperature of 45 F 7 C and switches it OFF at a CH flow temperature of 59 F 15 C This feature does not protect the central heating system from freezing If there is a risk of radiators or pipe sections freezing up we recommend setting the pump run over time to 24 hours paragraph 13 4 BC10 Display settings page 59 on 3 5 Tools materials and further equipment For the installation and maintenance of the boiler you will need the standard tools for space heating gas and water fitting In addition a hand truck with a fastening belt is useful 3 6 Disposal Dispose of the boiler p
62. eck that the boiler starts the DHW mode Setthe space heating water temperature knob fig 93 8 and the DHW temperature knob fig 93 10 to the required temperatures 10 9 8 6720645916 47 1N Fig 93 BC10 basic controller Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 57 E Display information 13 Display information 13 1 Removing the control panel To make it easier to use the buttons on the control panel when the boiler door is open and to make it easier to read the values in the display you can disassemble the control panel from the boiler door and hang it from the boiler frame Open the boiler door Loosen the 2 screws of the control panel at the rear side of the boiler door fig 94 1 6720645916 95 Fig 94 Loosening the screws Loosen the cable tie fig 95 1 Remove the control panel fig 95 6720645916 96 1 Fig 95 Removing the control panel 13 3 BC10 Display readings Use the 2 hooks to hang the control panel from the boiler fig 96 6720645916 97 1N Fig 96 Hanging the control panel from the boiler frame 13 2 Replacing the control panel Take the control panel from the boiler frame Install the control panel in the boiler door by followin
63. els Do not operate the boiler when there is a lot of dust in the boiler room e g due to building work gt An air filter must be fitted if the supply of combustion air contains large quantities of dust e g from unpaved roads and tracks or dusty workplaces such as quarries mines etc or airborne seeds from plants Buderus 6 7 Flue gas adapter 6 720 645916 19 1N Fig 19 Connecting the flue gas adapter parallel e When installing PVC vent pipes remove the upper lip ring and insert fig 19 1 CAUTION N DO NOT use lubricants to avoid degradation of the lip rings n case of open venting use basket fig 19 2 on the air intake 6 8 Installation of the Exhaust and Air Intake system NOTICE Consult local and state codes pertaining to special building code and fire department requirements Adhere to national code requirements Observe the listed maximum lengths of vent system which are boiler model dependent The maximum permissible lengths are listed in table 8 page 25 Optional vent kits are 1 horizontal 2 pipe parallel wall terminal fields 20 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Installation EM Y j 2 6 720 645916 20 1N Fig 20 Vent pipes The termination shall be at least 4 ft 1 22
64. em components for Operational tightness 9 8 page 45 Visible corrosion 11 2 page 52 Signs of wear Fill the condensate trap 9 3 page 42 4 Measure the ionization current 9 11 page 47 mA mA mA mA mA mA mA 5 Measure the gas inlet pressure 9 7 page 44 working pressure Wc WC wc wc wc wc WC 6 Check and adjust the flue gases 9 9 page 45 C uus Les VIG EE NVC ee UENIRE AS NV VIG EVI 7 Carry out a leakage test in 9 8 page 45 L L L L L C operating conditions 8 Check and adjust the flue gases 9 9 page 45 pp pp pp pp pp pp pp CO emissions m m m m m m m 9 Fill the heating system L L L L L Pre pressure of expansion vessel psi psi psi psi psi psi psi also see installation instructions for expansion vessel Filling pressure 9 2 page 41 psi psi psi psi psi psi psi 10 Check the air flue gas connection 9 5 page 43 m Ol al L C O 11 Checking the boiler settings of the documents for L L L L L control device in accordance with the control requirements device 12 Final check of the inspection activities documenting the measurement and test results 18 Confirming proper inspection Company Company Company Company Company Company Company stamp stamp stamp stamp stamp stamp stamp signature signature signature signature signature signature signature Tab 28 Inspection report Buderus Logamax plus GB162 L B 80 100 kW Subjec
65. ensate trap must be turned 1 4 rotation clockwise to click into position 12 B 56 uderus 3 6 Remove the condensate collector Disconnect the flexible condensate drain hose and bend it backwards fig 89 Fig 89 Removing the condensate trap hose Open the 2 clamps on the right and left at the bottom of the condensate collector fig 90 1 e Pull the condensate collector down fig 90 1 and remove it by pulling it towards you fig 90 2 Check the condensate collector for damage and replace it if required 6720645916 91 Fig 90 Removing the condensate collector Clean the condensate collector mechanically using compressed air or a soft brush and rinse it with clean water fig 91 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Fig 91 Cleaning the condensate collector 12 3 7 Clean the heat exchanger CAUTION N Incorrect handling can damage the boiler Do not use metal brushes or similar hard cleaning tools Handle the glow ignitor with care it is made from fragile ceramic material Coverthe boiler interior using a blanket or a cover to prevent dirt entering the boiler WARNING N If the condensate collector is installed incorrectly gt Flue gas or condensate may leak Clean the heat exchanger with compressed air or a soft brush
66. ently measured system pressure in psi gt paragraph 13 3 BC10 Display readings page 58 Step 15 Press the button Step 16 R Display code Operating phase The boiler is in service mode gt paragraph 13 5 BC10 Display codes page 59 Step 17 After 30 minutes or after a power interruption the flue gas test ends automatically To end manually press and hold the amp button for more than 2 seconds until the dot disappears Step 18 The boiler input rating drops to the preset capacity gt table 15 Settings page 39 Tab 13 Service mode Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 37 xg Operation Manual Operation menu Step 1 20 Shows currently measured space heating water temperature in F gt paragraph 13 3 BC10 Display readings page 58 Step 2 To activate manual operation Press and hold the button for more than 5 seconds Step 3 154 A flashing dot in the right hand bottom corner of the display shows manual operation is active This means that the boiler is permanently in heating mode Space heating water temperature is as set on the BC10 basic controller The LED Heating system status lights DHW mode is possible during manual operation Step 4 Press the button Step 5 P22 Shows currently measured system pressure in psi gt paragraph 13 3 BC10
67. ere is a current heat demand but too much energy has been supplied OH 203 Readiness for operation 1 The boiler is in standby mode There is no current heat demand OL 284 Ignition phase 1 The gas valve is activated ou Start up phase 2 1 The boiler starts up after activation of the mains power supply or 1 completion of a system reset This code is displayed for a maximum of 4 minutes Tab 23 Display codes Buderus 60 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Display information EN Display codes Main display code Sub display code Key to display code Other effects e DH Operating phase The flow temperature sensor has detected that the current flow temperature is higher than the flow temperature setting on the BC10 or that it is higher than the flow temperature calculated according to the heating curve or that it is higher than the flow temperature calculated for the DHW mode The room temperature is not possibly reached Locking fault The flow temperature sensor has measured a current flow temperature higher than 203 F 95 C The room temperature is not possibly reached Locking fault The safety temperature sensor has measured a current flow temperature higher than 203 F 95 C The ro
68. es not have to be removed from the boiler 12 3 Clean the heat exchanger burner and condensate trap The boiler heat exchanger has a self cleaning coating CAUTION To avoid a short circuit Do not spray the cleaning agent onto the burner the hot surface ignitor the ionization electrode or other electric components 12 3 1 Remove the gas valve Undo the gas fitting screw connection fig 79 1 and pull the 4 connectors fig 79 2 from the gas valve Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 53 TURA A 2 2 BJ 4 CAN 6720645916 80 Fig 79 Undoing the connections to the gas fitting 12 3 2 Remove the burner cover with the fan and the gas valve Pull the mains connector fig 80 1 from the fan Pullthe connector of the harness fig 80 2 from the fan while pushing on the connector lock to loosen it 1 3 RL pe 4 i 6720645916 81 Fig 80 Removing the connectors from the fan Pullthe air suction tube from the fan fig 81 Buderus 6720645916 82 1N Fig 81 Pulling the air suction tube from the fan Carefully open the 4 snap retaining clips on the burner cover
69. fications resulting from technical improvements 19 5 Installation 305 mm of the top and one opening shall commence within 12 805 mm of the bottom of the enclosure The minimum dimension of air openings shall be not less than 4 101 6 mm 1 Where directly communicating with the outdoors each opening shall have a minimum free area of 1 per 4 000 Btu hr of total input rating of all equipment in the enclosure 2 Where communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 per 4 000 Btu hr of total input rating of all equipment in the enclosure 3 Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 per 2 000 Btu hr of total input rating of all equipment in the enclosure 4 Where ducts are used they shall be of the same cross sectional area as the free area of the opening to which they connect All Air from Outdoor sealed combustion The closet shall be provided with two permanent openings one commencing within12 305 mm from the top and one commencing within12 305 mm from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors The minimum dimension of air openings shall be no less than 4 101 7 mm CAUTION N Risk of boiler damage due to excessive dust and airborne debris lev
70. flue gases CO emissions If necessary open the boiler door and adjust the CO percentage to 9 3 by means of the adjustment screw on the gas valve with the red sleeve fig 64 and close boiler door again Note the set value in table 15 1 Start up report page 68 If the CO percentage is not adjustible above 9 the problem can be The gas presure is to low paragraph 9 7 Measure the gas inlet pressure working pressure page 44 CO analyzer set incorrectly Set CO analyzer on natural gas Very low calorific gas No solution accept lower CO percentage Buderus n MiSs m WM s e REN T l AE NN To ol ERR te 6720645916 64 1 Fig 64 Adjusting flue gases CO emissions at full load NOTICE The adjustment screw has no limit stop there for it is not defined in advance that turning left or right will give a higher or lower value Simultaneously press and hold the buttons for more than 2 seconds to activate service mode for partial load setting Press and hold the button until the display shows L 35 with a 80 kW boiler or 40 with a 100 kW boiler After the load is adjusted to partial load wait for 1 minute until the boiler burns at partial load Measure in the flue gas measuring port the CO percentage The value has to be 1 to 1 5 lower than the measured value at full load E g
71. g NOTICE i Appliance input rates are based on minimum vent length operation Longer vent lengths up to maximum will reduce the input proportionally Equivalent Fittings or Piping feet m 45 elbow 4 1 22 90 elbow 7 2 1l plastic pipe per foot 1 0 30 parrallel vent kit 2 0 61 concentric roof terminal 4 6 100 150 mm zi 6 10 Tab 8 Friction Loss Equivalent in piping and fittings gt table 8 for the Friction Loss Equivalent in piping and fittings Example When you end up using 3 x 45 elbows and the concen tric roof terminal then the total venting length may not exceed 68 ft 20 72 m 3 x 45 elbow 3 x 4 ft 1 22 m concentric roof terminal 4 6 12 ft 3 66 m 20 ft 6 10 m Total friction loss equivalent 32 ft 9 76 m Total venting length for this example is GB162 L B 80 kW 100kW 100 ft 30 48 m 32 ft 9 76 m 68 ft 20 72 m each for the intake and exhaust piping NOTICE The minimum covering wall thickness is 1 25 4 mm The maximum covering wall thickness is 16 406 mm For direct venting properly reassemble and reseal the vent and air intake systems CAUTION N Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure Installation 6 At the time of removal of an existing
72. g 28 Vertical venting system non sealed combustion 6720645916 25 1N Fig 26 Vertical parallel venting system sealed combustion 1 exhaust 4 102 mm i 2 intake 4 102 mm 1 exhaust 4 102 mm 3 12 300 mm over max snow level or 24 600 mm 2 intake 4 102 mm whichever is greater 3 107 0 MIN 250 mm 0 mm MIN 4 10 0 MIN 250 mm 0 mm MIN 4 12 300 mm over max snow level or 24 600 mm whichever is greater I I SOT sow yk t gt 3 6 720 645916 26 1N SS kt bj gt gt 6720645916 101 1N Fig 27 Vertical venting system sealed combustion 1 exhaust 4 102 mm 2 intake 4 102 mm 3 12 300 mm over maximum snow level or 24 600 mm whichever is greater D Fig 29 Vertical concentric system sealed combustion Buderus 24 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Do not exceed the total equivalent venting length of 100 feet 30 480 mm maximum requirement each for the intake and exhaust pipin
73. g the procedure in paragraph 13 1 Removing the control panel on page 58 in reverse order Display readings Display reading Key to display reading Unit Range Remarks 15 Current space heating water temperature F H 190 Ped Current system pressure psi POO PSH Tab 21 BC10 Display readings Buderus 58 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 13 4 BC10 Display settings Display information EN Display readings Display setting Meaning of display setting Unit Range Factory adjusted setting L3H Low BTU 4 001 10 200 ft configured target load GB162 L B 80 kW L 3b Low BTU 4 001 10 200 ft configured target load GB162 L B 100 kW r LL ra Configured target value of the pump run over time NOTE Do not set the pump run over time to less than F 5 5 minutes min 73 DHW flow operating condition setting NOTE If the setting L l is displayed the frost protection of the DHW flow has also been switched off r1 ra u Off r r 100 100 100 100 i L r
74. g system filling pressure psi 3 Fill the condensate trap with water 42 4 Write down the gas characteristics Heat input btu ft 9 Heat output btu PM 5 Bleed the gas supply valve 43 6 Check the air flue gas connection 43 7 Checking the appliance configuration 44 8 Measure the gas inlet pressure working pressure 44 W C 10 Carry out a leakage test in operating conditions 45 3 11 Check and adjust the flue gases CO emissions 45 ppm 12 Carry out a function test 47 Measure the ionization current 47 uA 13 Measure the pH value Fill in the record book 14 Boiler settings 48 LJ 15 Final activities 49 o CLose the boiler door and the control panel Hand over Confirming proper start up Company stamp signature date Tab 27 Start up report Buderus 68 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 15 2 Inspection report Reports 15 Indicate the inspection activities that have been carried out enter the values measured and enter your signature and the date Date Date Date Date Date Date Date Inspection activities See paragraph 1 Check the general condition of the L L L L L heating system 2 Carry out a visual inspection and C L C L O O O function test of the heating system 3 Checking the gas and L L L L L water bearing syst
75. 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 Thelow 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 6 3 Installing the boiler Observe the installation distances of the combustion air flue gas system Before starting installation check that the carrying capacity of the wall is sufficient for the boiler weight Buderus A UJ 6 720 646157 07 1TD Fig 7 Installing the wall bracket Mark both holes with the wall bracket fig 7 page 14 using a spirit level Install the wall bracket with 2 screws fig 7 page 14 With 2 people lift the boiler by holding it by its back and by the transport rail at its bottom and install it on the wall bracket fig 5 page 12 The boiler can be moved sideways to get the correct position 14 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 6 720 646157 08 1 Fig 8 Aligning the boiler with the set screw Level the boiler
76. ion about the use of the BC10 basic controller is provided in chapter 8 Operation page 34 2s e Push on the control panel to open it Switch OFF the appliance by pressing the main switch of the BC10 VA yY fig 71 1 LP NSS N g N a A E by 10 9 8 110 130 150 6720645916 74 Fig 73 Draining the heating system example 10 3 Shutting down the heating system in the event of an emergency You must immediately close the main shutoff valve or gas shutoff valve and disconnect the power from the appliance 6 6720645916 47 1N Close the main shutoff valve Fig 71 BC10 basic controller Close the main gas supply or the gas valve fig 72 6720645916 73 1N Fig 72 Closing the gas valve Buderus 50 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 11 Inspection Offer your customer an annual inspection and maintenance contract The activities to be included in an annual inspection and maintenance contract can be found in the inspection and service reports paragraph 15 2 Inspection report page 69 and paragraph 15 3 Service report page 70 WARNING N 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 an
77. its connection i e direct sealing location to the gas fitting for leaks using a foaming product 6720645916 49 1N Fig 49 Open the gas valve pressure relief valve supply water valve pump manual gas shutoff valve return water valve ahondD Li NOTICE Atinitial start up the boiler will start as soon as the system pressure exceeds 15 psi 1 0 bar gt If the system pressure falls below 3 psi 0 2 bar the boiler will stop and generate a fault code 6720645916 47 1N Fig 50 BC10 basic controller Push and open the control panel cover Turn the Space heating water temperature knob fig 50 8 and DHW temperature knob fig 50 10 counterclockwise to the O position Turn the vent key a quarter rotation to undo the boiler door lock fig 51 detailed picture Push the fastener down fig 51 step 2 and open the boiler door Remove the insulation cover of the pump group fig 51 step 4 Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 41 EJ Start up procedure 6720645916 51 1N Fig 51 Opening the boiler door To purge the boiler every radiator in the heating system must have a purge facility In some situations it may even be necessary to provide extra purging facilities at certain locations The boiler itself has an automatic air ve
78. king order and if applicable check them for correct adjustment The gas and water circuits must be tested for leaks gt paragraph 9 1 Check for gas leaks page 41 gt paragraph 9 9 Check and adjust the flue gases CO 2 emissions page 45 9 11 Measure the ionization current Press on the control panel to open it Open at least 2 radiator valves if present Do not switch ON the boiler Switch OFF the appliance by pressing the main switch of the BC10 basic controller fig 66 1 Turn the vent key through a quarter turn to undo the boiler door lock fig 51 step 1 Push the fastener down fig 51 step 2 and open the boiler door Fig 66 BC10 basic controller Undothe plug and socket connection of the monitoring cable fig 67 6720645916 67 1 Fig 67 Removing the ionization electrode plug and socket connection Connect the multi meter in series fig 68 Select the pA DC range on the multi meter The multi meter must have a resolution of at least 1 pA Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 47 Ea Start up procedure 6720645916 68 1N Fig 68 Measuring the ionization current Switch ON the appliance by pressing the main switch of the BC10 basic controller fig 66 1 Activate the Service mode in accordance
79. lbow must terminate at least 12 305 mm below exhaust elbow or outlet but not exceed 15 381 mm maximum separation fig 31 oahah Horizontal termination shall not extend beyond 18 from the building based on minimum 12 305 mm required separation between intake and exhaust Exhaust vent vertical rise shall not extend beyond 39 991 mm from building penetration to termination elbow gt fig 31 Condensate could freeze and block vent pipe Terminate all exhaust vents at the same height and all combustion air inlets at the same height while maintaining the minimum 12 305 mm vertical height clearance from between exhaust and combustion air inlet Exhaust vent termination edge shall be at least 12 805 mm 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 Buderus 26 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Electrical connections 7 Electrical connections Devices such as pumps outdoor sensor and 3 way valve are all connected to the external connection board The electrical connections to the boiler must be made in accordance with all applicable local codes and the latest 72 revision of the National Electrical Code ANSI NFPA 70 If installed in Canada electrical connections should conform with CSA C22 1 Code part 1
80. led at the time of installation No valve is to be placed between the PRV and the boiler No reducing coupling or other restriction may be installed in the discharge line The discharge line must be within 12 305 mm with a minimum of 4 100 mm above a drain and installed such that it allows complete drainage of both the PRV and the line The location of the PRV must be readily accessible for servicing or replacement and be mounted as close to the boiler as possible To install the PRV a suitable fitting connected to an extension on a T fitting can be sweated to the hot water line Support all piping Maintain an installation clearance from combustible construction of at least 1 25 mm from the hot water piping 6 4 5 Making the gas connection Steel pipe Equivalent length for Pipe Fittings in feet m diameter 7 S in inches Type of pipe fitting anm Tee flow thru 90 Elbow branch Gate valve Gas cocks Equivalent length in feet m 34 19 2 1 0 64 4 1 1 25 0 5 0 150 1 25 0 38 1 25 2 6 0 79 5 2 1 59 0 6 0 18 1 60 0 49 114 32 3 5 1 07 6 9 2 11 0 8 0 24 2 15 0 66 1 38 4 0 1 22 8 0 2 44 0 9 0 27 2 50 0 76 DANGER N Only carry out work on gas lines if you are a qualified gas fitter The manual gas shutoff valve is part of the pump group and is installed in accordance with the pump group installation instructi
81. ler to be run in full load operation manually for a short period gt table 12 Flue gas test page 36 The service mode enables the boiler to be run in part load operation manually for a short period Measurements and settings can be carried out on the boiler gt table 13 Service mode page 37 The manual operation mode enables the boiler to be operated manually for a longer period Use this mode when the control system has not been installed yet or is out of order table 14 Manual operation page 38 Service button fig 47 4 The Service button is used to display the current space heating water temperature the current system pressure etc Service Tool connection fig 47 5 For further information please contact Buderus LED Burner operation fig 47 6 The LED Burner operation lights when the burner of the boiler is active and is extinguished when the burner is switched OFF The LED Burner operation indicates the burner status LED Status Explanation ON Burner Boiler water is being heated operational OFF Burner off The space heating water temperature has reached the target value and there is no heat demand Tab 10 Meanings of LED Burner operation indications 34 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements LED Central heat demand fig 47 7 The LED Central heat demand
82. lve Venturi Burner cover Flow temperature sensor lonization electrode Sighting glass Glow igniter Safety temperature sensor Heat exchanger Pressure sensor Return temperature sensor Universal Burner Automatic Version 3 UBA 3 Draw with function module integration options Cover shield Condensate trap Pump group scope of delivery 37 38 39 40 41 42 43 44 Isolating valve blue CH boiler return with pump drain cock check valve and thermometer Manual gas shut off valve yellow GAS Isolating valve red CH boiler flow with drain cock pres sure gauge and thermometer Pressure gauge Isolating valve Thermometer optional accessory Drain valve Safety valve 30 psi 2 bar or 50 psi 3 45 bar optional The pump group also includes an insulation cover see also pump group installation instructions 45 Low loss header scope of delivery single appliance only Low loss header not illustrated Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Buderus 3 i Contents Contents 1 Guideline to symbols and safety instructions 6 1 1 Guideline to symbols 04 6 1 2 General warnings csse ew Ex EST 6 133 Safety instructions 0000 7 2 Regulations and guidelines 8 2 1 Massachusetts Installations Only 8 3 General information
83. m water dripping spraying rain etc during boiler operation and service Do not restrict or seal any air intake or outlet openings Ifyou find any defects you must inform the owner of the system of the defect and the associated hazard in writing The boiler must not be installed on carpeting What to do if you smell gas e Do not try to light any boiler Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 7 ea Regulations and guidelines 2 Regulations and guidelines The installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Install CO detectors per local regulations Boiler requires yearly maintenance chapter 12 Maintenance page 53 Operating Limits of the boiler Max boiler temperature Max operating pressure with optional pressure relief valve 230 F 110 C 30 psi 2 6 bar 50 psi 3 45 bar
84. ments that you have made have been confirmed Tab 15 Settings Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 39 Ea Start up procedure 9 Start up procedure There are several steps involved in starting up the boiler Complete the commissioning record log book after carrying out all activities described in this chapter gt paragraph 15 1 Start up report page 68 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life 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 WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instruction If you cannot reach your gas supplier call the fire department C Useonly 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 at
85. n electrode and or glow ignitor After checking or replacing the ionization electrode and or the glow ignitor fit a new cover plate and rubber seal 7 746 800 040 128 2TD Fig 85 Checking the ionization electrode 6720615405 035 1TD Fig 86 Replacing the ignition unit glow ignitor lonization electrode Rubber seal Cover plate with seal Nut E 12 3 5 Disconnect the condensate trap Disconnect the condensate trap hose fig 87 3 and the rubber sleeve fig 87 2 from the condensate trap fig 87 1 Turn the condensate trap a quarter rotation counterclockwise fig 87 Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 55 ED Maintenance 6720645916 88 1N 6720645916 91 Fig 87 Disconnecting the condensate trap hose 1 2 3 Condensate trap Rubber sleeve Condensate trap hose Disconnect the condensate trap from the coupling and remove it fig 87 1 Rinse the condensate trap to clean it Fill the condensate trap with water and reinstall it 6720645916 89 1 Fig 88 Disconnecting the condensate trap NOTICE i The condensate trap has a bayonet connector After inserting it the cond
86. nder stress Use a return pipe with a minimum diameter of 11 2 38 mm Installation L8 6 4 5 Installing the pump Always use the supplied Buderus pump group and the low loss header when installing a single boiler so correct flows are guaranteed It is not necessary to install a low loss header for cascade systems Install the pump fig 12 8 in the return circuit fig 12 2 6 4 6 Installing the condensate trap WARNING N Danger of fatal accident due to poisoning gt If the condensate trap is not filled with water flue gas can escape and put people s lives at risk 6 720 646157 13 1TD Fig 13 Filling the condensate trap with water Fill the condensate trap supplied with the boiler with water fig 13 High temperature applications Top off with vegetable oil in case of high temperature systems and non condensing applications Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 17 5 Installation 6 720 646157 014 1T Fig 14 Installing the condensate trap Connect the condensate trap fig 14 1 to the condensate outlet The condensate trap has a bayonet connector insert and turn 1 4 rotation clockwise to click into position O 2 od i O T 6 720 646157 15 1TI Fig 15 Installing the condensate trap hose Connect the condensate trap hose fig 15 3 and the ru
87. ng pressure Open at least 2 radiator valves if present Do not switch ON the boiler e Push on the control panel to open it Switch OFF the power supply to the appliance Close the gas valve in a clockwise direction fig 60 Turn the vent key through a quarter rotation to undo the boiler door lock fig 51 page 42 Push the fastener down and open the boiler door Buderus 6720645916 60 1N Fig 60 Closing the gas valve Open the screw plug on the testing nipple for the gas inlet pressure by 2 turns fig 61 1 Resetthe digital pressure gauge to O 6720645916 61 1N Fig 61 Measuring the gas supply pressure NOTICE i Throughout the measuring operation keep the digital pressure gauge in the same position horizontal or vertical in which it was reset to 0 Connect the pressure gauge connection tube to the positive port of the testing nipple fig 61 2 Slowly open the gas valve by pushing on the gas valve and turning it 1 4 rotation in an counterclockwise direction fig 58 page 43 The gas valve is open when it is in the vertical position Switch ON the appliance by pressing the main switch of the BC10 basic controller fig 62 1 Press and hold the Chimney sweep button fig 62 3 approx 2 seconds until the dot in the right hand bottom corner of the displa
88. nt Loosen the cap of the automatic air vent fig 52 by turning 1 4 rotation counterclockwise N 6720645916 52 1N Fig 52 Opening the automatic air vent Open the heating supply and return isolating valves on the pump group fig 53 The open position is parallel to the pipe Fill the heating system to a pressure of about 20 psi 1 5 bar Buderus 6720645916 53 1N Fig 53 Opening the isolating valves here open position Read the pressure PSI from the pressure gauge on the pump group or on the control panel of the BC10 fig 54 110 130 Pec 90 Eco d o Aut I eeee 6720645916 54 1N Fig 54 Reading the pressure gauge The pressure in the heating system which is measured directly at the boiler must be at least equal to the required pre pressure of the expansion vessel plus 7 psi 0 5 bar This minimum pressure must not be less than 12 psi 0 8 bar if the heating system is cold The maximum pressure in the heating system measured directly at the boiler must not exceed 30 psi 2 6 bar or 50 psi 3 5 bar when the optional 50 psi 3 5 bar pressure relief valve is used Purge the heating system via the air vents on the heating bodies Start at the lowest floor of the premises and then work your way up from floor to floor
89. o the boiler door lock fig 75 step 1 Push the fastener down fig 75 step 2 and open the boiler door NOTICE gt If the boiler door cannot be opened completely remove it gt paragraph 12 2 Remove the boiler door page 53 6720645916 76 1N Fig 75 Opening the boiler door Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 51 EB Inspection 11 2 Carry out a visual check for general signs of corrosion e Check all gas and water bearing pipes for signs of corrosion and for leaks Replace any pipes that are corroded Carry out a visual inspection of the burner heat exchanger condensate trap automatic air vent and all fittings in the boiler 11 3 Gas valve leakage test Check the internal tightness of the gas fitting on the input side with the boiler switched OFF at a test pressure of 7 0 W C 17 4 mbar for natural gas and 8 0 W C 19 9 mbar for LPG Check that the appliance is switched OFF Open the screw plug on the testing nipple for the gas connection by 2 turns fig 76 1 Connect the pressure gauge tube to the testing nipple fig 76 2 The pressure drop allowed after 1 minute is max 3 8 W C 10 mbar e If the pressure drop is higher check all sealing locations of the gas fitting for leaks using a foaming product Repeat the pressure test if no leaks are found Replace the ga
90. om temperature is not possibly reached Locking fault The return temperature sensor has measured a current return temperature higher than 203 F 95 C The room temperature is not possibly reached Blocking fault The flue gas sensor temperature is too high No heating operation and no DHW Locking fault There is no connection between contacts 78 and 50 of the UBA 3 installation base No heating operation and no DHW Blocking fault The flue gas sensor contacts have shorted No heating operation and no DHW Blocking fault The flue gas sensor contacts are open No heating operation and no DHW BE Locking fault The system pressure is too low less than 3 psi 0 2 bar No heating operation and no DHW BF Locking fault The flow temperature sensor has not after burner start up detected any temperature increase in the heating systems water BF Locking fault The heating water temperature difference measured between the flow temperature sensor and the safety temperature sensor is too high pP Locking fault The flow temperature sensor has measured a heating water temperature increase of over 40 F s 5 C s Locking fault The temperature difference measured between the flow temperature sensor and the return temperature sensor
91. onnecting the condensate drain pipe page 18 Periodic cleaning of the vent terminal and air intake screens is mandatory Avoid locating vent terminals near equipment or construction which can be subject to degradation from exhaust gases T gt ad gt bar PE id e 200v gt 7 6720645916 024 1N 2 Fig 24 Horizontal venting system non sealed combustion exhaust 4 102 mm 1 KRD 2 intake 4 102 mm 1 m 2 Bent JU ee N ae 1 ae E T gt o gt 6720645916 23 1N Fig 23 Horizontal venting system sealed combustion 1 exhaust 4 102 mm 2 intake 4 102 mm v Iq 6 720 645916 29 1N Fig 25 Horizontal venting system sealed combustion 1 exhaust 4 102 mm 2 intake 4 102 mm Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 23 gt 6 720 645916 27 1N Fi
92. ons Buderus Tab 5 Equivalent length for pipe fittings in feet 16 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 6 4 4 Installing the heating supply and return pipe 6720645916 12 1TD Fig 12 Connecting the boiler supply and return Supply Return Isolating valves Drain cock Gas valve Pressure relief valve Condensate trap Pump Non return valve 10 Dirt filter for example scale cartridge or y strainer 11 Gas supply 12 Air gap gt 1 25 4 mm omm Oo NOTICE i When using plastic pipes observe the supplier s instructions especially those referring to recommended jointing techniques and the notes relating to the heating system water on page 9 NOTICE To prevent contamination in the heating system we recommend you integrate a dirt filter fig 12 10 in the return pipe near the boiler In an old system it is a requirement to install a dirt filter Also install shutoff valves to enable filter cleaning immediately upstream and downstream of the dirt filter scale cartridge or y strainer Connectthe supply pipe with a flat rubber seal installed to the Supply connection fig 12 1 making sure it is not under stress Use a supply pipe with a minimum diameter of 11 2 38 mm Connectthe return pipe with a flat rubber seal installed to the Return connection fig 12 2 making sure it is not u
93. or fire place is vented into or through chimney All non steel vent pipes must be glued except for the flue gas adapter Installed you can slide the pipe onto the adapter properly supported and the exhaust pipe must be pitched a minimum of a 1 4 6 35 mm per foot back to the boiler This allows the condensate to drain away All non steel combustion air and vent pipe materials and fittings must comply with the following and must be UL approved venting material United states Canada ANSI ASTM D1785 ANSI ASTM D2665 BH gas venting systems ULC ANSI ASTM F441 636 ANSI ASTM D2564 Item Material PVC schedule 40 80 4 100 mm Intake combustion air pipe PVC DWV and fitting CPVC schedule 40 80 PVC Pipe cement primer CPVC ANSI ASTM F493 Tab 6 Approved intake combustion air pipe material 1 Components of the certified vent systems must not be interchanged with other vent systems or unlisted pipe fittings Plastic components and specified primers and glues of the certified vent system must be from a single system manufacturer and not intermixed with other system manufacturer s vent system parts Approved flue material are from Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 21 5 Installation Roof terminals Flue System trade name Supplier 4 6 100 150 mm concentric PVC IPEX Wall terminals Flue
94. oss header Cascade units are available for installing the boilers inline or back to back These cascade units make installing a cascade system easier and less labor intensive Please contact Buderus for further information about cascade Systems Updating of documentation The following technical documentation is available for the Logamax plus GB162 L B 80 kW 100 kW Installation instructions User s manual Service manual Subject to technical modifications Slight changes may be made without prior notice to the illustrations process steps and technical data as a result of our policy of continuous improvement GB162 L B Natural Gas Propane Gas 80 kW 290 000 btu hr 270 000 btu hr 100 kw 333 000 btu hr 315 000 btu hr Tab 2 max input rate 3 1 Designated use The boiler was designed to heat water in a central heating system and generating domestic hot water It is suitable for connection to fully pumped sealed water systems only with a maximum supply temperature set point off 180 F 82 C The boiler can be installed either as a single system or as part of a multiple system cascade system This boiler may not be installed in places below 4 001 ft above sea level General information 8 3 2 Heating system water quality The quality of the system water is very important Poor water quality can damage heating systems due to scale formation and corrosion For further details pl
95. pendent in mm 4 100 Flue gas system room air independent in mm 4 100 4 100 parallel Electrical data Tab 24 Technical specifications of GB162 boilers low BTU Buderus 66 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Technical specifications ES General specifications unit GB162 L B 80 NG GB162 L B 80 LP GB162 L B 100 NG GB162 L B 100 LP Mains connection voltage VAC Hz 120 60 Electrical protection rating IPX4D Fuses Amp 5 Electrical power consumption full load without a pump group w 193 i Electrical power consumption w 29 29 partial load without a pump group Boiler dimensions and weight Height x width x depth with pump group in mm 50 4x20 5x18 3 1280x520x465 Weight without a pump group Ib kg 154 70 Other specifications Pump group pump UP 26 99 Tab 24 Technical specifications of GB162 boilers low BTU Thermal Gaclorliice Factory pre setting of the gas control power Type of diameter Type of gas supply valve gas gas Altitude inmm Set number n boiler Sapte Leas inch with orifice Natural gas Delivered factory set Natural Gas LP gas Suitable for propane after conversion also see GB162 Natural 4 001 10 200 40 0 370
96. permissible 5 A 28 Mains switch 29 120 VAC function module 30 Ground IMPORTANT The wires in this mains lead are colored in accordance with the following code GREEN AND YELLOW EARTH BLUE NEUTRAL BROWN LIVE As the colors of the wires in the mains lead of the appliance may not correspond with the colored markings identifying the terminals in your connector proceed as follows The wire colored green and yellow must be connected to the terminal on the connector marked with the letter E or by the earth symbol or colored green or green and yellow The wire colored brown must be connected to the terminal marked with the letter L or colored red The wire colored blue must be connected to the terminal marked with the letter N or colored black WARNING THIS APPLIANCE MUST BE EARTHED Ensure that your appliance is connected correctly if you are in any doubt consult a qualified electrician For location of individual components see service section and the exploded views in this manual Electrical connections Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 33 Es Operation 8 Operation 8 1 BC10 basic controller The boiler is fitted with a control unit the BC10 basic controller This controller can be used to control the heating system Fal 6 720 646157 46 1N Fig 46 Opening the control panel Push on the control panel fig
97. port page 70 Maintenance ES Unscrew the bolt from left hand top hinge of the boiler door and remove it together with the washer fig 78 Slightly lift the door and pull it from the hinge Putthe door upright in a safe position CAUTION Risk of electric shock Before opening the appliance disconnect the appliance from the power supply using the appliance emergency OFF button or disconnect the relevant circuit breaker of the house from the power grid Secure the appliance against accidental restarting NOTICE There is no need to lubricate the combustion motor as it is permanently lubricated 12 1 Prepare the heating system for maintenance gt If gas pipes have to be disconnected from the gas burner fitting the burner cover must only be opened by a specialized professional i INSTRUCTION FOR THE INSTALLER Switch OFF the appliance by pressing the main switch of the BC10 Close the gas valve fig 77 1 Close the isolating valves fig 77 2 TET 2 6720645916 75 1N Fig 77 Closing the valves here in closed position 12 2 Remove the boiler door Unscrew the control panel from the boiler door and hang it on the boiler frame gt paragraph 13 1 Removing the control panel page 58 6720645916 79 1N Fig 78 Removing the boiler door NOTICE The cover over the electrical connections do
98. portation 0 0 cece eee ee 13 Freeze protection seen 8 function modules llle esses 30 31 Function TES sedan eere th ER RE ee 47 Ww working pressure sees 45 53 69 G gas TOW s ist anew fon ena o dcs aetna amp anehg 42 gas supply pressure 0 cee eee 46 JASONE oe sx tel ate Ron x sane cea CRT A tone d 42 H heat exchanger 0 00 cece eee 54 58 heating capacity lessen 49 Heating system water see 8 Hydraulic resistance ssslleeeeeesssse 70 l Inspection report 0 eee 72 installation room ous eere Reemi e 15 ionization Current 0 kada eee 48 53 L leakage test 6 eee eee 46 53 Buderus 74 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Notes Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 75 United States and Canada Bosch Thermotechnology Corp 50 Wentworth Avenue Londonderry NH 03053 Tel 603 552 1100 Fax 603 584 1681 www bosch us U S A Products manufactured by Bosch Thermotechnik GmbH Junkersstrasse 20 24 D 73249 Wernau www bosch thermotechnology com Bosch Thermotechnology Corp reserves the right to make changes without notice due to continuing engineering and technological advances Buderus 6720645916 0001
99. re only permitted to operate the condensing gas boiler with the combustion air flue gas system that has been specifically designed and approved for this type of boiler Please note that local approval of the flue system and the condensate connection to the public sewer system may be required If boiler installation is provided as replacement heater DO NOT connect new boiler venting to an existing vent system if it is shared with other appliances Thelocal building regulations stipulating the installation rules at the time of installation Thelocal building regulations concerning the air intake and outlet systems and the chimney connection The regulations for the power supply connection The technical rules laid down by the gas utility company concerning the connection of the gas burner fitting to the local gas main The instructions and standards concerning the safety equipment for the water space heating system The Installation Instructions for building heating Systems The boiler must be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the boiler or to lower floors of the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the boiler The pan must not restrict combustion air flow The boiler must be installed such that the gas ignition system components are protected fro
100. roller llssssss esses 35 51 Manual Operation csi sorcen aineis e eens 39 BC10 basic controller usuen esnaera 35 menu structure isses nne 36 DUEN aussen tem hh pr br wee bee ca EE Eres 54 N C Normal Operation iiia vau sd ERR bak cresti 36 condensate pi secre eee ene 43 connections 1 eee eee 11 16 28 P pump Ils esca cick a a ra tenen can am d Qc p apie 8 49 D Puimp test cies dus katred oiii enn Een 8 DHW circulation pump 000 eee 29 DEIN PUND iir sx ec acte e i Rok e nde 29 R diagnosis connector seen eee e eee 46 Room Controller 0 0 00 cece eee eee eee 29 Display ivesteees epe geaeW sdk pee tae 60 display cis cet RR REA Rer ER ERE TEE 35 S Display 6odes ens eme oo ke te Rake es 61 DM sane s e aae E duis emat ope taal etes deus 51 BION dace dpeusst daled a cicetsu qui etti THE Safely iss bos eva tod E ad E E E RR MEE 6 Service Mode 6 6 cee eee 38 E Service Tool iicet RR hon 35 Se ee eee patct a iU a ATE 51 SIM E T E T 40 settings sse em eR exe hrs 49 61 F Shutting GOWN i 2 eeece Che duae nnb 51 fault 61 signs of COrrOSION 2 ee eese esses 51 53 flow temperature 0 cece eee eee 69 Space heating isis bern 36 Flue gas connection 0 cee eee 69 flue gas connection 0 0 ee eee 44 53 T Flue Gas Test cen 37 Technical specifications 00ee ee aee 69 freeze damage 1 2 2s settee rece eee eee 49 trans
101. rom terminal 2 to terminal 2 fig 41and fig 42 7 2 2 Installing function modules outside the boiler 6 720 646157 43 1N Fig 48 EMS bus polarity Install the module on the wall according to the installation instructions of the module 30 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Make an EMS bus connection cable using a 2 core cable and the connector enclosed with the module fig 43 Important Use the connector of the same color as the connections on the module NOTICE Pay attention to the polarity when using an EMS bus connection cable gt Connect the wire from terminal 1 to terminal 1 and from terminal 2 to terminal 2 fig 41 amp fig 42 1 NOT FA WA FW EV DWV 6 720 646157 44 1N Fig 44 External connection board Room controller RC and EMS bus connection color orange Connect the EMS bus connection cable to the orange RC connection of the external connection board fig 44 1 To connect other modules see paragraph 7 2 1 7 3 Electrical wiring diagram CAUTION N Wiring errors can cause improper and dangerous operation Label all wires prior to disconnection when servicing Verify proper operation after servicing Electrical connections Buderus Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technic
102. rrent after g g 4 start up attempts TE E ya 3B Blocking fault No heating operation and no DHW The system has detected an ionization current before burner start up Tab 23 Display codes Buderus 62 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Display information EN Display codes Main Sub display display Key to display code Other effects code code YE n JE Blocking fault No heating operation and no DHW 125 va An ionization current has been measured after the burner shut down g Blocking fault BL gg Hr The system has detected an insufficient ionization current during the d TET operating phase E T Blocking fault BP 264 The system has detected an insufficient ionization current during the No heating operation and no DHW il operating phase Blocking fault ri Jhd y JEGAT The ionization curent is doo high No heating operation and no DHW Blocking fault The power supply was interrupted during a locking fault LL ur F l n C f yz 3 TAR U sale L JHE L JHE x No heating operation and no DHW 14 1l E jf Es E M oL Tu
103. rt 2c eee 70 16 Spare parts cece eee eee 71 Index 22 4 de peu rre wy xp rho seins 74 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Buderus 5 EA Guideline to symbols and safety instructions 1 Guideline to symbols and safety instructions 1 1 Guideline to symbols DANGER Warnings f if flammable gas explodes Warnings are indicated in the text by a f E Beware if you smell gas there may be an warning triangle and a gray background explosion hazard Donotstore or use gasoline or other flammable vapors In case of danger from electric shock the and liquids in the vicinity of this or any other boiler exclamation point on the warning triangle is replaced with a flash WARNING N Dangerous flue gas can escape if the air Signal words at the beginning of a warning are used to supply is insufficient indicate the type and seriousness of the ensuing risk if measures for minimizing damage are not taken NOTE indicates that damage to property may occur CAUTION indicates possible minor to medium personal injury WARNING indicates possible severe personal injury DANGER indicates a potential for loss of life Make sure that air vents are not reduced in size or obstructed The boiler may only be operated after the defect has been remedied Warn the user of the system of the defect verball
104. s fitting if the pressure drop is higher than 3 8 W C 10 mbar per minute again gt paragraph 12 3 2 Remove the burner cover with the fan and the gas valve page 54 for instructions on how to remove tr 6720645916 77 1N Fig 76 Checking the gas fitting for internal tightness 11 4 Measure the ionization current gt paragraph 9 11 Measure the ionization current page 47 Buderus 11 5 Measure the gas inlet pressure working pressure gt paragraph 9 7 Measure the gas inlet pressure working pressure page 44 11 6 Check and adjust the flue gases CO emissions gt paragraph 9 9 Check and adjust the flue gases CO2 emissions page 45 11 7 Carry out a leakage test in operating conditions gt table 9 8 Carry out a leakage test in operating conditions page 45 11 8 Fill the heating system To ensure a trouble free operation of your boiler check the pH value every year and correct it if necessary See accompanying manual about water quality for more information gt table 9 2 Fill the heating system page 41 11 9 Check the air flue gas connection 2 table 9 5 Check the air flue gas connection page 43 52 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 12 Maintenance INSTRUCTION FOR THE INSTALLER i Record the activities in the service report gt paragraph 15 3 Service re
105. s running too fast Blocking fault No heating operation and no DHW 4A 2 Br The flow temperature sensor has detected a flow temperature of over 221 F 105 C Blocking fault No heating operation and no DHW 4E ggHr There is no bridging cable between contacts 22 and 24 of the UBA 3 i g contact strip yg E 1s 1B Blocking fault No heating operation and no DHW J5 The sensor test has failed a x Blocking fault No heating operation and no DHW MF g Hr The safety temperature sensor has detected a flow temperature of over i 266 F 130 C Blocking fault No heating operation and no DHW Tq ya 3n The contacts for the safety temperature sensor have shorted or the JS 5 1 safety temperature sensor has detected a flow temperature of over 266 F 130 C im F ys EE Blocking fault No heating operation and no DHW The contacts for the safety temperature sensor have been interrupted Mr F Ia Bg Blocking fault No heating operation and no DHW The contacts for the safety temperature sensor have shorted Mr J 1213 Blocking fault No heating operation and no DHW J The contacts for the safety temperature sensor have been interrupted Operating phase aH cebu Component test phase Locking fault BA gg The system has detected an insufficient ionization current during the ignition phase amp Blocking fault No heating operation and no DHW BA gg ir The system has detected an insufficient ionization cu
106. ses nisi pia 9 sili mixer Adie H E jon the MM10 and the RC35 do not match up the MM10 or the bus a etre acti pine se circuit is connected incorrectly or is defective MM10 is not recognized tivated continuously Monitor data in the by the RC35 RC35 is invalid Blocking fault LH Eg BB The return temperature sensor has measured a return temperature No heating operation and no DHW higher than 221 F 105 C Blocking fault JE o je HHr The contacts for the pressure sensor have been interrupted or have No heating operation and no DHW shorted L EP HHr Blocking fault Lu No heat t d no DHW The contacts for the pressure sensor have shorted Se ee RS T Lu 240 Blocking fault L u No heat t d no DHW The contacts for the return temperature sensor have shorted Roue RE 4 g Blocking fault L No heat t d no DHW The contacts for the return temperature sensor have been interrupted eee Guan H Locking fault E E o co P No fealpg operation And NERENN I Jews uu Any display code starting with the letter E except EL thru Blocking fault No heating operation and no DHW yz iT The UBA 3 or the KIM is defective LI Operating phase The system pressure is too low less than 12 psi 0 8 bar No heating operation and no DHW display was pressed for 5 seconds H 4 Operating phase The system pressure is too low
107. sition in the wall bracket fig 39 Remove the drawer M M 6 720 646157 40 1N Fig 40 Removing the covers Remove the covers of both free connectors on the function module connection cables fig 40 Slide the drawer back into the boiler Fe ST pe lo o CK Module 1 A Module 2 ki 3 sarar ao zi e cio Module X 6 720 646157 42 1 Fig 42 Connecting several modules NOTICE i The module may have the letters RC or EMS above the connection fig 42 1 Connect the free connector of the EMS bus connecting cable fig 41 to the first module fig 42 f more modules are used the EMS bus connection for the second module may be branched off from the first module using the cable enclosed with the module fig 41 amp fig 42 lt x TE S 7 gu E 4 f j 6 720 646157 4 Fig 41 Interconnecting modules Connect the free 120 VAC mains cable fig 40 to the module fig 41 1 If more modules are used the 120 VAC supply for the second module can be taken from the first module using the cable enclosed with the module Buderus NOTICE i Pay attention to the polarity when using an EMS bus connection cable Connect the wire from terminal 1 to terminal 1 and f
108. t to modifications resulting from technical improvements 69 ES Reports 15 3 Service report Indicate the maintenance activities that have been carried out enter the values measured and enter your signature and the date Date Date Date Date Date Date Date Needs dependant maintenance activities Page 1 Clean the heat exchanger burner and condensate trap 99 L L E 2 Check and adjust the flue gases CO emissions a8 W C W C W C W C W C W C NO CO content at full load CO content at part load 3 Function check 57 L L L L L L 4 Confirming proper inspection Company Company Company Company Company Company Company stamp stamp stamp stamp stamp stamp stamp signature signature signature signature signature signature signature Tab 29 Service report Buderus 70 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements 16 Spare parts Spare parts E The following are parts commonly required due to damage or replacements Their failure will affect safety or performance of this appliance For a pictorial representation of the part see the respective position number on the exploded view pictures on page 72 and page 73
109. tempted repair may result in a fire or explosion D Do not use this appliance if any parts have 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 OPERATING INSTRUCTIONS STOP read the safety information above on this label Turn off all electric power to the appliance Set the thermostat or other operating control to lowest setting This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Close main gas shut off valve 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 on this label If you don t smell gas go to the next step Open main shut off valve Set the thermostat or other operation control to desired setting Turn on all electric power to the appliance If the appliance will not operate follow the instruction To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Turn off all electric power to the appliance if service is to be performed Set the thermostat or other operating control to lowest setting 3 Close main gas shut off valve PY gt on 9 o N 708 375A 2172B 6720645916 48 1N Fig 48 Safety sticker Buderus 40 Logamax plus GB162 L B
110. ter temperature Set the upper space heating water temperature limit for heating mode with the space heating water temperature knob fig 69 8 gt table 19 This limitation does not apply to DHW preparation Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Start up procedure PS Knob Explanation Knob Explanation position position 0 No supply to appliance e g only DHW mode 0 DHW mode is OFF only heating mode 86 190 The temperature in F set on the BC10 cannot ECO Economy mode The DHW will only be reheated to be changed with a room controller The supply 140 F 60 C if the temperature has significantly temperature does not rise above this set fallen This reduces the number of burner starts temperature maximum supply temperature set and saves energy As a result the water may be a point 180 F 82 C bit colder initially Aut The temperature is determined automatically on 86 140 The temperature set on the BC10 is a temperature the basis of the heating curve If no room controller that cannot be changed using a RC thermostat is connected the maximum supply temperature is 180 F 82 C Aut The temperature is set on the thermostat e g RC35 If no thermostat is connected the Tab 19 Setting of the space heating water temperature 10 9 8 110 My E BBB 0 A S Aut
111. tive Locking fault The boiler no longer receives a heat AG I H E No connection to EMS EMS bus system is overloaded UBA 3 MC10 demand The heating system does not heat is defective any longer Locking fault AG I H2H Water pressure sensor generates a fault code The digital water No heating operation and no DHW pressure sensor is defective Locking fault Abe H B No communication with BC10 Contact problem at BC10 or BC10 is ECTS settings are no longer takeniover by ROxx devices defective Locking fault The water flow to the downstream heating H ig g amp The contacts to the switch sensor have shorted or are interrupted the circuits may be faulty now they can no sensor has been connected incorrectly or is defective longer be provided with the required heat capacity Locking fault Heating circuit pump 1 is activated R12 HiE WM10 not available or no communication WM10 or bus circuit continuously connected incorrectly or defective WM10 is not recognized by the RC thermostat Locking fault Both RC35 and RC20 activate heating Conflicting addresses Both RC20 and RC35 are registered as Master circuit 1 and DHW Depending on the HiB H25 heating programs set and the required room temperatures the heating system can no longer work correctly DHW mode does not work well Since there is no actual room temperature Locking fault information room influence and Lu H emperature sensor The integrated temperature sensor of optimi
112. ucts to locate leaks Start up procedure 9 NOTICE gt If the supply pressure is too low check the gas supply pipe or contact the relevant gas utility company if the required supply pressure is not available gt If the supply pressure is too high a gas pressure regulator must be integrated upstream of the gas fitting Contact the gas utility company Close the gas valve Remove the gauge connection tube and tighten the screw plug on the testing nipple again Open the gas valve again by pushing on the gas valve and turning it 1 4 rotation in a counterclockwise direction 9 8 Carry outa leakage test in operating conditions WARNING N Leaks may be caused to pipes and screw connections during commissioning and maintenance activities Carry out a proper leak test Only use approved leak detection agents for leak detection e Press and hold the Chimney sweep button fig 62 3 approx 2 seconds until the dot in the right hand bottom corner of the display fig 62 9 appears table 12 Flue gas test page 36 Afterthe LED Burner operation fig 62 6 has lit up wait for 1 minute until the boiler is burning at full load e Use a foaming product to check all sealing locations in the total gas circuit of the burner while the burner is active Press the Chimney sweep button fig 62 3 to clear the reading gt table 12 Flue gas test page 36
113. ween the UBA 3 and the BC10 basic controller H n Any display code with a dot in bottom right hand corner eB operati perating phase The boiler is in flue gas test or service mode H 200 Operating phase 1 The boiler is in heating mode Hsk ano Any display code with a blinking dot in bottom right hand corner a Operating phase The room temperature is too high The boiler is in manual operation mode LH 2G Operating phase 1 The boiler is in DHW mode LH Operating phase 20 Pump run over time via the external hot water cylinder 130 seconds at 1 minimum speed The LED Burner operation is off BR Operating phase The switch optimization program is activated 202 This program is activated if there has been a DHW request from an RC The room temperature is not possibly 1 regulator more frequently than once every 10 minutes This means that reached the boiler cannot be restarted until at least 10 minutes have elapsed since initial burner start up OF 305 Operating phase 1 The boiler cannot start up temporarily after a DHW request has ended HE 3H3 Pre operative phase The boiler prepares for a burner start up whenever a heat demand or a DHW request arises ODE HEB Readiness for operation The boiler is in standby mode Th
114. y fig 62 9 appears table 12 Flue gas test page 36 Afterthe LED Burner operation fig 62 6 has lit up wait for 1 minute until the boiler is burning at full load 44 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Measure the gas supply pressure and enter it in the start up report paragraph 15 1 Start up report page 68 To obtain the best preformance of the appliance the gas supply pressure must be Gas supply Senel gas LPG inch ressure n W C mbar P mbar dus Min 7 17 4 8 19 9 Nom 8 19 9 11 27 4 Max 10 5 26 1 13 32 3 Tab 17 Gas supply pressure Press the Service button fig 62 4 repeatedly until the temperature reading is shown in the display e Press the Chimney sweep amp button fig 62 3 to clear the reading table 12 Flue gas test page 36 10 9 8 6720645916 47 1N Fig 62 BC10 basic controller Main switch Reset button Chimney sweep button Service button Connection possibility for the diagnosis connector LED Burner operation LED Central heat demand Space heating water temperature knob Display DHW temperature knob LED DHW demand e CON OOAWHN WARNING N A leaking testing nipple causes explosive fumes gt Check the used testing nipples for leaks Only use approved detection prod
115. y and in writing Important Information WARNING Important information neither indicating N Danger of fatal accident from explosive i personal injury nor damage to property are fumes marked with this symbol They are separated gt Only carry out work on gas pipes and by lines above and below the text fittings if you are properly registered Additional symbols gt Sequence of steps 2 Cross reference to other points in this document or to other documents Q Listing list entry Listing list entry 2nd level Tab 1 1 2 General warnings Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING N A fire or explosion may result causing property damage personal injury or death gt If the information in these instructions is not followed exactly Buderus 6 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Guideline to symbols and safety instructions 31 1 3 Safety instructions f you cannot reach your gas supplier call the fire department The following instructions must be observed The boiler must only be used for its designated purpose observing the Installation Instructions Only use the boiler in the combinations and with the accessories and spares listed Maintenance and repairs must only be carried out by trained professionals e You a
116. zation of the switch times do not Az HO RC20 HK1 temperat The integrated temperat f lop f th h d the remote control control unit of heating circuit 1 is defective work The EMS works on the basis of the values last set on the remote control Locking fault Since there is no actual room temperature Hegi H E The contacts to the heating circuit flow sensor have shorted or are informatori Hearn eves and i optimization of the switch times do not interrupted the sensor has been connected incorrectly or is defective ork Tab 23 Display codes Buderus 64 Logamax plus GB162 L B 80 100 kW Subject to modifications resulting from technical improvements Display information EN Display codes Main Sub display display Key to display code Other effects code code Heating circuit pump 2 is activated Locking fault depending on the preset value The power Ade HH The contacts to the heating circuit flow sensor have shorted or are to the mixer is switched off and the mixer interrupted the sensor has been connected incorrectly or is defective stays in the state it was last put in can be adjusted manually Locking fault Heating circuit 2 cannot be operated MM10 not available or no communication The heating circuit addres

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