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Service manual - GB162-80kW/100kW - US(en)

1. Remove the fuse holder by turning the bayonet connector 1 in a counterclockwise direction using a flat head screw driver Remove the fuse from the fuse holder Measure the fuse using a multimeter If the fuse has an infi nite electrical resistance it is defective Replace the defective fuse with a new 5 AT 2 spare fuse Install the UBA 3 burner automat in reverse order of removal e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 A DANGER OF FATAL ACCIDENT L amp L due to electric shock DAMAGE TO THE INSTALLATION To prevent damage do not insert the multimeter measuring electrodes too far into the holes of the plug and socket connection e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Set the multimeter to VAC 1 Minimum measuring range 250 VAC Remove the 120 VAC plug 2 from the fan unit e Connect the multimeter to the two outer contacts blue and brown of the fan unit power supply plug 3 e Switch on the power supply to the heating system see section 79 e Put the main power switch on the control panel in position 1 On see section 80 e Put the boiler
2. Main Sub a display a display code code OY 28S LES tA 6 ll iC Je 1D IES ty 24 y 13 18 dE cor gF 2BD gF elt Salus w Ly el 266 oat yo As gP ele eu 2 td ey cot ey cad Buderus Display code a Meaning Blocking fault code The return temperature sensor section 1 31 has measured a cur rent return water temperature higher than 203 F 95 C Locking fault code The flue gas sensor tem perature is too high Locking fault code The safety temperature switch has measured an excessively high tem perature and is open or no connection is made between contacts 50 and 78 of the UBA 3 mounting base CAUTION The boiler can have a flue gas ther mostat or a connection between contacts 50 and 78 of the UBA 3 mounting base depend ing on the boiler type Locking fault code The flue gas sensor con tacts have shorted Locking fault code The flue gas sensor con tacts are open Blocking fault code The heating system water pressure is too low and is less than 3 PSI Neither the boiler nor the pump are started up As soon as the water pressure of the heating system is 14 PSI or more the display code 2E 20 1 will disappear and both the boiler and the pump will start running As soon as the water pressure of the heating system is less than 6 PSI the boiler perfor ma
3. Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 93 EA Appendix General specifications unit Gas category Rated thermal load btu h Rated heating capacity btu h heating curve 176 140 F 80 60 C Rated heating capacity btu h heating curve 122 86 F 50 30 C Boiler efficiency at max capacity heating curve 176 140 F 80 60 C Boiler efficiency at max capacity heating curve 122 86 F 50 30 C CSA Output btu h De ration altitudes 2 000 4 000 ft AFUE at 80 180 F 27 82 C BTS 2000 at 80 180 F 27 82 C part load BTS 2000 at 80 180 F 27 82 C full load 1 000 ft Heating Maximum flow temperature F C Maximum working pressure boiler PSI bar Minimum water circulation volume Gal h 1 h Supply temperature F C Resistance at AT 38 F 20 C psi mbar Heating circuit volume of heat exchanger Gal L Pipe connections boiler without pump group Gas connection in Heating water connection in Condensate connection in mm Flue gas values Condensate quantity at 104 86 F 40 30 C Gal h L h pH value of condensate pH Flue gas mass flow rate full load g s Flue gas temperature 176 140 F F C 80 60 C full load Flue gas temperature 176 140 F F C 80 60 C partial load Flue gas temperature 122 86 F F C 50 30 C full load Flu
4. Step 14 Set the DHW mode On or Off with the nese or 8 buttons E is On E is Off Note If c is set the frost protection for the internal or external hot water tank heater is switched off Step 15 Have at least 5 seconds passed without a button being pressed and or has the main voltage been interrupted Yes Step 17 No gt Step 16 Step 16 Press the o t button Step 17 15 Display reading Currently measured heating system supply temperature in F Step 1 See also section 27 Display readings page 21 Any adjustments that you have made have been confirmed Buderus 16 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Step 1 Switch On the power supply to the boiler Step 2 e Turn the main power switch on the BC10 to position 1 On also see section 14 Step 3 The LED of the UBA 3 section 1 32 lights up for 1 second This means that the UBA 3 is reading the KIM When installing a new KIM or a new UBA 3 the LED will flash at a high frequency for max 10 seconds while the data is being exchanged Step 4 88 8 Operating code The display is tested during starting up immediately after switching on the main voltage This code is displayed for a maximum of 1 second See also section 29 Display codes and other symptoms page 21 Step 5 Operating code A communic
5. e Zero the digital pressure gauge CAUTION EX Throughout the measuring operation keep the pressure gauge in the same position horizontal or vertical in which it was zeroed e Loosen the gas air ratio testing nipple screw 1 by two turns e Connect the pressure gauge to the gas air ratio testing nipple 2 e Open the gas stop valve as indicated in section 81 e Switch on the power supply to the heating system see section 79 e Put the boiler in service mode see section 21 e During service mode adjust the capacity to L 2 5 25 with an 80 kW boiler or L 2 0 20 with a 100 kW boiler e Briefly wait for the boiler to modulate down to minimum capacity 84 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements wrong correct wrong 15 10 5 0 5 Pa 0 15 0 10 0 05 0 00 0 05 mbar 0 06 0 04 0 02 0 00 0 02 inch W C f l turn counterclockwise turn clockwise e Check the gas air ratio The gas air ratio is measured as a pressure difference between the pressure in the gas valve and the ambient pressure This pressure difference must be between 0 04 0 inch W C As a result the nominal pres sure difference is 0 02 inch W C e l necessary adjust the gas air ratio using the set screw 1 a NOTE The set screw is located behind the cover e Switch off the power supply to the heating system se
6. Diagnosis En E Locking fault code The fan unit section 1 20 is running irregularly while starting up fat Ei at TT Step 1 O Attempt to rectify the fault by temporarily replacing the fan unit see section 86 Step 2 Has the fault been remedied Yes Section 67 No gt Section 66 Blocking fault code The boiler has been switched off for a couple of seconds since it had A 4 ar SF El been operational for 24 hours This is a safety check Step 1 e Fully switch off the DHW mode and the heat demand and check that the fan unit remains operational after 1 minute Step 2 Is the fan unit still operational Yes gt Section 66 No gt Section 67 E Locking fault code The fan unit section 1 20 is running too slowly Er fO 42 tet t tt Step 1 Check that the fan unit is not dirty or wet see section 86 Step 2 Is the fan unit dry and clean Yes Step 4 No Step 3 Step 3 Diagnosis The fan unit is dirty or wet Action Clean or replace the fan unit see section 86 Step 4 e Check that the main voltage at the grounded plug is between 102 VAC and 132 VAC Step 5 Is the main voltage sufficient Yes Step 7 No Step 6 Step 6 Diagnosis The main voltage is not OK Action Solve the problem in the electrical system gt Section 67 Step 7 Diagnosis The fan unit is defective Action Replace the fan unit see section 86 Step 8 Has the fault been remedied Yes
7. O Hang the BC10 from the boiler 2 using the 2 hooks on the left and the right 1 e After completing the service activites install the BC10 on the boiler door in reverse order of removal and secure the BC10 with the 2 screws Buderus 56 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Close the cover of the BC10 on the front of the boiler 1 e Open the door lock by turning it a quarter turn counterclock wise using a bleed key 1 Push the lock down 2 and open the door 3 e f a pump group is available Remove the casing of the pump group 4 O f a pump group is available Close the heating supply and return isolating valves 1 by turning them in a clockwise direction closed position at a right angle to the pipework e f a pump group is available Close the gas stop valve 2 by turning it in a clockwise direction closed position at a right angle to the pipework e Switch off the power supply to the heating system see section 72 e if a pump group is available Remove the casing of the pump group as indicated in section 73 e Close the service valves if a pump group is available see section 74 1 Loosen the cap on the automatic air purging system located on the top left hand part of the boiler by turning it through
8. e Open the 2 snap closures 1 on the left and the right and remove the condensate water tank U sl 2 Remove both clamp springs Remove both the ground lead of the heat exchanger and the ground lead of the ionization circuit as instructed in section 108 90 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Actions ww DANGER OF FATAL ACCIDENT 4 5 due to electric shock e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 Remove the cover from the connection tray see section 114 Remove the UBA 3 as instructed in section 82 O Install the new UBA 3 in reverse order of removal Install the lid on the connection tray in reverse order e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 e e Remove the heat exchanger e Install the new heat exchanger and all other parts in reverse order e Fill and purge the heating system see section 78 e Open the gas stop valve as indicated in section 81 e Close the boiler door and install the casing of the pump group in reverse order of removal e Switch on the power supply to the heating system see section 79 Buderu
9. Section 67 gt Section 67 gt Section 66 Locking fault code The pressure sensor section 1 pos 30 failed to measure a pressure Ll 2 L E E E Ef increase on the heating side during any of four attempts TT Step 1 e Check the pump for mechanical obstructions as instructed in section 87 Step 2 Is the pump blocked Yes Step 3 No Step 4 Step 3 Diagnosis The pump is blocked Action Attempt to start up the pump again as indicated in section 87 or replace gt Section 67 the pump as indicated in section 92 Step 4 Is the pump running while is displayed Yes Step 5 No step 15 Step 5 e Check the pump for contamination as instructed in section 91 Step 6 Is the pump dirty Yes Step7 No Step8 Step 7 Diagnosis The pump is dirty Action Clean pump see section 91 gt Section 67 Step 8 Is the expansion tank connected to the supply pipe Yes gt Step 9 No Step 10 Step 9 Diagnosis The expansion tank is connected to the supply pipe gt Section 67 Action Connect the expansion tank to the return pipe Step 10 e Check the pressure sensor for contamination as instructed in section 128 Step 11 Is the pressure sensor dirty Yes Step 12 No Step 13 Step 12 Diagnosis The pressure sensor is dirty Action Clean the pressure sensor see section 128 gt Section 67 Buderus 40 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Step 13 Step 1
10. Pin 81 KIM gt Pint oa DY O FLUKE 73111 mermera e Set the multimeter to Measure resistance 1 e Check the safety temperature sensor cable for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the black contacts low voltage connector pins 38 and 39 on the UBA 3 mounting base 3 e Check the safety temperature sensor cable for internal short circuiting The electrical resistance measured between two random wires must be infinite e Measure the electrical resistance over the safety temperature sensor cable to ground The electrical resistance must be infi nite for every individual wire e Disconnect the return temperature sensor plug as instructed in section 93 1 Buderus i 16 pin high voltage connector y Q 3 a po LD AAA 81 pin low voltage connector LU n pogoni opoopoga Pin 1 P pgoopog _p pddddo 28 Pin 81 OOOO Onmin l KIM Pina a e ptr Pin 16 16 pin high voltage connector 3 73111 vune a e Set the multimeter to Measure resistance 1 e Check the return temperature sensor cable for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the bla
11. wio PRA AAA EITA SEEN E IA PRI EAEE EESE A EEEL I A i er O pal ve OF gr 32 Es SAR Saas 8 SNe Sse S ages 8 BBE 85 O sn Or Om P Oz Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Buderus 92 section 132 Legend of electrical wiring diagram section 133 Power rating 81 pole connector AC 0 10 24 and 230 V 16 pole connector AC 120 V Connection for pump in connection kit accessory Fan Gas valve Transformer Glow ignitor Earth lonization Pressure sensor Return sensor Safety temperature sensor Supply sensor Flue gas sensor Fuse 5 amp FAST sand filled BUS function modules Connector for BC10 Basic Controller Room controller RC and EMS bus Outdoor temperature sensor On off temperature controller potential free DHW sensor External switch contact potential free e g floor heating External three way valve Boiler pump 120 VAC max 100 W DHW pump pump 120 VAC max 100 W DHW re circulation pump pump 120 VAC max 100 W 29 490 Main power connection 120 V 60 Hz 23 462 max permissible 5 A Mains switch 120 VAC function module Ground MBNAAABYNSA D oO N be Se me w o a N o N Q NE section 134 Sensor resistance readings Sos N N 18 787 15 136 12 268 10 000 8 197 6 754 5 594
12. DANGER OF FATAL ACCIDENT 2 due to electric shock e Switch off the power supply to the heating system see section 72 e Open the boiler door and remove the casing of the pump group as instructed in section 73 e Remove the UBA 3 as instructed in section 82 e Remove the cover from the connection tray see section 114 e Pull the supply cord plug from the pump as instructed in section 88 81 pin low voltage connector eines EEEE Pin o SHEA Pin 16 16 pin high voltage connector 3 O Set the multimeter to Measure resistance 1 e Connect the multimeter 2 e Check the power supply cord of the pump for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 e Check the power supply cord of the pump for internal short circuiting The electrical resistance measured between two random wires must be infinite Measure between the plug and the black contacts high voltage connector pins 12 13 and 14 on the UBA 3 mounting base 3 e Attach the pump power supply cord plug in reverse order of removal Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 65 Actions e Install the lid on the connection tray in reverse order 81 pin low voltage connector eine PERERA Y pin Asa Pin 16 16 pin high voltage connector O Install the UBA 3 i
13. Section 67 No gt Section 66 t S y Locking fault code The fan unit section 1 20 is running too fast fay Je 15f Tt TT Step 1 e Check the plug and socket connection of the tacho cable to the fan unit This is the narrow plug see section 85 2 Step 2 Is the plug and socket connection okay Yes Step 4 No Step3 Step 3 Diagnosis The plug and socket connection of the tacho cable to the fan unit is loose gt Section 67 Action Replace the plug and socket connection see section 86 2 Step 4 e Check the fan unit tacho cable as indicated in section 85 Step 5 Is the tacho cable okay Yes Step 7 No Step 6 Step 6 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 7 e Check that the main voltage at the grounded plug is between 102 VAC and 132 VAC Step 8 Is the main voltage okay Yes Step 10 No Step 9 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 43 E Diagnosis Step 9 Diagnosis The main voltage is not OK Action Solve the problem in the electrical system Step 10 e Check that there is no obstruction in the fan unit burner heat exchanger or flue gas system Step 11 Is there an obstruction Yes No Step 12 Diagnosis There is an obstruction in the fan unit burner heat exchanger or flue gas system Action Remove the obstruction Step 13 e C
14. As soon as a non flashing dot is shown in the bottom right hand comer of the display the flue gas test has been ted This means that the boiler is in heating mode at a capacity of 100 for a maximum period of 30 minutes The maximum heating system flow temperature set on the BC10 basic controller now applies DHW mode is not possible during the flue gas test Press the button Display reading Currently measured heating system water pressure in bar See also section 30 Display readings page 22 Press the 5 button Operating code A flue gas test is being carried out or the boiler is in service mode Flue gas test The boiler is in heating mode at a capacity of 100 for a maximum of 30 minutes The maximum heating system flow temperature set on the BC10 basic controller now applies Service mode The boiler is in heating mode at a reduced capacity for a period of 30 minutes The maximum heating system flow temperature set on the BC10 basic controller now applies DHW See al Press Have Deacti To deactivate the flue gas test mode is not possible during the flue gas test or during service mode Iso section 32 Display codes and other symptoms page 22 and further the 6 button Display reading Currently measured heating system flow temperature in C See also section 30 Display readings page 22 30 minutes passed or has the mains voltage been interrupted ivate flue gas test Pres
15. No Off No Off Other symptoms The target room temperature pos sibly is not reached Possibly no DHW operation No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW Diagnosis gt section 37 gt section 38 gt section 39 gt section 40 gt section 40 gt section 41 gt section 37 gt section 37 gt section 42 gt section 37 gt section 37 gt section 43 gt section 44 24 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 10 Main Sub a display a display code code JA 264 30 211 3F 213 Jat i FLO J Jip Oig mip J To 224 Fie Jeet MELO 3218 ML 220 JT O Jeet qu dde J44 4225 SE 26H 11 SH 1 SH Display code a Meaning Blocking fault code The fan unit ta
16. 7746700422 73961 7746900404 73958 74549 7746900403 73081 7101410 7746900406 7746900384 7746900385 7746900386 7746900387 7746900388 7746900398 7746900405 7746900400 73948 7746900394 7746900395 73986 Pos Description 1 Door 2 Sealing door 3 Door lock 4 Hinge door 5 Wall mounting bracket 6 Bracket left 7 Bracket right 8 Adjusting foot 9 Transport slide L R 10 Drawer modules 11 Screw 4 2 x 8 5 x 10 pc 12 Condensate collector 13 Seal condensate collector 14 Seal 80 mm 3 2 15 Upper side condensate collectors 16 Mounting flue gas pipe 17 Exhaust pipe 20 Condensate collector 21 Seal condensate collector 22 Drain pipe 23 Sealing bush white 24 Condensate drain pipe 25 Fan 26 Seal Fan 27 O ring 70 x 3 2 pc 28 Venturi 29 Seal 60 mm 2 4 30 Gas valve 31 Seal 33 x 24 x 3 5 10 pc 32 Gas pipe 33 Flange Gas valve 34 O ring 10 pc 36 Screw M5 x 20 10 pc 37 Screw M5 x 16 10 pc 38 Screw M6 x 16 10 pc 39 Air inlet pipe 40 Sealing 10 pc 41 Air vent revision set 42 Clip 43 Sensor NTC 44 Clip 3 x 2 pc 45 O ring 9 19 x 2 62 10 pc 46 Pressure sensor 47 O ring 14 x 1 78 10 pc 48 Return Supply pipe 49 Connection nipple CH 50 Clip 51 O ring 10 pc 52 Flue gas sensor 56 Mountig set with sight glass with glow ignitor with ionization electrode 60 Heat exchanger Buderus 96 Logamax plus GB162 80 kW 100 k
17. Connect the plug and socket connection correctly e Check the cable of the ionization electrode as indicated in section 106 Is the wiring okay Diagnosis The wire harness is defective Action Replace the wire harness or the affected part e Check the ionization electrode as indicated in section 105 and section 107 Is the ionization electrode okay Diagnosis The ionization electrode is defective Action Replace the ionization electrode see section 103 e Temporarily remove the combustion air supply and exhaust gas outlet connections from the top of the device Put the device into operation as instructed in section 20 Note Ensure that there is sufficient air supply during this test Check that the fault has been rectified Has the fault been remedied Diagnosis The cause of the fault is to be found in the air inlet flue gas outlet system Action Switch off the device and remedy the fault but before opening the gas valve section 1 21 Yes No Yes No Yes No Yes No Yes No Yes No gt Step 52 gt Step 51 gt Section 67 gt Section 67 gt Step 54 gt Step 57 gt Step 56 gt Section 67 gt Step 60 gt Step 59 gt Section 67 gt Step 63 gt Step 62 gt Section 67 gt Step 65 gt Section 66 gt Section 67 Locking fault code Flames ionization current were measured after a heat demand occurred Step 1 e Check the onization electrode a
18. No e Check the meaning of the new fault see section 29 and resolve the fault O Install the removed components in reverse order of removal Install the boiler casing e Put the main power switch on the control panel in position 0 Off see section 70 e Put the main power switch on the control panel in position 1 On see section 80 The fault has now been rectified The Logamax plus GB162 80 kW 100 kW is working correctly Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements gt Step 4 gt Step 7 gt Step 6 gt Step 5 gt Step 2 gt Step 8 gt Section 67 Buderus 55 Actions To make it easier to operate the BC10 when the boiler door is open and to make it easier to read the display the BC10 can be temporarily attached to the boiler in a suspended position Proceed as follows Put the boiler out of operation see section 69 70 and 72 e Open the door as instructed in section 73 170 190 amp Aut TD TJ ecsqe e Put the selector for the DHW temperature setting 1 and the selector for the maximum heating system supply tempera ture 2 in position O e Remove the cable ties 1 e Remove the basic controller BC10 2 o EQ 9090 e Putthe main power switch 1 on the control panel in position 0 Off
19. Section 66 No Step 26 Buderus 32 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Diagnosis 6 Step 26 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 27 e Check that the heating boiler starts up to supply hot water according to section 24 Step 28 Does the heating boiler start up Yes Step 30 No Step 29 Step 29 e Check the meaning of the current display code in section 29 and resolve the fault gt Section 67 Step 30 e Check the pump for contamination as instructed in section 91 Step 31 Is the pump dirty Yes Step 32 No gt Step 33 Step 32 Diagnosis The pump is dirty Action Clean pump see section 91 gt Section 67 Step 33 e Check the following elements for contamination and or damage outer flue duct air suction tube orifice if present see section 135 fan unit connection between fan unit and burner burner heat exchanger flue gas system Step 34 Are the above mentioned components clean and free of damage Yes Step 36 No gt Step 35 Step 35 Diagnosis The above components are contaminated or damaged gt Section 67 Action Clean and or replace the relevant components Step 36 e Check the static and dynamic gas supply pressure as instructed in section 117 Step 37 Are the static and dynamic gas supply pressures correct Y
20. Turn off all electric power to the appliance if service is to be performed 2 Set the thermostat or other operating control to lowest setting 3 Close main gas shut off valve 708 375A 2172B e Open the boiler door and remove the casing of the pump group as instructed in section 73 Buderus e Open both service valves 1 e Open the gas stop valve 2 e Open the cover of the BC10 on the front of the boiler as instructed in section 69 110 120 90 130 E 140 au 0 Aut L eoe Put the selector for the DHW temperature setting 1 and the selector for the maximum heating system supply tempera ture 2 on the control panel in the required position e Switch on the power supply to the heating system see section 79 Put the main power switch on the BC10 in position 1 On see section 80 e Close the cover of the BC10 on the front of the boiler see section 71 e Open the boiler door and install the casing of the pump group see section 77 60 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements DANGER OF FATAL ACCIDENT L 5 due to electric shock e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 Undo the mounting screw 1 of the UBA 3 Remove the UBA 3 by moving it in the direction indicated by the arrow 2
21. gt Section 67 Action Increase the setting of the RC regulator or ON OFF controller as indicated in the Operating instructions for the regulator or controller Step 4 e Check that the LED Central heat demand on the BC10 lights up see section 14 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 33 ea Diagnosis Step 5 Does the LED Central heat demand light up Yes Step 11 No Step6 Step 6 e Check the ON OFF controller according to section 114 or the RC regulator according to section 115 Step 7 Does the boiler start heating operation within approx 3 minutes H Yes Step 8 No Step 9 Step 8 Diagnosis The thermostat cable is defective Action Replace thermostat cable gt Section 67 Step 9 Diagnosis The ON OFF controller the RC regulator or the RCC module if present is defective Action Replace ON OFF controller RC regulator or RCC module The RCC module is a suspended connection tray required for certain RC regulators Step 10 Has the fault been remedied Yes Section 67 No Section 66 Step 11 Check that the heating system supply temperature on the BC10 or on the RC regulator or ON OFF controller has been set high enough as instructed in section 81 or in the operating instructions of the regulator or controller Step 12 Is the heating system supply temperature adjusted to a high enough setting Yes Step 13 No St
22. venturi pipe 1 Install the new O ring in the fan unit and then install the venturi pipe including the gas valve on the fan unit in reverse order of removal e Install the gas air unit including the burner cover on the heat exchanger in reverse order of removal e Install the air suction pipe on the fan unit Re connect the gas supply to the gas valve Ensure when doing so that the flat rubber sealing ring is correctly fitted Fit the power supply plug or plugs to the gas valve and to the fan unit and fit the tacho cable plug to the fan unit e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 Remove the casing of the pump group as indicated in section 73 e Open the cover of the BC10 as instructed in section 69 Loosen the vent screw on the front of the pump see section 80 Put the boiler in flue gas test mode see section 20 e Check that the pump is running while operating code GC_ is displayed or while the locking fault code 2L_ 266 is dis played The locking fault code may be displayed after appr 4 minutes The pump may become mechanically blocked if the boiler has been out of use for an extended period e In this event attempt to start the pump again using a screw driver Use the screwdriver to turn the pump rotor in the direc tion of rotation shown on the pump identification plate e Stop the flue ga
23. 31 Checking the supply safety return and Replacing cleaning the burner 88 DHW temperature sensors 68 Replacing cleaning me hiaat a kiss seat an Checking the supply safety return and Replacing cleaning the siphon 89 DHW temperature sensors cables 69 Checking the transformer internal electrical T resistance 6 1 cece eee 85 Technical specifications o o 94 Checking the transformer power supply cord and low voltage cord oooooo o oo o 86 V Checking replacing fuses 2 00005 61 Checking replacing the pressure sensor VONIUM 2 ccGceengdat cae Gawwe ar 95 pollution ves c eve ea da eae ds 89 W D Working pressure 000 cee eee eee 94 Draining the system 0000 eee eee 57 E Electrical wiring diagram o oo oo o 92 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 99 United States and Canada Bosch Thermotechnology Corp 50 Wentworth Avenue Londonderry NH 03053 Tel 603 552 1100 Fax 603 965 7581 www bosch climate 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 6720614965 0005
24. 5 e Check that the heating curve of the external temperature dependent RC regulator has been set high enough as instructed in the operating instructions of the relevant regulator Step 6 Has the heating curve of the external temperature dependent RC regulator been set high enough Yes gt Step 8 No Step7 Step 7 Diagnosis The heating curve setting is too low Action Increase the heating curve setting of the external gt Section 67 temperature dependent RC regulator as instructed in the operating instructions of the relevant regulator Step 8 e Check that enough thermostatic valves are open on the radiators convectors etc Step 9 Are enough thermostatic valves open on the radiators convectors etc Yes Step 11 No Step 10 Step 10 Diagnosis There are not enough thermostatic valves open on the radiators convectors etc gt Section 67 Action Open more thermostatic valves Step 11 E Check that no hot water tap is dripping and that there is no leakage in the hot water pipe Step 12 Is a hot water tap dripping or is there a leakage in the hot water pipe Yes Step 13 No Step 14 Step 13 Diagnosis The hot water tap is dripping or the hot water pipe is leaking gt Section 67 Action Fix the dripping hot water tap or the leakage in the hot water pipe Step 14 Find out whether a hot water tap or taps have been opened on brief consecutive occasions Buderus 36 Logamax plus GB162 80 kW 100 kW Subject to modifications resu
25. 72 e Remove the multimeter e Connect the plug of the ionization electrode e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 Actions e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 ELOK E 73111 vu mere e Disconnect the plug and socket connection of the ionization electrode 1 e Set the multimeter to Measure resistance 2 e Measure the ionization electrode to ground to make sure that there is no short circuit between the ionization electrode and ground The electrical resistance between the ionization elec trode and ground must be infinite 3 e Attach the plug of the ionization electrode in reverse order e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 77 Actions gt DANGER OF FATAL ACCIDENT LIS due to electric shock DAMAGE TO THE INSTALLATION EX To prevent damage do not insert the multimeter measuring electrodes too far into the holes of the plug and socket connection e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Remove the UBA 3
26. Buderus 78 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements ASA X Xx e Check the ionization electrode for signs of wear 2 damage 3 or contamination 4 e Replace the ionization electrode if necessary e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Check that the ground lead of the onization circuit 1 has been installed correctly Note The upper cable is the ground lead of the heat exchanger pump the lower cable 1 is the ground lead of the onization cir cuit e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 Actions e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 gt rectly to the gas valve e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 e Open the boiler door as instructed in section 73 O Set the multimeter to Measure A
27. If the difference between the static and dynamic gas supply pressures is too much this indicates that the dynamic gas supply pressure is not OK Statically measured gas supply pressure Natural gas LPG inch W C mbar inch W C mbar Min 5 12 4 8 19 9 Nom 8 19 9 11 27 4 Max 10 5 26 1 13 32 3 1 Measured statically perpendular to flow at full load e Switch off the power supply to the heating system see section 72 e Close the gas stop valve as indicated in section 74 Remove the pressure gauge e Tighten the gas connection pressure testing nipple screw e Open the gas stop valve as indicated in section 81 e Check the gas connection pressure testing nipple for leaks using a foaming agent which has been approved for gas leak testing Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 83 Actions e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 DANGER OF FATAL ACCIDENT FIRE A from explosive fumes All work on gas pipe work and fittings must be carried out by authorized gas technicians After carrying out these activities check the measuring nipples used for leaks using a foaming agent which has been approved for gas leak testing e Switch off the power supply to the heating system see section 72 e Open the boiler door and remove the casing of the pump group as
28. P 20 2 or read out the pressure from the analog pressure gauge 3 in the pump group Li UT e Purge all radiators in the heating system Start at the lowest floor of the premises and then work your way up from floor to floor If the boiler has been in use for approx one week and the pres sure reading on the display is less than 14 PSI the system has to be topped up The pressure loss in a heating system is caused by air bubbles escaping via screw connections and automatic air purging units The oxygen contained in the fresh heating water will also escape from the heating water after some time and cause the water pressure in the heating system to drop Should it be necessary to top up the heating system more fre quently because the water pressure keeps dropping water is probably escaping due to a leakage in the heating system or a defective expansion vessel In this case the cause of the water loss must be removed as soon as possible Ne K as e Drain the pump by removing the vent screw at the front of the pump 1 CAUTION EA Since a little heating water may escape when purging the pump you are advised to lay a dry cloth under the pump CAUTION A Correct purging of the pump will help ensure that it runs for its specified service life The sliding bearing located behind the vent screw is lubricated by the heating water e Check the water pressure of the
29. Section 67 gt Section 66 Buderus 41 2 Diagnosis Operating code The tacho signal of the pump is missing yey 10 Jn TT Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 BA EEN Jar E Jz not available during the pre operative phase 0 E Step 1 e Check that both plug and socket connections of the fan unit are correctly fitted see section 86 2 Step 2 Are the plug and socket connections fitted correctly Yes Step 4 No Step3 Step 3 Diagnosis The plug and socket connections have not been installed correctly gt Section 67 Action Reconnect the plug and socket connections of the fan unit Step 4 e Check the fan unit activation 120 VAC as indicated in section 83 and section 131 Step 5 Is the activation okay Yes Step 9 No Step 6 Step 6 e Check the fan unit power supply cord 120 VAC as instructed in section 84 Step 7 Is the fan unit power supply cord okay Yes gt Section 66 No Step 8 Step 8 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 9 O Check the fan unit tacho cable as indicated in section 85 Step 10 Is the tacho cable okay Yes Step 12 No Step 11 Step 11 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 12 e Check that the main voltage at the grounded plug is between 102 VAC and 132 VAC Step 13 Is the main vo
30. are not enough thermostatic valves open on the radiators convectors etc Action Open more thermostatic valves e Attempt to rectify the fault by temporarily replacing the room thermostat or external temperature dependent controller Has the fault been remedied Yes No gt Step 11 Step 10 Section 67 gt Step 14 gt Step 13 gt Section 67 gt Section 67 gt Section 66 Operating code The supply temperature sensor section 1 24 has detected that the current heating system supply temperature is higher than the temperature entered at the BC10 section 1 4 or that it is higher than the heating system supply temperature calculated according to the heating curve or that itis higher than the heating system supply temperature calculated for the purposes of DHW supply Step 1 e Check that the heating system supply temperature setting on the BC10 is high enough see section 81 Step 2 Has the heating system supply temperature been set correctly on the BC10 Yes Step 4 No Step 3 Step 3 Diagnosis The heating system supply temperature setting is too low Action Increase the heating system gt Section 67 supply temperature setting on the BC10 or on the RC regulator or ON OFF controller as instructed in section 81 or in the operating instructions of the regulator or controller Step 4 Has an RC regulator been set as an external temperature dependent controller Yes gt Step 5 No Step 8 Step
31. bottom right hand corner of the display the boiler will run in heating mode at 100 performance for a maximum of 30 minutes The maximum heating system supply temperature set on the control panel now applies DHW mode is not possible during service mode operation Step 5 To activate service ab step 2 O Press and hold the E 4 buttons for more than 2 seconds Step 6 L __ Display setting Maximum capacity setting during heating mode as a See also section 28 Display settings page 21 In this case L _ _ 100 Service mode has been activated You can now temporarily lower the boiler performance to partial load to check and if relevant adjust the gas air ratio or the ionization current Step 7 O Press and hold the ngese button until the display shows for boilers at sea level L 25 with a 80 kW boiler or L eE with a 100 kW boiler Step 8 L 2 or L 25 Display setting Minimum capacity setting during service mode asa See also section 28 Display settings page 21 Within a couple of seconds the boiler will be modulated back to 20 of its capacity in case of an 80 kW boiler and 25 in case of a 100 kW boiler The maximum heating system supply temperature set on the control panel now applies section 1 4 Check the gas air ratio or the ionization current and if necessary set the gas air ratio according to section section 119 Measuring and adjusting the gas air ratio page 84 or section 104 Measure the ionization current page 7
32. gas air ratio 84 Checking the gas valve electrical resistance Measuring the gas supply pressures static a a mii gh addag aig 80 and dynamic essaa rerrcsasariakisid eamas 83 Checking the gas valve internal electrical TOSIS ANCO corroe rr dd 80 Checking the gas valve power supply plug 79 P Checking the glow ignitor activation 74 PUMP run over time 0 0 0 0 eee eee eee 8 Checking the glow ignitor power supply cord 75 Pump test ooo 8 Checking the glow ignitor resistance 75 Checking the ionization circuit ground lead 79 R Checking the ionization electrode 78 Checking the ionization electrode cable 78 Fleplace Tenses AO 86 Checking the ionization electrode short circuit 77 Heplacng Tha automasi Air PU Sientes 88 Checking the ON OFF controller 82 Aplacing e DEN Temporal a SENGON pass Us Checking the pump activation 65 nepiaciig he CEEC SA NA TRU EDSO nenad Checking the pump mechanical obstruction 64 Replacing Wie TUG JAS SENSO east aaa es Checking the pump pollution 67 Replacing he gas Valve eg ee a Checking the pump power supply cord 65 Replacing the ignition unit oo o oo o 76 Checking the pump tacho cable 66 Replacing O oll pepa Eo qUe ar Checking the RC regulator o o o 82 Replacing ihe UBA o
33. in flue gas test mode see section 20 e Check whether with operating code active there is a voltage of 120 VAC at the two outer contacts blue and brown of the plug e Switch off the power supply to the heating system see section 72 e Connect the fan unit power supply plug in reverse order e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 61 Actions DANGER OF FATAL ACCIDENT LL due to electric shock DAMAGE TO THE INSTALLATION L amp S To prevent damage do not insert the multimeter measuring electrodes too far into the holes of the plug and socket connection e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Remove the UBA 3 burner automat as instructed in section 82 Remove the cover from the connection tray see section 114 81 pin low voltage connector opapadononadoadandnddadoag Pin 1 OOODOOODododnon0dononooododo 28 SSeS eee een 5 y j Pin81 an Gai O Pint POLO OA DOLO 16 pin high voltage connector ELLIE 73111 eer Undo the fan unit power supply cord plug as instructed in section 86 1 e Set the multimeter to Measure resistance 1 e Che
34. more than 2 seconds until the dot disappears Step 25 The boiler performance is then reduced according to the settings made in the Settings menu in section 23 Step 1 page 15 Buderus 14 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Operation ES Step 1 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Step 2 Activate manual operation Yes Step 1 No Step 1 Step 3 To activate manual operation O Press and hold the 3 button for more than 5 seconds Step 4 15 1 Display reading Currently measured heating system supply temperature in F As soon as a flashing dot is shown in the bottom right hand corner of the display manual operation is active This means that the boiler is permanently in heating mode The maximum heating system supply temperature set on the control panel now applies section 1 4 The LED Central heat demand lights up Step 5 O Press the button Step 6 P 224 Display reading Currently measured heating system water pressure in PSI See also section 27 Display readings page 21 Step 7 Press the nome button Step 8 H Operating code The device is in manual operation mode See also section 29 Display codes and other a symptoms page 21 During manual operation the Settings menu in section 23 from step 3 can be used to temporarily change the
35. 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 Pump test If the boiler has not been operational for approx 4 weeks 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 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 supply 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 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 Disposal Dispose of the boiler packaging 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 8 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements The installation must conform to the requirements of the au
36. one rotation Remove the cap of the filling and drain valve of the boiler e Connect the filling hose to the filling and drain valve of the boiler Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 57 e f a pump group is available Open the heating supply and return isolating valves on the pump group open position par allel to the pipework e Close the heating supply and return isolating valves on the pump group in reverse order e if a pump group is available Install the casing of the pump group 1 again e Close the door 2 and then the lock by turning it a quarter turn clockwise using a bleed key 3 Buderus e Open the cover of the control panel as instructed in section 69 e Turn the Space heating water temperature knob 1 and DHW temperature knob 2 counterclockwise to the 0 posi tion as indicated in section 69 e Turn the vent key a quarter rotation to undo the boiler door lock and remove the insulation cover of the pump group as instructed in section 73 To purge the boiler every radiator in the heating system must have a purge facility In some situations it may even be neces sary to provide extra purging facilities at certain locations The boiler itself has an automatic air vent e Loosen the cap of the automatic air vent by turning one rota tion counterclockwise see section
37. other symptoms page 21 Step 44 Have approx 30 seconds elapsed Yes Step 45 No gt Step 44 Buderus 18 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Operation ES Step 45 The fan unit section 1 20 stops Step 46 Have approx 60 seconds elapsed Yes gt Step 47 No Step 46 Step 47 The pump stops See also section 29 Display codes and other symptoms page 21 Step 48 The LED Central heat demand lights up Step 49 o E Operating code The boiler prepares for a burner start up whenever a heat demand arises The fan unit section 1 20 and the pump are started The glow ignitor section 1 27 is activated See also section 29 Display codes and other symptoms page 21 Step 50 0 L Operating code The gas valve section 1 21 is activated See also section 29 Display codes and other symptoms page 21 Step 51 Maximum of four ignition attempts are carried out Does the ionization current exceed 1 4 microamperes within these Yes Step 52 4 ignition attempts No Step 12 Step 52 H Operating code The device is in heating mode See also section 29 Display codes and other symptoms page 21 The LED Burner operation on the control panel section 1 4 lights up The startup load on the boiler is approx 50 for the purposes of flow monitoring and is then modulated up or
38. over the power supply cord and the low voltage cord to ground The electrical resistance must be infinite for every individual wire Install the transformer in reverse order Buderus 86 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Remove the UBA 3 as instructed in section 82 e Remove the cover from the connection tray see section 114 Pin 1 28 55 Pin 81 KIM pint Pa pin 16 16 pin high voltage connector e Set the multimeter to Measure resistance 1 e Check the electrical resistance of the connection between the two black contacts low voltage connector pins 22 and 24 on the UBA 3 mounting base 2 The electrical resistance of this connection must be approximately O Q 2 e Check the electrical resistance of the connection between the two black contacts low voltage connector pins 50 and 78 on the UBA 3 mounting base 2 The electrical resistance of this connection must be approximately 0 Q 2 O Install the lid on the connection tray in reverse order Install the UBA 3 in reverse order of removal e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 Actions e Open the cove
39. pressure is approx 22 PSI Step 10 Diagnosis The pressure sensor is defective Action Replace the pressure sensor see section 128 Step 11 Has the fault been remedied Yes No Buderus gt Step 4 gt Step 3 gt Section 67 gt Step 7 gt Step 6 Section 67 gt Section 67 gt Section 66 gt Section 67 gt Section 67 gt Section 66 54 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Poor electrical contacts UBA 3 defective or KIM defective Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 1 Step 2 Step 3 Step 4 Diagnosis Poor electrical contacts UBA 3 is defective or KIM is defective Action Check the contact between the UBA 3 and the UBA 3 mounting base by screwing the UBA 3 tightly onto the UBA 3 mounting base BC10 and the bottom plate of the BC10 by pushing the BC10 tightly onto the bottom plate all other plug and socket connections remedy any contact problems found O Press and hold the a button for at least 2 seconds See section 14 Is the same fault message shown again Yes No Has the UBA 3 already been replaced Yes No Diagnosis The UBA 3 is defective Action Replace the UBA 3 see section 130 Diagnosis The KIM is defective Action Contact the boiler manufacturer before replacing the KIM See the back of this document for contact details Has a new fault occurred Yes
40. pump tacho cable plug in reverse order of removal O Install the lid on the connection tray in reverse order O Install the UBA 3 in reverse order of removal Buderus 66 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Close the boiler door and install the casing of the pump group in reverse order of removal e Switch on the power supply to the heating system see section 79 O Drain the boiler as indicated in section 75 e Loosen the four Allen screws on the pump 1 e Remove the upper part of the pump e Clean the pump impeller wheel by removing any deposits from the inner edges and or the center of the pump impeller wheel e Install the upper part of the pump in reverse order e Fill and purge the heating system see section 78 DANGER OF FATAL ACCIDENT 4 due to electric shock e Drain the boiler as indicated in section 75 Undo the pump s power supply cord plug and the tacho cable plug as instructed insection 88 and 89 haf Unscrew both unions 1 from the top and bottom of the pump Remove the pump CAUTION LS Use new rubber seals when installing the new pump Install the new pump e Attach the pump s power supply plug and tacho plug Fill and purge the heating system see section 78 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improv
41. speed applies to all Logamax plus GB162 devices This code is displayed for a maximum of 4 minutes oy Operating code The supply temperature Off The target room temperature gt section 36 sensor section 1 24 has detected that the possibly is not reached current heating system supply temperature is higher than the temperature entered at the control panel section 1 4 or that it is higher than the heating system supply temperature calculated according to the heating curve or that it is higher than the heating system supply temperature calculated for DHW mode oy 2716 Blocking fault code The supply temperature No Off The target room temperature section 37 sensor section 1 24 has measured a cur 5 7 possibly is not reached rent heating supply temperature higher than 203 F 95 C Possibly no DHW operation A aq Blocking fault code The safety temperature No Off The target room temperature section 37 sensor section 1 28 has measured a cur 5 7 possibly is not reached rent supply temperature higher than 203 F 95 C Possibly no DHW operation Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 23 EA Symptoms
42. the connection tray see section 114 e Remove the RC regulator from the mounting plate e Remove the mounting plate from the wall RC FA WA FW EV DWV Sopa pp 1 e Use a short length of two pole electric cable to connect the RC regulator including the mounting plate to the orange plug directly at the boiler RC 1 When using an RC regulator which must be connected with an RCC connect the RC reg ulator to the RCC using a short length of two pole electric cable e When using an RCC Check that the RCC has been con nected correctly to the boiler connection tray e Check that the contacts 1 and 2 on the back of the RCC cor respond with contacts 1 and 2 of the orange plug RC 1 e Switch on the power supply to the heating system see section 79 e Adjust the selector for the DHW temperature setting on the control panel to position 0 see section 70 1 e Set the RC regulator to heat demand operation If the boiler runs in heating mode H for approx 3 minutes the cause of the fault lies outside the heating boiler e Switch off the power supply to the heating system see section 72 e Attach the RC regulator to the wall in reverse order of removal Connect the RC regulator to the boiler in reverse order Install the lid on the connection tray in reverse order Close the boiler door as instructed in section 77 Switch on the power supply to the heating system see section 79 e Adjust the s
43. the gas pipe Action Remove the obstruction gt Section 67 Step 16 Has the gas supply pipe been purged Yes Step 18 No Step 17 Step 17 Diagnosis The gas supply pipe has not been purged Action Bleed the gas supply pipe see section 118 gt Section 67 Step 18 e Check that the glow ignitor activates when the operating code DE is displayed see section 100 Step 19 Does the glow ignitor activate when the operating code OE is displayed Yes Step 23 No Step 20 Step 20 e Check the electrical resistance of the power supply cord of the glow ignitor as indicated in section 102 Step 21 Is the power supply cord okay Yes Section 66 No Step 22 Step 22 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 23 Check the electrical resistance of the glow ignitor as indicated in section 102 Step 24 Is the electrical resistance of the glow ignitor okay Yes Step 26 No Step 25 Step 25 Diagnosis The glow ignitor is defective Action Replace the glow ignitor see section 103 gt Section 67 Buderus 46 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Diagnosis 6 Step 26 e Put the boiler in operation see section 19 and check that the glow ignitor activates when the operating code HE is displayed Step 27 Does the glow ignitor activate when the operating code OC is dis
44. the gas utility company to check that there is no nitrogen in the new or existing gas tank and the gas supply pipe Step 3 Is there still nitrogen in the new or existing gas tank and the gas supply pipe Yes Step 4 No gt Step5 Step 4 Diagnosis There is nitrogen in the gas tank and the gas supply pipe gt Section 67 Action Remove the nitrogen in conjunction with the gas utility company Step 5 e Check that the device gas stop valve is open as instructed in section 81 and that the main gas stop valve is open Step 6 Are both gas stop valves open Yes Step 8 No Step7 Step 7 Diagnosis The device gas stop valve and or the main gas stop valve is are closed gt Section 67 Action Open the device gas stop valve as instructed in section 81 and open the main gas stop valve Step 8 e Check the static and dynamic gas supply pressures as indicated in section 117 Step 9 Are the static and dynamic gas supply pressures correct Yes Step 16 No Step 10 Step 10 e Check that there is no obstruction in the gas pipe between the device gas stop valve and gas valve Step 11 Did you find an obstruction Yes Step 12 No Step 13 Step 12 Diagnosis There is an obstruction in the gas pipe Action Remove the obstruction gt Section 67 Step 13 e Check that there is no obstruction in other parts of the gas pipe Step 14 Did you find an obstruction Yes Step 15 No Step 39 Step 15 Diagnosis There is an obstruction in
45. this code continues to flash on Off or No heating operation and no gt section 66 Ho the display there is a fault in the communica flashing DHW tion between the UBA 3 section 1 32 and at 8 Hz the control panel section 1 4 Operating code The boiler is in flue gas test Off No DHW operation or service mode Flue gas test The boiler is in heating mode at a performance capacity of 100 for a period of 30 minutes The maximum heating system supply temperature set on the control panel now applies section 1 4 Service mode the boiler will run in heating mode at a reduced performance capacity for 30 minutes The maximum heating system supply temperature set on the control panel now applies section 1 4 DHW mode is not possible during the flue gas test or during service mode Operating code The boiler is in manual oper Off aR ation mode F Operating code The boiler is in flue gas test Off No DHW operation J or service mode Flue gas test the boiler will run in heating mode at 100 performance capacity for 30 minutes The maximum heating system supply temperature set on the control panel now applies section 1 4 Service mode the boiler will run in heating mode at a reduced performance capacity for 30 minutes The maximum heating system supply temperature set on the control panel now applies section 1 4 DHW mode is not possible during the flue ga
46. up The boiler is in heating mode Step 70 Is the current heating system supply temperature higher than 59 F 15 C Yes Step 59 No Step 69 Buderus 20 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements section 25 Symptoms You can find a further explanation of the symptoms in section 6 on page 6 section 26 Removing the control panel To make it easier to operate the BC10 when the boiler door is open and to make it easier to read the display the BC10 can be temporarily attached to the boiler in a suspended position while carrying out service activities See section 68 page 56 section 27 Display readings Meaning Display reading Current heating system supply temperature in F Display reading Current heating system water pressure in PSI Display settings Meaning Display setting Logamax plus GB162 80 kW target J 100 boiler performance as a Display setting Logamax plus GB162 100 kW J La target boiler performance as a Ls Display setting Target pump over run time in minutes after heating mode has ended 24 hours Recommendation Do not set a pump over run time i Fid of less than 5 minutes Display setting required DHW supply position on off This setting has priority over for example a possible DHW mode On Off setting on a room thermostat Note If the setting has been made the
47. 16 pin high voltage connector e Set the multimeter to Measure resistance 1 e Check the power supply cord of the glow ignitor for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the black contacts low voltage connector pins 5 and 6 on the UBA 3 mounting base 3 Check the power supply cord of the glow ignitor for internal short circuiting The electrical resistance measured between two random wires must be infinite Measure the electrical resistance over the glow ignitor cable to ground The electrical resistance must be infinite for every individual wire Attach the plug of the glow ignitor in reverse order O Install the lid on the connection tray in reverse order O Install the UBA 3 in reverse order of removal e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 75 Actions A DANGER OF FATAL ACCIDENT LIS due to electric shock e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Disconnect the plug of the glow ignitor as instructed in section 101 1 and or the plug of the ionization electrode as instructed in section 104 1 Type A old version e Loosen both nuts 1
48. 2 or the KIM is defective Reset required Yes No No 5 7 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 No 5 7 Yes 4 6 7 8 Yes 4 6 7 8 No 5 7 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 LED on UBA 3 Off flashing 1 Hz Off flashing 1 Hz flashing 1 Hz flashing 1 Hz Off flashing 1 Hz flashing 1 Hz Off flashing 1 Hz flashing 1 Hz Off flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz Other symptoms Diagnosis Possibly no heating operation and no DHW gt section 54 No heating operation and no gt section 54 DHW No heating operation and no gt section 55 DHW No heating operation and no gt section 56 DHW No heating operation and no gt section 57 DHW No heating operation and no gt section 58 DHW No heating operation and no gt section 59 DHW gt section 60 No heating operation and no gt section 66 DHW No heating operation and no gt section 66 DHW No heating operation and no gt section 61 DHW No heating operation and no gt section 62 DHW No heating operation and no gt section 66 DHW No heating operation and no gt section 66 DHW No heating operation and no gt section 66 DHW No heating operation and no gt section 63 DHW No heating operatio
49. 3 Pin 81 ckim bt E AS y 0 Pn OOOO aa a P 16 pin high voltage connector 3 e Set the multimeter to Measure resistance 1 e Check the power supply cord of the gas valve for breaks e The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the black contacts low voltage connector pins 71 and 72 on the UBA 3 mounting base 3 e Check the power supply cord of the gas valve for internal short circuiting The electrical resistance measured between two random wires must be infinite LS approx 75 Q gt ELLE 73111 marmeren e Carry out a measurement to ground to make sure that there aX NY is no short circuit between the gas valve and ground The 1 electrical resistance between the gas valve cable and ground Disconnect the plug of the gas valve 1 must be infinite See section 131 e Set the multimeter to Measure resistance 2 e Attach the gas valve plug or plugs in reverse order of e Check the internal electrical resistance of the right hand coil removal of the gas valve by measuring it The electrical resistance of Install the lid on the connection tray in reverse order the right hand coil must be approximately 75 Q 3 Install the UBA 3 in reverse order of removal Attach the gas valve plug or p
50. 4 Diagnosis The fuse is defective Action Replace fuse see section 82 e Put the main power switch on the BC10 in position 1 On as referred to in section 80 Is there any indication on the BC10 display within a few minutes e Turn the main power switch to position 0 OFF see section 72 O Disconnect the following boiler components from the electrical power supply pump see section 88 fan unit see section 84 1 Check the fuse again Test the fuse on the rear of the UBA 3 using a multimeter as indicated in section 82 Is the fuse working correctly O Replace the fuse again see section 82 e Put the main power switch on the BC10 in position 1 On see section 80 Is there any indication on the BC10 display within a few minutes Use a multimeter to check the power supply cords of the pump section 89 the fan unit Section 84 and the hot surface ignitor section 102 for signs of short circuiting Are the wires okay Diagnosis The wire harness is defective Action Replace the wire harness or the affected part Replace the fuse again as indicated in section 82 e Check the internal electrical resistance of the transformer see section 120 Is the internal electrical resistance of the transformer okay Diagnosis The transformer is defective Action Replace transformer section 120 e Check the power supply cord and the low voltage cord of the transformer as indicated in section 121
51. 4 Step 15 Step 16 Step 17 Step 18 Step 19 Step 20 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Step 16 Step 17 Step 18 Step 19 Diagnosis The pressure sensor is defective Action Replace the pressure sensor see section 128 Has the fault been remedied e Check the pump activation as instructed in section 88 Is the activation okay Diagnosis The pump is defective Action Replace the pump see section 92 e Check the pump power supply cord as instructed in section 89 Is the pump power supply cord okay Diagnosis The power supply cord is defective Action Replace the power supply cord of the pump Diagnosis 3 Yes No Yes No Yes No gt Section 67 gt Section 66 gt Step 17 gt Step 18 Section 67 gt Section 66 gt Step 20 gt Section 67 Operating code The pump speed was found to be too high or too low while starting up Es t Jn e pump speed is fixed e Check that the pump has been purged correctly see section 78 Has the pump been purged correctly Diagnosis There is air trapped in the pump Action Purge the pump see section 78 e Check the pump for mechanical obstructions as instructed in section 87 Is the pump blocked Diagnosis The pump is blocked Action Attempt to start up the pump again as indicated in section 87 or replace the pump as i
52. 6 Step 9 O Press the o lt button Step 10 F 5 Display setting required pump run over time after the end of the heating operation in minutes See also section 28 Display settings page 21 Step 11 Press the o button Step 12 C Display setting required DHW mode position on off This setting has priority over for example a possible DHW mode On Off setting on a room thermostat See also section 28 Display settings page 21 Step 13 Press the lt button Step 14 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Step 15 Press the button Step 16 P22 Display reading Currently measured heating system water pressure in PSI See also section 27 Display readings page 21 Step 17 Press the o button Step 18 H Operating code The boiler is in service mode See also section 29 Display codes and other symptoms page 21 and further Step 19 Press the o button Step 20 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Step 21 Have 30 minutes passed or has the main voltage been interrupted Yes Step 22 No gt Step 23 Step 22 Service mode is deactivated gt Step 25 Step 23 Deactivate service mode Yes Step 24 No Step 15 Step 24 To deactivate the service mode O Press and hold the 8 button for
53. 6 720 614 965 11 2012 US CA Service Instructions Condensing gas boiler WARNING Improper installation adjustment alteration service or maintenance can cause injury loss of life or property damage Refer to this manual For assistance or addi tional information consult a qualified installer service agency or the gas supplier 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 e Do not try to light any boiler Do nottouch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions gt e If you cannot reach your gas supplier call the fire department i Installation and service must be performed by a qualified installer service agency or the gas supplier yr Notice e This manual is available in the English and French language e This manual must be retained for future reference Logamax plus For the contractor GB162 80 kW 100 kW Please read these instructions carefully before servicing Buderus 4 Prod
54. 67 Step 9 O Check that the fault can be remedied by making a connection see section 116 Step 10 Has the fault been remedied Yes Step 11 No Step 6 Step 11 Diagnosis The external switch contact has opened or a wire has broken in the external switch contact gt Section 67 wiring outside the boiler Action Remedy the cause of the external switch contact opening or replace the wiring Buderus 52 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements i S Locking fault code The KIM is too new for the UBA 3 section 1 32 fan amp feast Tt HT Step 1 Replace the UBA 3 by a UBA 3 provided with the most recent software possible Step 2 Has the fault been remedied Yes No Step 3 Diagnosis The KIM is too new for the UBA 3 Measure Contact the manufacturer See the back of this document Si E e Locking fault code The contacts of the gas valve section 1 21 are open far fO feaut Th TT Step 1 e Check the plug and socket connection of the gas valve see section 109 Step 2 Is the plug and socket connection okay Yes No Step 3 Diagnosis The plug and socket connection has come loose Action Replace the plug and socket connection see section 109 Step 4 e Check the electrical resistance of the power supply cord of the gas valve as indicated in section 111 Step 5 Is the wire okay Yes No Step 6 Diagnosis The wire harness is defective Action R
55. 75 e Open the heating supply and return isolating valves on the pump group see section 76 The open position is parallel to the pipework Fill the heating system to a pressure of about 22 PSI 1 5 bar 110 130 e Read the pressure PSI from the pressure gauge 1 on the pump group or on the control panel 2 of the BC10 The pressure in the heating system which is measured directly atthe 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 38 PSI 2 6 bar or 50 PSI 3 5 bar when the optional 50 PSI 3 5 bar pressure relief valve is used e 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 58 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Switch on the power supply to the heating system m IRE az 2090 e Putthe main power switch 1 on the control panel in position 1 On 100 120 gt 130 159 90 130 1 170 Eco 140 LL 190 0 Aut 0 Aut i 0 wD El j Press the Service button 1 a number of times until the pressure is displayed e g
56. 80 kW 100 kW Subject to modifications resulting from technical improvements Step 3 Step 2 gt Section 67 gt Step 5 gt Step 4 gt Section 67 Buderus 37 ea Diagnosis Step 6 Has the boiler been purged correctly Yes Step8 No Step 7 Step 7 Diagnosis The boiler has not been properly purged Action Purge the boiler of air see section 78 gt Section 67 Step 8 Are enough thermostatic valves open on the radiators convectors etc Yes Step 10 No Step 9 Step 9 Diagnosis There are not enough thermostatic valves open on the radiators convectors etc gt Section 67 Action Open more thermostatic valves Step 10 e Check the supply safety and return temperature sensors indicated in section 93 Step 11 Are the supply safety and return temperature sensors okay Yes Step 26 No Step 12 Step 12 Diagnosis The relevant sensor is defective Action Replace the relevant sensor see section 95 gt Section 67 Step 13 e Check the pump for mechanical obstructions as instructed in section 87 Step 14 Is the pump blocked Yes Step 15 No Step 16 Step 15 Diagnosis The pump is blocked Action Attempt to start up the pump again as indicated in section 87 or replace gt Section 67 the pump as indicated in section 92 Step 16 Is the pump running while the display code is shown Yes Step 17 No Step 20 Step 17 e Check the pump for contamination as instructed in section 91 S
57. 9 91 92 93 95 96 98 99 100 101 102 105 106 107 108 109 110 111 112 113 114 117 118 119 120 Description Cover controler BC10 Burner Seal Burner Burner box Front connection board BC10 USA On Off switch Knob BC10 Drawer connection board Cover control box Cover connection board 120 VAC Transformer UBA 3 Fuse 5AF 10 pc Connection board Electronic connection red Electronic connection grey Electronic connection green Electronic connection blue Electronic connection orange Flue gas adapter Measure nipple cap Cable harness low voltage Cable harness high voltage Cable harness on off switch Cable harness earth Union nut 1 5 pc Sealing 5 pc Nut 1 Gas valve Pump UP26 99U Lever Ball Valve blue Lever Ball Valve red Casing Thermometer Manometer Valve housing return Air Release Tap Connection pressure gauge Drain pipe Valve housing supply Adapter parallel 4 Adapter insert 4 Open venting insert Lipring 114 Lipring 103 Strain relief bracket Safety valve ASME Low loss header Plug protector BCM 1100 100 kW 0 4 000 ft BCM 1101 80 kW 0 4 000 ft Screw 6 3 x 19 10 pc Product No 73698 73917 73918 73919 7101490 78186 73660 38724 7101480 73977 73815 78191 8718600083 73904s 73814 73776 73774 73773 73775 73777 73936 73937 7746900392 7746900393 73946 73947 73481s 7746700417 73675 7746900401 7746900402 7746700421
58. Are the power supply cord and the low voltage cord of the transformer okay Diagnosis The wire harness is defective Action Replace the wire harness or the affected part e Turn the main power switch to position 0 OFF as indicated in section 72 e Re connect the power supply plug to the pump in reverse order e Put the main power switch on the BC10 in position 1 On see section 80 Is there any indication on the BC10 display within a few minutes Diagnosis The pump is defective Action Replace pump see section 92 e Turn the main power switch to position 0 OFF as indicated in section 72 e Re connect the power supply plug to the fan unit in reverse order e Put the main power switch in position 1 On see section 80 Is there any indication on the BC10 display within a few minutes Diagnosis The fan unit is defective Action Replace the fan unit see section 86 O Replace the fuse again see section 82 Diagnosis 3 Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements gt Section 67 gt Step 28 gt Step 33 gt Step 32 gt Step 44 gt Step 35 gt Step 38 gt Step 37 gt Section 67 gt Step 41 gt Step 40 gt Step 54 gt Section 66 gt Step 43 gt Step 54 gt Step 49 gt Step 48 gt Step 54 gt
59. C voltage 1 Minimum measuring range 40 VAC e Put the boiler in flue gas test mode see section 20 e Check that the gas valve is activated While operating code aL is displayed approx 24 VAC must be available on the two contacts of the right hand coil 2 and on the two contacts of the left hand coil 3 of the gas valve power supply plug O Stop the flue gas test as instructed in section 20 e Close the boiler door as instructed in section 77 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 79 Actions e Switch off the power supply to the heating system see e Switch off the power supply to the heating system see section 72 section 72 e Open the boiler door as instructed in section 73 e Open the boiler door as instructed in section 73 Remove the UBA 3 as instructed in section 82 Remove the cover from the connection tray see section 114 Undo the plug or plugs of the gas valve supply cord as shown in the illustration in section 109 MG CCA ELOKE T3I vermenn e Disconnect the plug of the gas valve 1 e Set the multimeter to Measure resistance 2 e Check the internal electrical resistance of the left hand coil of the gas valve by measuring it The electrical resistance of the left hand coil must be approximately 6 Q
60. Check the burner and the distributor plate for dirt and cracks and clean or replace the burner e Check the burner gasket for signs of ageing Replace the burner gasket if necessary e Install the burner and the burner cover in reverse order e Open the gas stop valve and put the boiler into chimney sweep operation as instructed in section 81 e Check all couplings and locations in the gas train which have been disconnected to install the burner for leaks Use a foaming agent which has been approved for gas leak testing e f a gas leak is found switch off the power supply to the heat ing system see section 72 close the gas stop valve as indi cated in section 74 and deal with the cause of the gas leak e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 e Open the gas stop valve as indicated in section 81 88 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Switch off the power supply to the heating system see section 72 e Remove the casing of the pump group as indicated in section 73 e Remove the rubber sleeve including the ribbed pipe 1 e Turn the siphon a quarter turn in a counterclockwise direction 2 e Remove the siphon by pulling it downwards 3 e Clean the siphon if necessary O Install the new or cleaned sip
61. INSTALLATION due to frost while manual operation is switched on After a power failure or after switching off the main voltage the heating system may freeze since man ual operation is no longer active Re activate manual operation after switching on the heating system so that the system is perma nently in operation Service button The Service button 4 is used to display the heating system supply temperature the water pressure on the heating system etc See also section 27 Display readings section 28 Display settings and section 29 Display codes and other symptoms USER INSTRUCTION i If there is a risk of radiators or pipe sections freezing up we recommend setting the pump run over time to 24 hours See section 28 Display settings Operation ES LED Burner operation The LED Burner operation 6 lights up when the burner of the heating boiler is active and it is extinguished when the burner is no longer in operation The LED Burner operation indicates the burner status LED Status Explanation On Burner operational The heating water is being heated The heating water has reached the Off Burner off required temperature range and there is no heat demand LED Central heat demand The LED Central heat demand 7 lights up as soon as there is a heat demand from the control system and is extinguished as soon as there is no longer a heat d
62. Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Step 33 Step 34 Step 35 Diagnosis 6 e Check the operation of the bypass or the low loss header in the heating system Adjust a possible bypass to a protection pressure of max 3 6 PSI 25 kPa Is the bypass or the low loss header okay Yes Section 66 No gt Step 35 Diagnosis The bypass or the low loss header is defective gt Section 67 Action Replace the bypass or the low loss header Sip S isi Locking fault code The flue gas sensor temperature is too high plat pi T TT Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 e Check the entire flue gas system for obstructions Is the flue gas system okay Yes Step 4 No Step3 Diagnosis The flue gas system is obstructed Action Remove the obstruction gt Section 67 e Check the heat exchanger for contamination on the flue gas side Is the heat exchanger dirty Yes Step 6 No Step 7 Diagnosis The heat exchanger is dirty Action Clean the heat exchanger gt Section 67 e Check the flue gas sensor as indicated in section 97 Is the flue gas sensor okay Yes gt Section 66 No Step 9 Diagnosis The flue gas sensor is defective Action Replace the flue gas sensor see section 99 gt Section 67 and is open or no connection is made between the contacts 50 and 78 of the UBA 3 mounting tt E PO SR Lockin
63. N MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter 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 gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling buiding 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 wired car bon monoxide detectors a Inthe 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 b Inthe 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 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated car bon monoxide detector with an alarm shall be installed Regulations and guidelines Le 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in a
64. Remove the retaining plate 2 Remove the complete ignition unit glow ignitor ionization electrode sight glass with rubber seal ignition unit housing and bolts fig 5 Old version ignition unit Type B new version e Remove the complete ignition unit ignition unit housing 1 glow ignitor 2 ionization electrode 3 seal 4 rubber seal with sight glass 5 bolts 6 and nuts 7 fig 6 New version ignition unit DANGER OF FATAL ACCIDENT FIRE EX due to flue gas escaping or explosion of flamable gases All work on gas pipe work and fittings must be carried out by authorized gas technicians Buderus N DAMAGE TO THE INSTALLATION 23 due to incorrect glow ignitor assembly e The glow ignitor is highly breakable Handle with care e Install the glow ignitor so that the lug of the heat exchanger is located in the relevant opening in the glow ignitor N DAMAGE TO THE INSTALLATION Z due to incorrect assembly e Check that both bolts of the rubber seal with sight glass are tightened evenly e Install all new parts of tthe ignition unit ignition unit housing 1 glow ignitor 2 ionization electrode 3 seal 4 rubber seal with sight glass 5 bolts 6 and nuts 7 Attach the plug of the glow ignitor and the ionization electrode in reverse order e Open the gas stop valve and put the boiler into chimney sweep operation as instructed in section 81 e Check all couplings and locations in the gas
65. Replacing the UBA 3 cece cee eee eee 91 8 APpendiX ia cease 2 msc doe esa inni E aves ghee wm are a 92 Electrical wiring diagram 0 0 cee eee 92 Legend of electrical wiring diagram oo oo oo oo ooo 93 POWer ating 26 ried ee oie alata da dere ea dik dee eee 93 Sensor resistance readings 0 0 e eee eee eee eee 93 Technical Specifications of GB162 boilers at sea level 0 4 000 ft 94 Spare parts list ico ita id needs 96 Spare parts list continued 0 0 cee eee 96 Exploded view Logamax plus GB162 80 kW 100 kW 97 Exploded view pump group Logamax plus GB162 80 kW 100 kW 98 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements About these instructions These servicing instructions contain important information for the safe and professional servicing of the boiler with boiler input rating of 80 kW and 100 kW The name of the boiler is made up of the following components Logamax plus heating boiler typical GB162 single boiler without domestic hot water supply 80 kW 100 kW maximum heating capacity is 80 or 100 kW GB162 Natural Gas Propane Gas 80 kW 290 000 btu hr 270 000 btu hr 100 kw 333 000 btu hr 315 000 btu hr Table 1 max input rate These servicing instructions are intended for professional installers who have the necessary training and experience for working on heating a
66. Section 67 gt Step 53 gt Step 54 gt Section 67 Buderus 31 2 Diagnosis For devices with a hot water supply no or insufficient DHW radiators convectors etc may be heated without a heat demand Step 1 e Put the main power switch on the BC10 in position 0 Off as referred to in section 70 and put the main power switch in position 1 on as indicated in section 80 Step 2 e Open a hot water tap Step 3 e Check to ensure that the hot water primary supply pipe to the tank warms up Step 4 Does this pipe warm up to approx 140 F 60 C Yes Step5 No Step 15 Step 5 Diagnosis The cause of this fault does not lie with the heating boiler but with the water supply or hot water tank Step 6 e Check to see if the cold water inlet and hot water outlet have been incorrectly connected to the storage type water heater Step 7 Are the pipes connected correctly Yes Step9 No Step8 Step 8 Diagnosis The pipes have been connected incorrectly Action Connect the pipes correctly gt Section 67 Step 9 e Close the stop tap in the cold water inlet and open a hot water tap at random to see if water is still flowing Step 10 Is this the case Yes Step 11 No Step 12 Step 11 Diagnosis The cause is a defective thermostat controlled mixer tap a thermostat controlled mixer valve gt Section 67 or a short circuit between the hot and cold water pipe circuits Action Replace the relevant compo
67. Step 48 Diagnosis The wrong orifice has been installed gt Section 67 Action Fit the correct orifice see section 113 and 135 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 47 ea Diagnosis Step 49 Step 50 Step 51 Step 52 Step 53 Step 54 Step 55 Step 56 Step 57 Step 58 Step 59 Step 60 Step 61 Step 62 Step 63 Step 64 Step 65 ETTO Ea e Check the following elements for contamination damage and or incorrect installation Siphon section 127 Air suction tube section 1 12 Seal and connection between venturi pipe and fan unit Venturi pipe see section 86 Orifice see section 113 Fan unit Seal and connection between fan unit and burner Burner section 126 Heat exchanger Flue gas outlet and air inlet system Ground wire insulation see section 108 Are the above mentioned components clean free of damage and or correctly installed Diagnosis The above components are dirty damaged or not correctly installed Action Clean replace and or re install the relevant components e Check the ionization current as indicated in section 104 Is the ionization current okay e Check the plug and socket connection between the ionization electrode and wire harness as instructed in section 104 Is the plug and socket connection okay Diagnosis The plug and socket connection has come loose Action
68. Step 6 Section 67 Blocking fault code The heating system water pressure is too low and is less than 3 PSI ZE E co 7 Neither the boiler nor the pump are started up As soon as the water pressure of the heating system is 14 PSI or more the display code ZE 201 will disappear and both the boiler and the pump will start running As soon as the water pressure of the heating system is less than 6 PSI the performance of both the heating operation and the DHW mode will be limited Operating code The heating system water pressure is too low and is less than 12 PSI H A fluctuating current water pressure of the heating system may be shown e g 05 As soon as the water pressure of the heating system is 14 PSI or more the display code H q will disappear As soon as the water pressure of the heating system is less than 6 PSI the performance of both the heating operation and the DHW mode will be limited O Check that the heating system water pressure measured on the control panel is at least 14 PSI see section 19 Is the heating system water pressure measured on the BC10 at least 14 PSI Yes No Diagnosis The water pressure of the heating system is too low Action Fill and bleed the heating system see section 78 Diagnosis The pressure sensor is defective Action Replace the pressure sensor see section 128 Has the fault been remedied Yes No gt Step 4 gt Step 3
69. The boiler must be installed such that the gas ignition system components are protected from water dripping spraying rain etc during boiler operation and service The boiler must not be installed on carpeting Do not restrict or seal any air intake or outlet openings If you find any defects you must inform the owner of the sys tem of the defect and the associated hazard in writing Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements EA Safety and general instructions DANGER AN if flammable gas explodes Beware if you smell gas there may be an explosion hazard Warning If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other boiler What to do if you smell gas e Do not try to light any boiler e 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 e Ifyou cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas sup plier WARNING Danger of fatal accident from explosive fumes e Only carry out work on gas pipes and fittings if you are pr
70. W Subject to modifications resulting from technical improvements Appendix Le Buderus 97 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements E Appendix Buderus 98 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements B F Filling the system and bleeding it of air 58 Bleeding the gas supply pipe 84 Flow temperature maximum 4 94 Flue gas connection 000 eee eee eee 94 C Front protection esto iris via 8 Checking an external switch contact 83 Checking and or replacing the fan unit 63 H Checking the cable harness connections 87 Heat exchanger 00ce cece ences 3 94 Checking the control panel supply voltage 87 Checking the fan unit operation 120 VAC 61 l Checking the fan unit power supply cord 120 VAC cos stents otteke had oate tne nd eos e 62 Initial startup 2 ee 60 Checking the fan unit tacho cable 62 Checking the flue gas sensor 72 M hacking he fus gas aaa abe ea ee eS ma Measure the ionization current 76 Checking Megas Vanek acivakon A de Measuring and adjusting the
71. an unit o ooooo oo o o 63 Checking the pump mechanical obstruction 64 Checking the pump activation 2 0 0 eee ee eee 65 Checking the pump power supply cord 00 00 ee 65 Checking the pump tacho Cable 00000 e eee eee 66 Checking the pump pollution 2 0 0 0 cece eee eee 67 Replacing the pump 0 cee eee ee eee eee 67 Checking the supply safety return and DHW temperature sensors 68 Checking the supply safety return and DHW temperature Sensors cables cnica rita eee ee ew eae ee 69 Replacing the feed safety and return sensors 71 Replacing the DHW temperature sensor 4 72 Buderus 4 Section page Checking the flue gas sensor 00 0 0 eee eee eee eee ee 72 Checking the flue gas sensor cable 00 000 e eee 73 Replacing the flue gas Sensor 00 00 eee eee eee 74 Checking the glow ignitor activation o o o oo 74 Checking the glow ignitor resistance ooo oooooooo 75 Checking the glow ignitor power supply cord LO Replacing the ignition unit 0 0 0 eee eee 76 Measure the ionization current 000 000 e eee eee 76 Checking the ionization electrode short circuit 77 Checking the ionization electrode cable 78 Checking the ionization electrode 0 0 eee eee 78 Checking the io
72. as instructed in section 82 e Remove the cover from the connection tray see section 114 circuit between the ionization electrode cable and ground The electrical resistance between the onization electrode cable and ground must be infinite e Connect the plug of the ionization electrode e Install the lid on the connection tray in reverse order e Install the UBA 3 in reverse order of removal e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 O Disassemble the ionization electrode as indicated in section 103 pin A Pin 16 16 pin high voltage connector e Disconnect the plug of the ionization electrode 1 e Set the multimeter to Measure resistance 2 e Carry out a measurement to make sure that there is no break age in the ionization electrode cable The electrical resis tance measured separately for every wire must be approx 0 Q 3 Measure between the plug and the black contact low voltage connector pin 2 on the UBA 3 mounting base 4 e Set the multimeter to Measure resistance 1 e Carry out a measurement to make sure that there is no break age in the ionization electrode The electrical resistance of the ionization electrode cable must be approximately 0 Q 2
73. ation test is carried out during starting up This display code flashes to check the communication between the UBA 3 section 1 32 and the control panel section 1 4 for 3 5 times during a period of 3 5 seconds while starting up If anew UBA3 or a new KIM was fitted this code will flash for max 10 seconds See also section 29 Display codes and other symptoms page 21 Step 6 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Step 7 O Press the ome button Step 8 P 22 Display reading Currently measured heating system water pressure in PSI See also section 27 Display readings page 21 Step 9 O Press the button Step 10 O Operating code The boiler starts up after activation of the mains power supply or completion of a system reset Start of water side flow check The pump will carry out max 4 attempts to restore the water flow Start of air side pre purge phase The fan unit runs at about 60 of maximum speed for 15 seconds See also section 29 Display codes and other symptoms page 21 Step 11 Has the air side pre purge phase been completed without any problems Step 12 Now remedy the fault by following the section relating to the error code that is now displayed See also section 29 As soon as a locking fault occurs indicated by a flashing display code the pump is activated to run conti
74. cal power consumption full load without a pump group Electrical power consumption partial load without a pump group Height x width x depth with pump group in mm 50 4 x 20 5 x 18 3 1280 x 520 x 465 Weight without a pump group Ib kg 154 70 Pump group pump Type of gas supply Natural gas H G20 delivery setting LP gas propane after conversion veia B23 C13 C33 C43 C53 Cea Cgg depending on room air and independent of room air ersion Compliance with increased tightness requirements with operation independent of room air Gas category according to EN 437 20 37 mbar Natural gas 0 4 000 0 1 220 8 40 0 331 7746900399 GB162 80 KW 100 KW LPG 0 4 000 0 1 220 4 70 0 185 7746900499 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 95 EA Appendix Product No 7746900396 73912 73911 73990 73965 73962 73963 73949 73951 73964 73988 73930 7746900152 73931 73934 73907 73935 73933 73463 73932 73449 73995 7746900382 73920 73983 7746901751 73563 8718600291 73479s 7746900397 8718600286 73982 73572s 73970 73971 73926 73969 73916 73973 7746900391 78156s 78175s 73915 78234s 73950 73080 73974 73972 7746700420 8718600172 7746900383 Pos 61 62 63 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 83 84 86 87 88 8
75. ccordance 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 min imum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 2 inch 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 fueled equipment shall not approve the installation unless upon inspections the inspector 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 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current 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 sepa rate from the dwelling building or structure used in whole or in part for residential puposes c MANUFACTURERS REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM REQUIRED When the manufacturer of Product Approved side wall horizon tally mounted gas equipment provides a v
76. cho signal section 1 20 or the fan unit voltage has failed during the operating phase Locking fault code The fan unit section 1 20 is running irregularly while starting up Blocking fault code the boiler has been switched off for a couple of seconds since it had been operational for 24 hours This is a safety check Locking fault code The fan unit tacho signal section 1 20 or the fan unit main voltage is not available during the pre operative phase OC Locking fault code The fan unit section 1 20 is running too slowly Locking fault code The fan unit section 1 20 is running too fast Locking fault code The supply temperature sensor section 1 24 has measured a heat ing supply temperature higher than 221 F 105 C Locking fault code The safety temperature switch has measured an excessively high tem perature and is open or no connection is made between contacts 22 and 24 of the UBA 3 mounting base The boiler can have a safety temperature switch or a connection between contacts 22 and 24 of the UBA 3 mounting base depend ing on the boiler type Locking fault code The sensor test has failed Locking fault code The safety temperature sensor section 1 28 has measured a sup ply temperature higher than 221 F 105 C Locking fault code The contacts of the safety temperature sensor section 1 28 have shorted to each other the contacts of the safe
77. ck contacts low voltage connector pins 11 and 12 on the UBA 3 mounting base 3 e Check the return temperature sensor cable for internal short circuiting The electrical resistance measured between two random wires must be infinite Measure the electrical resistance over the return temperature sensor cable to ground The electrical resistance must be infi nite for every individual wire RC FA WA FW EV DWV nono 1 e Disconnect the DHW temperature sensor FW plug in the connection tray 1 70 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Disconnect the DHW temperature sensor plug 1 e Set the multimeter to Measure resistance 2 e Check the DHW temperature sensor cable for breaks The electrical resistance measured separately for every wire must be approx 0 Q 3 e Check the DHW temperature sensor cable for internal short circuiting The electrical resistance measured between two random wires must be infinite Measure the electrical resistance over the DHW temperature sensor cable to ground The electrical resistance must be infi nite for every individual wire O Set the multimeter to Measure resistance 1 e Check the cable of the DHW temperature sensor between the connection tray and the UBA 3 mou
78. ck the power supply cord of the fan unit for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the black contacts high voltage connector pins 9 10 and 11 on the UBA 3 mounting base 3 e Check the power supply cord of the fan unit for internal short circuiting The electrical resistance measured between two random wires must be infinite See also section 131 Remove the multimeter e Connect the fan unit power supply plug in reverse order O Install the UBA 3 burner automat in reverse order of removal e Install the lid on the connection tray in reverse order e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 Buderus DANGER OF FATAL ACCIDENT LL due to electric shock DAMAGE TO THE INSTALLATION EX To prevent damage do not insert the multimeter measuring electrodes too far into the holes of the plug and socket connection e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Remove the UBA 3 as instructed in section 82 e Remove the cover from the connection tray see section 114 81 pin low voltage connector Pin 1 eH Bir HERA 28 al ooo ooo ooo ooo ooo pag coo coo omo oma pom ooo ooo oo oor ooo ooo ooo ooo ooo ooo coo Pin 81 fat AO 16
79. down The pump modulation degree will vary strongly during heating operation Step 53 Is there still a heat demand from the room or external temperature dependent controller Yes Step 54 No Step 59 Step 54 Is the heating system supply temperature higher than the target setting Yes Step 55 When working with an external temperature dependent controller the target setting is calculated by the controller No gt Step 52 when working with a room temperature control device it is set on the control panel section 1 4 Step 55 D4 Operating code The supply temperature sensor as measured a current heating supply temperature higher than the supply temperature setting on the control panel section 1 4 or higher than the supply temperature calculated according to the heating curve or higher than the supply temperature calculated according to the DHW mode See also section 29 Display codes and other symptoms page 21 Step 56 The LED Burner operation is extinguished Step 57 The fan unit section 1 20 continues to run for max 30 seconds Step 58 Has the heating system supply temperature fallen sufficiently Yes gt Step 49 No Step 58 Step 59 The LED Central heat demand is extinguished Step 60 0 H Operating code The boiler is in standby mode There is no current heat demand See also section 29 Display codes and other symptoms page 21 The gas valve section 1 21 is closed and t
80. e section 72 e Close the gas stop valve as indicated in section 74 Remove the pressure gauge e Tighten the gas air ratio testing nipple screw e Open the gas stop valve as indicated in section 81 e Switch on the power supply to the heating system see section 79 e Put the boiler in flue gas test mode as indicated in section 20 e Wait for the burner to ignite e Check the gas air ratio testing nipple for leaks using a foam ing agent which has been approved for gas leak testing e Put the boiler in flue gas test mode as indicated in section 20 e Close the boiler door as instructed in section 77 Actions e Disassemble the transformer as indicated in section 122 O Set the multimeter to Measure resistance e Check the resistance of the different coils of the transformer The resistance measured must not be zero or infinite C Contact Resistance Q 4 6 0 lt x lt 0 4 5 O lt x lt o00 13 14 O lt x lt oo 14 15 O lt x lt oo 16 17 O lt x lt oo 18 19 O lt x lt o00 O Install the transformer in reverse order Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 85 Actions DANGER OF FATAL ACCIDENT ao e Disassemble the transformer as indicated in section 122 due to electric shock e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 Re
81. e BiB Blocking fault code No communication with No Off The mixer module is operated the mixer module of heating circuit 2 Faulty in emergency operation mode communication via communication bus The heating circuit pump is run continuously A33 807 Blocking fault code The supply temperature No Off sensor of heating circuit address 3 indicates a fault A33 Bb Blocking fault code No communication with No Off L heating circuit address 3 takes place AS Bla Blocking fault code The solar collector No Off s module has not been adjusted correctly AS Ald Blocking fault code The solar collector sen No Off sor indicates a fault AS END Blocking fault code The solar collector sen No Off sor indicates a fault AS Hib Blocking fault code No communication with No Off L the solar collector module YER Yaa Bt E Locking fault code The return temperature Yes flashing No heating operation and no gt section 37 a AA sensor section 1 31 has measured a return 4 6 7 8 1 Hz DHW water temperature higher than 221 F 105 C tro ft Je Bal Locking fault code The pressure sensor Yes flashing No heating operation and no gt section 65 y A y contacts section 1 30 are open 4 6 7 8 1 Hz DHW trot east Locking fault code The pressure sensor Yes flashing No heating operation and no gt section 65 A y contacts section 1 30 have shorted 4 6 7 8 1 Hz DHW rut ya yo Locking fault code The contacts of the Yes flas
82. e gas temperature 122 86 F F C 50 30 C partial load CO content at full load Free fan feed pressure Inch w c Pa Flue gas connection flue gas system room air dependent in mm flue gas system room air independent in mm Buderus GB162 80 NG Natural gas 72 000 290 000 GB162 80 LP Propane 62 000 270 000 64 100 255 200 55 200 237 600 71 300 281 300 61 400 261 900 GB162 100 NG Natural gas 72 000 333 000 GB162 100 LP Propane 62 000 315 000 64 100 293 000 55 200 277 200 71 300 326 300 61 400 308 700 88 88 97 98 261 000 243 000 295 000 279 000 2 3 2 2 2 1 2 0 93 8 93 9 n a n a n a n a 96 1 96 1 n a n a 90 8 90 8 190 88 50 3 6 86 190 30 88 can be set on the control panel 3 26 225 4 57 315 1 3 5 0 Rp1 G1 union nut with female thread enclosed 114 32 mm 2 4 9 0 2 85 10 8 approx 4 1 35 3 44 9 153 67 149 65 169 76 165 63 142 61 136 58 142 61 136 58 118 48 114 46 124 51 120 49 93 34 88 31 93 34 88 31 9 3 9 6 9 4 9 7 0 602 0 883 150 220 Y 4 100 mm 4 100 mm 4 100 mm parallel 94 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements section 135 Technical Specifications of GB162 boilers at sea level 0 4 000 ft continued Mains connection voltage 120 60 Electrical protection rating IPX4D Fuses 5 Electri
83. e performance During the time proportional program the burner section 1 4 is switched on and off repeatedly during a period of 10 minutes The period in which the burner is switched on depends on the difference between the required performance of the modulating con trol and the lower limit of the device perfor mance As soon as the burner has been switched on the boiler runs at minimum capacity and the display of the control panel section 1 4 shows H As soon as the burner is switched off the oper ating code DE is indicated in the display Example The device performance is 25 kW the bottom limit of the device performance is at 20 and the required modulating control per formance is 5 This means that the burning time is then a quarter of the total time frame of 10 minutes i e the burning time is 2 5 min utes The Off time is then 10 min 2 5 min 7 5 min DH Operating code The boiler is in standby Off mode No heat demand is created OL Operating code The gas valve section 1 Off 21 is activated ou Operating code The boiler starts up after Off activation of the mains power supply or com pletion of a system reset Start of the water side supply check The pump will carry out max 4 attempts to restore the water flow Start of air side pre purging phase The fan section 1 20 runs for 15 seconds at about 60 of its maximum
84. e return temperature sensor to ground This electrical resistance must be infinite 68 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Disconnect the DHW temperature sensor plug 1 e Set the multimeter to Measure resistance 2 Measure the electrical resistance of the DHW temperature sensor 3 e Measure the electrical resistance over the DHW temperature sensor to ground This electrical resistance must be infinite e Use a digital contact type thermometer to measure the tem perature in the vicinity of the corresponding sensor e Compare the resistance values measured at the tempera tures measured to the values in section 134 Replace the relevant sensor if the reading fluctuates by more than 10 with respect to the reference value e g infinitely high resistance in the event of a line break or resistance of 0 Q in the case of a short circuit Attach the relevant sensor plugs e Close the boiler door and install the casing of the pump group in reverse order of removal e Switch on the power supply to the heating system see section 79 DANGER OF FATAL ACCIDENT 4 due to electric shock DAMAGE TO THE INSTALLATION EX To prevent damage do not insert the multimeter measuring electrodes too far into the holes of the plug and socket connection e Switch off the power supply to the heating system see sec
85. e way valve has been installed correctly Step 25 Has the three way valve been installed correctly Yes Step 33 No Step 26 Step 26 Diagnosis The three way valve has not been installed correctly Action Install the three way valve in the gt Section 67 correct way Step 27 e Check the three way valve activation Step 28 Does the activation of the three way valve work correctly Yes Step 29 No Step 30 Step 29 Diagnosis The servomotor of the three way valve is defective Action Replace the servomotor of the three gt Section 67 way valve Buderus 34 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Diagnosis 6 Step 30 e Check the wiring of the three way valve Step 31 Is the wiring of the three way valve okay Yes Step 36 No gt Step 32 Step 32 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 33 Check the interior of the three way valve for contamination mechanical obstructions etc Step 34 Is the three way valve okay Yes Section 66 No gt Step 35 Step 35 Diagnosis The three way valve is defective Action Replace the three way valve gt Section 67 Step 36 Check the wiring of the three way valve between the connection tray and the UBA 3 mounting base Step 37 Is the wiring of the three way valve okay Yes Section 66 No gt Step 32 No p
86. echnical improvements Symptoms Ea Display code LEDon Other symptoms Diagnosis a UBA 3 Main Sub displa displa Meanin A E MEW 9 required code code E Operating code Reset is carried out After Off pressing the Reset button this code is dis played for 5 seconds Not visible on the control panel Or any random display indication with a permanent dot in the bottom right hand corner Or any random display indication with a flashing dot in the bottom right hand corner The cause of the fault must be remedied first This fault code may deactivate again automatically after a specific time without reset Heating and DHW are now available once more The display values e g the heating system water pressure are also shown as flashing codes If more faults occur simultaneously the relevant display codes are shown one after another If one of these display codes is a flashing display code the other display codes will also flash 8 When this boiler fault occurs the pump is activated to run continuously thus minimizing the risk of the heating system freezing up 9 random digit or letter 10 Only visible on certain RC room thermostats 11 Only visible on the Service Tool ORE SLA SR Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 29 eq Diagnosis You can find a further explanation of the diagnosis in section 6 chapter 1 on page 6 No indicati
87. ect installation Siphon section 127 Air suction tube section 1 12 Seal and connection between venturi pipe and fan unit Venturi pipe see section 86 Orifice see section 113 Fan unit Seal and connection between fan unit and burner Burner section 126 Heat exchanger Flue gas outlet and air inlet system Ground wire insulation see section 108 Step 35 Are the above mentioned components clean free of damage and or correctly installed Yes Step 37 No Step 36 Step 36 Diagnosis The above components are dirty damaged or not correctly installed gt Section 67 Action Clean replace and or re install the relevant components Step 37 e Check the onization current as indicated in section 104 Buderus 50 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Diagnosis 6 Step 38 Is the ionization current okay Yes Step 54 No gt Step 39 Step 39 e Check the plug and socket connection between the ionization electrode and wire harness as instructed in section 104 Step 40 Is the plug and socket connection okay Yes Step 42 No Step 41 Step 41 Diagnosis The plug and socket connection has come loose gt Section 67 Action Connect the plug and socket connection correctly Step 42 e Check the cable of the ionization electrode as indicated in section 106 Step 43 Is the wiring okay Yes Step 45 No g
88. elector for the DHW temperature setting on the control panel to the required position as instructed in section 81 1 82 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 Remove the cover from the connection tray see section 114 e Check that an external switch contact has been connected at 1 e Check that a connection loop has been connected at 1 e Install the lid on the connection tray in reverse order e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 DANGER OF FATAL ACCIDENT FIRE from explosive fumes All work on gas pipe work and fittings must be carried out by authorized gas technicians e After carrying out these activities check the measuring nipples used for leaks using a foaming agent which has been approved for gas leak testing e Switch off the power supply to the heating system see section 72 e Open the boiler door and remove the casing of the pump group as instructed in section 73 e Close the gas stop valve as indicated in section 74 e Open some of the radiator valves O Zero the digital pressure gauge Actions CAUTION EX Throughout the measuring operation keep the pressure gauge in the same position horizontal or v
89. emand Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 11 EA Operation Space heating water temperature knob The Space heating water temperature knob 8 is used to set the maximum heating system supply temperature The unit is F See table 2 Knob Explanation position 0 Heating mode off but still DHW operation possible 85 194 The maximum heating system supply temperature in F Aut Y The maximum heating system supply temperature is 194 F 90 C table 2 1 for use with Buderus controls Display The display 9 can show display readings display settings and display codes If a fault occurs the display will immediately show the accompanying fault code If a locking fault has occurred the display code will flash DHW temperature knob The DHW temperature knob 10 is used to set the DHW temperature as required The unit is F See table 3 Knob 5 Legionella aes Meaning ene Shot position indication DHW mode is off but Legionella propagation 0 heating operation may still ruled out be possible ECO Do not use this setting The required DHW Very low risk if hot water 85 115 rae temperature in F is used daily Legionella propagation 415 140 he required DHW ruled out This position is temperature in F recommended The required DHW Legionella propagation Aut temperature is 140 F ruled out 60 C table 3 1 f
90. emedied by temporarily replacing the gas valve Step 55 Has the fault been remedied Yes Step 56 No gt Section 66 Step 56 Diagnosis The gas valve is defective gt Section 67 H Locking fault code The glow ignitor section 1 27 was activated too long for more than JE p JE E gf 10 minutes Tt TT Step 1 O Press and hold the nese button for at least 2 seconds Step 2 Has the fault been remedied Yes Section 67 No Step3 Step 3 Diagnosis The KIM is defective Action Contact the manufacturer See the back of this document for contact details Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 51 2 Diagnosis S Locking fault code The power supply was interrupted during a locking fault qar yw yi _ _ _ _ _ _ _ _ J 1c f J23 tf yaa f je tet Jac T feest ue F 32186 Jae f 42196 Jae f Jeent y wt Ys Gu f J222f orJuy Jez A ot U JS A Step 1 e Press and hold the button for at least 2 seconds Step 2 Is an error code displayed again Yes Step 3 No Section 67 Step 3 e Check the meaning of the new fault see section 29 and resolve the fault Blocking fault code The main voltage has been briefly interrupted m O Gea Step 1 e Check whether windmills generators or other equipment are present which may have caused the main voltage to be inter
91. ements 67 Actions e Open a hot water tap and wait for the boiler to start up then gradually close the hot water tap to bring the heating system supply temperature to over 176 F 80 C e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Disconnect the supply temperature sensor plug 1 This is the upper sensor e Set the multimeter to Measure resistance 2 Measure the electrical resistance of the supply temperature sensor 3 e Measure the electrical resistance over the supply tempera ture sensor to ground This electrical resistance must be infi nite Buderus e Disconnect the safety temperature sensor plug 1 This is the central sensor e Set the multimeter to Measure resistance 2 e Measure the electrical resistance of the safety temperature sensor 3 e Measure the electrical resistance over the safety temperature sensor to ground This electrical resistance must be infinite sell Wi e Disconnect the return temperature sensor plug 1 This is the lower sensor e Set the multimeter to Measure resistance 2 Measure the electrical resistance of the return temperature sensor 3 Measure the electrical resistance over th
92. enting system design or venting system components with the equipment the instruc tions 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 Acomplete parts list for the venting system design or venting system d MANUFACTURERS REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM NOT PROVIDED When the manufacturer of Product Approved side wall horizon tally vented gas fueled equipment does not provide the parts for the venting of flue gases but identifies special venting sys tems the following requirements shall be satisfied by the man ufacturer 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 instruc tions all parts lists for venting instructions and or venting design instructions shall remain with the appliance or equip ment at the completion of the installation Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 9 EA Operation General p
93. enturi pipe on the fan e Disassemble the gas valve as indicated in section 86 unit in reverse order as instructed before e Check the rubber seal 1 for signs of ageing and damage and replace it if necessary O Install the gas air unit including the burner cover in reverse order of removal as instructed in section 86 e Install the air suction pipe on the venturi pipe in reverse order as instructed in section 86 e 100 kW Loosen the 4 torx screws 1 and remove the gas se e Connect the plug of the fan unit power supply cord and the valve 2 from the venturi pipe 3 plug of the fan unit tacho cable in reverse order as instructed in section 86 e Attach the gas valve plug or plugs in reverse order of removal as instructed in section 86 CAUTION LS While connecting the gas pipe to the gas valve make sure that the rubber seal is fitted between the gas pipe and the gas valve e Connect the gas pipe to the gas valve in reverse order as instructed in section 86 e Open the gas stop valve as indicated in section 81 e Switch on the power supply to the heating system see section 79 e Check the gas air ratio and adjust it if necesaary see section 119 O Install a new O ring 1 in the venturi pipe e Close the boiler door as instructed in section 91 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 81 Actions e Switch off the power supply to the hea
94. ep 15 Step 13 Are enough thermostatic valves open on the radiators convectors etc Yes Step 16 No Step 14 Step 14 Diagnosis There are not enough thermostatic valves open on the radiators convectors etc gt Section 67 Action Open more thermostatic valves Step 15 Diagnosis The heating system supply temperature setting is too low Action Increase the heating system gt Section 67 supply temperature setting on the BC10 or on the RC regulator or ON OFF controller as instructed in section 81 or in the operating instructions of the regulator or controller Step 16 Check that the boiler performance has been set correctly in accordance with section 23 and 133 Step 17 Is the boiler performance setting high enough Yes gt Step 19 No Step 18 Step 18 Diagnosis The boiler performance setting is too low Action Adjust the boiler performance to a higher setting gt Section 67 see section 23 and 133 Step 19 Is the boiler performance of the wall mounted condensing gas boiler sufficient to heat the building Yes Step 21 No Step 20 Step 20 Diagnosis The boiler performance is too insufficient Action Install a larger heating boiler gt Section 67 Step 21 Is there a hot water supply Yes Step 22 No Section 66 Step 22 e Check the movement of the servomotor of the three way valve Step 23 Does the servomotor of the three way valve move Yes Step 24 No Step 27 Step 24 e Check that the thre
95. eplace the wire harness or the affected part Step 7 e Check the electrical resistance of the gas valve coils as indicated in section 111 Step 8 Is the resistance correct Yes No Step 9 Diagnosis The gas valve is defective Action Replace the gas valve see section 113 gt Section 67 gt Step 3 gt Section 67 gt Step 4 gt Step 3 gt Section 67 gt Step 7 gt Step 6 gt Section 67 gt Section 66 gt Step 9 gt Section 67 at the same time The DHW operation has been switched off after this period of 4 hours for as AG E A m Blocking fault code 4 hours of continuous DHW operation while a heat demand also occurred E EXE long as the boiler is active for the heating operation Step 1 e Check that no hot water tap is dripping and that there is no leakage in the hot water pipe This can be checked by feeling whether the hot water pipe is hot at half a metre below the boiler Step 2 Is a hot water tap dripping or is there a leakage in the hot water pipe Yes No Step 3 Diagnosis The hot water tap is dripping or the hot water pipe is leaking Action Fix the dripping hot water tap or the leakage in the hot water pipe Step 4 e Check the electrical resistance of the DHW temperature sensor as indicated in section 93 Step 5 Is the electrical resistance of the DHW temperature sensor okay Yes No Step 6 Diagnosis The DHW temperature sensor is defective Action Replace the DHW temperature se
96. ertical in which it was zeroed O Set the pressure gauge to the correct measuring range e Loosen the gas connection pressure testing nipple screw 1 by 2 turns e Connect the pressure gauge to the measuring nipple 2 e Open the gas stop valve as indicated in section 81 e Switch off all other gas fired equipment such as gas heaters gas cookers and any other boilers possibly in cascade etc e Check that the static gas supply pressure does not rise slowly for 2 minutes e Switch all other gas fired equipment such as gas heaters gas cookers and any other boilers possibly in cascade etc to full load operation Do NOT switch the Logamax plus GB162 on while the measurement is carried out to full load operation e Measure the static gas supply pressure e Switch on the power supply to the heating system see section 79 e Put the boiler in flue gas test mode as indicated in section 20 e Wait for 1 minute until the boiler is running at full load O Measure the dynamic gas supply pressure e Check the difference between the static and dynamic gas supply pressures The maximum difference between the static gas supply pressure and the dynamic gas supply pres sure allowed is for natural gas A 2 0 inch W C A 5 0 mbar between the minimum dynamic gas supply pressure of 5 inch W C 12 4 mbar for LPG A 8 0 inch W C A 19 9 mbar between the minimum dynamic gas supply pressure of minimum 8 inch W C 19 9 mbar
97. es Step 39 No gt Step 38 Step 38 Diagnosis The static and or dynamic gas supply pressure are not correct If the required static and dynamic gt Section 67 gas supply pressures are not detected consult your gas utility company Step 39 e Check the gas air ratio as indicated in section 119 Step 40 Is the gas air ratio okay Yes Step 42 No Step 41 Step 41 Diagnosis The gas air ratio is not okay Action Adjust the gas air ratio see section 119 gt Section 67 Step 42 Check the storage type water heater for furring lime scale build up Step 43 Does the storage type water heater furred up Yes Step 44 No Section 66 Step 44 Diagnosis The storage type water heater is furred up Action Decalcify the storage type water heater gt Section 67 For devices with a DHW mode DHW possibly available no heating operation For devices without a DHW mode no heating operation Step 1 e Check that the RC regulator or ON OFF controller is set to heat demand operation Consult the operating instruc tions of the RC regulator or the ON OFF controller The RC regulator or ON OFF controller is automatically set to heat demand operation when the temperature setting is higher than the current temperature Step 2 Is the RC regulator or ON OFF controller setting high enough Yes Step 4 No Step3 Step 3 Diagnosis The RC regulator or ON OFF controller has not been set to heat demand operation
98. es Service mode The boiler is in heating mode at a reduced capacity for a period of 30 minutes The maximum heating system supply temperature set on the control panel now applies DHW mode is not possible during the flue gas test or during service mode See also section 29 Display codes and other symptoms page 21 Press the Q button 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Have 30 minutes passed or has the main voltage been interrupted Yes Step 1 No Step 12 Deactivate flue gas test Yes Step 13 No Step 5 To deactivate the flue gas test gt Step 1 O Press and hold the B button for more than 2 seconds until the dot disappears Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 13 EA Operation Step 1 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Step 2 Activate service mode Yes Step 3 No Step 1 Step 3 To activate service ab step 1 O Press and hold the E button for more than 2 but not longer than 5 seconds Step 4 15 Display reading Currently measured heating system supply temperature in F As soon as a non flashing dot is shown in the
99. frost of On protection of the DHW heating system has also been switched off Display code Other symptoms Diagnosis Main Sub display display Meaning code code Reset required No display code No indication on the display of gt section 31 the BC10 section 1 4 No display code On devices with DHW opera section 32 tion no or insufficient DHW radiators convectors etc may be heated without current heat demand No display code On devices with DHW opera section 33 tion hot water may be available no heating operation On devices without DHW operation no heating operation No display code No indication on the display of gt section 34 the BC10 section 1 4 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 21 EA Symptoms Display code LED on Other symptoms Diagnosis 5 UBA 3 Main Sub displa displa Meanin Fese pay p ay 9 required code code J z f Operating code A communication test is car Off or ried out while starting up This display code flashing flashes to check the communication between at 8 Hz the UBA 3 section 1 32 and the control panel section 1 4 3 5 times during a period of 3 5 seconds while starting up If a new UBA 3 or a new KIM has been fitted this display code will flash for max 10 seconds y Fault code If
100. g fault code The flue gas thermostat has measured an excessively high temperature pet pi AR A Step 1 Step 2 Step 3 ie ui TT 13 Step 1 Step 2 Step 3 Step 4 base Note The boiler can have a flue gas thermostat or a connection between the contacts 50 and 78 of the UBA 3 mounting base depending on the boiler type e Check the connection between contacts 50 and 78 of the UBA 3 mounting base according to section 123 and section 131 Is the connection okay Yes Section 66 No Step 3 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 T S wnt Locking fault code The flue gas sensor contacts have shorted 71 TT E L Locking fault code The flue gas sensor contacts are open 10 4 HT e Check the flue gas sensor as indicated in section 97 Is the flue gas sensor okay Yes Step 4 No Step 3 Diagnosis The flue gas sensor is defective Action Replace the flue gas sensor see section 99 gt Section 67 e Check the wiring of the flue gas sensor see section 98 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 39 157 Diagnosis Step 5 Step 6 Step 1 Step 2 Step 3 Step 4 Step 5 Is the flue gas sensor wiring okay Yes No Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 66 gt
101. he burner section 1 23 is shut down Step 61 The LED Burner operation is extinguished Step 62 Start of pump over run time for the heating system The pump over run time for the heating system can be adjusted as per section 23 Factory adjusted setting 5 minutes Start of air side flushing phase of the fan unit section 1 20 for approx 30 seconds Step 63 Have approx 30 seconds elapsed Yes Step 64 No Step 63 Step 64 The fan unit section 1 20 stops gt Step 15 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 19 ca Operation Step 65 The LED Central heat demand lights up Step66 Mf Operating code The boiler prepares for a burner start up whenever a heat demand arises The fan unit section 1 20 and the pump are started The glow ignitor section 1 27 is activated See also section 29 Display codes and other symptoms page 21 Step 67 flL Operating code The gas valve section 1 21 is activated See also section 29 Display codes and other symptoms page 21 Step 68 Maximum of four ignition attempts are carried out Does the ionization current exceed 1 4 microamperes within these Yes Step 69 igniti 2 4 ignition attempts No Step 12 Step 69 H Operating code The device is in heating mode See also section 29 Display codes and other symptoms page 21 The LED Burner operation is lit
102. heating system after all air has been purged from the heating system If the water pres sure is less than 14 PSI the heating system has to be topped up again as described above Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 59 Actions e Close the water stop valve e Close the filling valve on the boiler e Disconnect the filling hose e Install the cover on the filling valve e Open the boiler door and install the casing of the pump group as instructed in section 77 e Adjust the set buttons on the control panel to the target value see section 81 e Close the cover of the BC10 on the front of the boiler as instructed in section 71 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 inst
103. heck that there is a second fan unit in the flue gas pipe or air inlet system Step 14 Is a second fan unit fitted Yes No Step 15 Diagnosis A second fan unit has been fitted Action Take the second fan unit out of service Step 16 Check that the fan unit wheel has not come loose at the motor spindle see section 86 Step 17 Has the fan unit wheel come loose Yes No Step 18 Diagnosis The fan unit is defective Action Replace the fan unit see section 86 Step 19 Has the fault been remedied Yes No HEE Je mounting base Section 67 gt Step 12 gt Step 13 gt Section 67 gt Step 15 gt Step 16 gt Section 67 gt Step 18 gt Step 19 gt Section 67 gt Section 66 Locking fault code The safety temperature switch has measured an excessively high temper ature and is open or no connection is made between the contacts 22 and 24 of the UBA 3 Note The boiler can have a safety temperature switch or a connection between the contacts 22 and 24 of the UBA 3 mounting base depending on the boiler type Step 1 e Check the connection between contacts 22 and 24 of the UBA 3 mounting base according to section 123 and section 131 Step 2 Is the connection okay Yes No Step 3 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part oe Locking fault code The sensor test has failed HEO Ji Step 1 e Check the supply and safety temperature sensors and t
104. heir wiring for short circuits as instructed in section 93 Step 2 Are the supply and safety temperature sensors and their wiring okay Yes No Step 3 Diagnosis The supply and safety temperature sensors and or their wiring are defective Action Replace the supply and or safety temperature sensor as instructed in section 95 the wire harness or the relevant part of the wire harness HETO za over 266 F 130 C Step 1 Are the service valves open as instructed in section 78 Yes No Step 2 Diagnosis The service valves are closed Action Open the service valves see section 78 Buderus gt Section 66 gt Step 3 Section 67 gt Section 66 gt Step 3 gt Section 67 Locking fault code The contacts of the safety temperature sensor section 1 28 have shorted to each other the contacts of the safety temperature sensor have shorted to ground or the safety temperature sensor have measured a supply water temperature of Step 3 gt Step 2 44 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Step 3 Is the water pressure of the heating system at least 14 PSI Step 4 Diagnosis The water pressure of the heating system is less than 14 PSI Action Fill and bleed the heating system see section 78 Step 5 Are enough thermostatic valves open on the radiators convectors etc Step 6 Diagnosis There are not enough thermostatic valves open on the radiators convect
105. hing No heating operation and no gt section 53 A return temperature sensor section 1 31 4 6 7 8 1 Hz DHW have shorted to each other or the contacts of the return sensor have shorted to ground arm De mg Locking fault code The contacts of the Yes flashing No heating operation and no gt section 53 AAA HA return temperature sensor section 1 31 are 4 6 7 8 1 Hz DHW open EL 290 Blocking fault code The UBA 3 section 1 no Off No heating operation and no gt section 66 82 or the KIM is defective 5 7 DHW ire yay at Locking fault code The UBA 3 section 1 Yes flashing No heating operation and no gt section 66 ARA 32 or the KIM is defective 4 6 7 8 9 1 Hz DHW 2 to 1 cal HA Operating code The heating system water No Off Possibly no heating operation section 41 pressure is too low and is less than 12 PSI and no DHW A fluctuating current water pressure may be shown e g P0 5 As soon as the water pressure of the heating system is 14 PSI or more the display code H_ 1 will disappear As soon as the water pressure of the heating system is less than 6 PSI the boiler perfor mance for both the heating operation and the DHW mode will be limited p Operating code The water pressure of the No Off gt section 65 a heating system is beyond the measuring range of the pressure sensor section 1 30 Buderus 28 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from t
106. hon Install the casing of the pump group in reverse order of removal e Switch on the power supply to the heating system see section 79 Actions e While carrying out these activities check all sealing rings and gaskets for damage deformation and signs of aging and replace if required e Take the boiler out of operation and drain the boiler as instructed in section 75 SS YA EN JON Y LS Ee XI 1 ple Rd RS gt GA e Disconnect the plug of the pressure sensor 1 e Remove the clamp spring 2 Remove the pressure sensor 3 e Check the pressure sensor for dirt and clean it if necessary O Install the new or cleaned pressure sensor in reverse order e Fill and purge the heating system and put the boiler into oper ation see section 78 DANGER OF FATAL ACCIDENT 4 i due to electric shock _ DANGER OF FATAL ACCIDENT FIRE y from explosive fumes All work on gas pipe work and fittings must be carried out by authorized gas technicians While carrying out these activities check all sealing rings and gaskets for damage deformation and signs of ageing and replace if required e After carrying out these activities check the system for leaks on the gas side and or the flue gas side DAMAGE TO THE DEVICE 2 due to damage to the coating e The heat exchanger has been coated Avoid damaging this coating Do not use steel bristle bru
107. i H A 55 E E gt DCEL oOO i H tLe 2 2 3 3 A i i a OE F H E 5323 353 235 33 ec 2 i sO seg 235 o a o o aT 23 i 9 O umaq O y gt S gt 222838 lt 3 w i el O Oe aco0oDol gt i H Oz i L O mokua O y 8 PS 2 2 grey gris gris Patilla Broche 3 vert 311 lilac lila i lilas PK 16 6 green verde H i p i ys O abueio O ls O nla 70 o PA External connection for professional use Conexi n para expertos t cnicos Connexion externe pour l enterprise d entretien sp cialiste Logamax plus GB162 80 kW 100 kW i i i i i i i i i i i i i i i i i i i i i 4 15 pi i 10 2 S9 i i i RG oy O O gy 13 Et H 6L oa ebuejo HO v1 L ge peuo yous ez Op amm AO EL HBB PL gg pe o 5 i 1 i a 2 zea WA 62 O Pe O 24 3 19 S S eG i OSEE ova yz es Oj A amp b Ol 158 0335 4 i i Li C pas O 01 a 09 N WO m 406 ges AN o au B0 o ot Os Boise a i 99 Oi m O 555 IN AA H s O wmwoq 309 oise i nm O mg Og FESS o 4 l O oam Or tesa 0 a So E oS i le O enym 08 5 da 32 38 SE Sas 8 55 i lg O Oz 4978 Ps 35 5 gena ss O i f H 958 E 58 s O e O PEER ES Ld ESO yy y ejq E E aig 323 FR eR BE a 2 glelgeggig 4 pao a 7 BR FE pe S 3SSSSSS g i i alelalelelsis H s O F A916 a NIN i 8 O
108. indications and their meanings as well as other symptoms are described in section 29 Display codes and other symptoms on page 21 There are three types of display indication display reading section 27 Display readings on page 21 display setting section 28 Display settings on page 21 display code section 29 Display codes and other symptoms on page 21 There are three types of display code operating code This code gives the status of the boiler No action is necessary blocking fault code The boiler is locked and will only restart after a manual reset The pump will operate continuously for frost protection locking fault code The boiler resumes normal operation when the fault has cleared Every display code e g the locking fault code consists of a main code in this case JL f a subcode in this case J266 After reading the main code the subcode can be called up by pressing the service key Step 2 chapter 6 Diagnosis Diagnosis establishing the cause of the fault or error on the basis of the symptoms A diagnosis chapter 6 Diagnosis on page 30 can be made after determining all symptoms The right hand column of the symptoms overview section 5 Symptoms on page 21 refers to the corresponding diagnosis box The diagnosis box can be used next to easily find the cause of the fault Step 3 chapter 7 Actions Action remedying the cause of the fault or e
109. instructed in section 73 e Close the gas stop valve as indicated in section 74 e Loosen the gas connection pressure testing nipple screw 1 by two turns e Connect a long hose 2 to the gas connection pressure test ing nipple and lay this hose so that it ends up outside the building e Open the gas stop valve as instructed in section 81 until no further air escapes from the hose e Close the gas stop valve as indicated in section 74 e Remove the hose from the gas connection pressure testing nipple e Tighten the gas connection pressure testing nipple screw e Open the gas stop valve as indicated in section 81 e Check the gas connection pressure testing nipple for leaks using a foaming agent which has been approved for gas leak testing e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 Buderus N DANGER OF FATAL ACCIDENT FIRE y from explosive fumes All work on gas pipe work and fittings must be carried out by authorized gas technicians e Check the measuring nipples used for leaks using a foaming agent which has been approved for gas leak testing e Switch off the power supply to the heating system see section 72 e Open the boiler door and remove the casing of the pump group as instructed in section 73 e Close the gas stop valve as indicated in section 74 e Open some of the radiator valves
110. into operation see section 20 End the heat demand in accordance with section 20 wait for the LED Burner operation to extinguish and then check that there is still a voltage on the gas valve see section 110 Step 7 Is there still a voltage on the gas valve Yes Section 66 No Step 8 Step 8 Diagnosis The gas valve is defective Action Replace the gas valve see section 113 Blocking fault code Insufficient flame activity ionization current was measured during the ER g burner procedure Step 1 Is the heating system propane gas fired Yes Step 2 No Step5 Step 2 e Contact the gas utility company to check that there is no nitrogen in the new or existing gas tank and the gas supply pipework Step 3 Is there still nitrogen in the new or existing gas tank and the gas supply pipework Yes Step 4 No Step 5 Step 4 Diagnosis There is nitrogen in the gas tank and the gas supply pipework gt Section 67 Action Remove the nitrogen in conjunction with the gas utility company Step 5 e Check that the device gas stop valve is open as instructed in section 81 and that the main gas stop valve is open Step 6 Are both gas stop valves open Yes Step 8 No Step 7 Step 7 Diagnosis The device gas stop valve and or the main gas stop valve is are closed gt Section 67 Action Open the device gas stop valve as instructed in section 81 and open the main gas stop valve Step 8 e Check the static and dynamic gas s
111. ject to modifications resulting from technical improvements 71 N CAUTION Note that some water may escape when the sensor is removed Keep a bucket and a cleaning rag ready e Disconnect the safety temperature sensor plug 1 Remove the clamp spring of the safety temperature sensor by moving it in the direction indicated by the arrow 2 e Remove the safety temperature sensor 3 Ye A E Nei ji OS Y TZ MON N CAUTION 423 Note that some water may escape when the sensor is removed Keep a bucket and a cleaning rag ready e Disconnect the return temperature sensor plug 1 Remove the clamp spring 2 Remove the return temperature sensor 3 e Install the relevant new sensor in reverse order e Fill and purge the heating system and put the boiler into oper ation see section 78 e Switch on the power supply to the heating system see section 79 Buderus e Switch off the power supply to the heating system see section 72 24 AE e Disconnect the DHW temperature sensor plug 1 e Remove the DHW temperature sensor from the tank 2 e Install the new DHW temperature sensor in reverse order e Attach the plug of the DHW temperature sensor in reverse order e Switch on the power supply to the heating system see section 79 N DANGER OF FATAL ACCIDENT FIRE y due to flue gas escaping After carrying out these activitie
112. leaks on the gas side and or the flue gas side Take the boiler out of operation see section 72 and 73 e Close the gas stop valve as indicated in section 74 N xS OEE e Remove the power supply plug s of the gas regulation CIC valve 1 Wy E e 2 Undo the union from the gas supply 2 J e Remove the gas air unit including the burner cover 1 by moving it in the direction indicated by the arrow yy a Remove both the fan unit power supply cord plug 1 and the fan unit tacho cable plug 2 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 63 Loosen the torx screws 1 and remove the gas valve inclu ding the venturi pipe 2 from the fan unit e Check that the fan unit is not dirty or wet clean or dry it if required e Check that the fan unit wheel has not come loose at the motor spindle Loosen the two torx screws 1 and remove the fan unit 2 from the burner cover 3 O Install the new fan unit in reverse order on the burner cover Buderus e f necessary replace the O ring between the fan unit and the
113. ltage okay Yes Step 15 No Step 14 Step 14 Diagnosis The main voltage is not OK Action Solve the problem in the electrical system gt Section 67 Step 15 Diagnosis The fan unit is defective Action Replace the fan unit see section 86 Step 16 Has the fault been remedied Yes Section 67 No Section 66 Buderus 42 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Check that the tacho plug of the pump valve has been installed correctly see section 90 Has the tacho plug of the pump been installed correctly Diagnosis The tacho plug of the pump has not been installed correctly Action Install the tacho plug of the pump correctly see section 90 e Check the electrical resistance of the tacho cable of the pump as indicated in section 89 Is the pump tacho cable okay Diagnosis The wire harness is defective Action Replace the wire harness or the affected part e Attempt to rectify the fault by temporarily replacing the pump see section 92 Has the fault been remedied during the operating phase Yes No Yes No Yes No gt Step 4 gt Step 3 Section 67 gt Step 7 gt Step 6 Section 67 Section 67 gt Section 66 Blocking fault code The fan unit tacho signal section 1 20 or the fan unit voltage has failed Locking fault code The fan unit tacho signal section 1 20 or the fan unit supply voltage is
114. lting from technical improvements Step 15 Have a hot water tap or taps been opened briefly and consecutively on several occasions Step 16 Diagnosis A hot water tap or taps have been opened briefly and consecutively on several occasions Action Inform the user Step 17 Check the electrical resistance of the DHW temperature sensor as indicated in section 93 Step 18 Is the electrical resistance of the DHW temperature sensor okay gt section 134 Step 19 Diagnosis The DHW temperature sensor is defective Action Replace the DHW temperature sensor see section 96 heating supply temperature higher than 203 F 95 C 04 215 m S ey 04 285 E Pan 2 11 E O pa eu 3 supply temperature higher than 203 F 95 C return water temperature higher than 203 F 95 C heating water temperature increase after a burner start much water temperature increase of more than 9 F sec 5 C sec 90 F 50 C Diagnosis 6 Yes No Yes No gt Step 16 gt Step 17 Section 67 gt Section 66 Step 19 Blocking fault code The supply temperature sensor section 1 24 has measured a current Blocking fault code The safety temperature sensor section 1 28 has measured a current Blocking fault code The return temperature sensor section 1 31 has measured a current Blocking fault code The supply temperature sensor section 1 24 has not mea
115. lugs in reverse order of e Close the boiler door as instructed in section 77 removal e Switch on the power supply to the heating system see e Close the boiler door as instructed in section 77 section 79 e Switch on the power supply to the heating system see section 79 Buderus 80 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements DANGER OF FATAL ACCIDENT FIRE A from explosive fumes XA All work on gas pipe work and fittings must be carried out by authorized gas technicians e While carrying out these activities check all sealing 1 rings and gaskets for damage deformation and signs of ageing and replace if required e After carrying out these activities check the system for leaks on the gas side and or the flue gas side e After carrying out these activities check the measuring A o nipples used for leaks using a foaming agent which has E ee been approved for gas leak testing Install the orifice 1 in the venturi pipe e Switch off the power supply to the heating system see e Install the new gas valve on the venturi pipe in reverse order section 72 as instructed before e Open the boiler door and remove the casing of the pump e if necessary replace the gasket between the fan unit and the group as instructed in section 73 venturi pipe as instructed in section 86 e Close the gas stop valve as indicated in section 74 e Install the new gas valve including the v
116. move the UBA 3 as instructed in section 82 Remove the cover from the connection tray see section 114 Pin ang egy yng Pin 16 16 pin high voltage connector While depressing the lock using a screwdriver 1 pull the transformer upwards 2 Remove both the power supply plug 3 and the low voltage plug 4 O Install the new transformer in reverse order Install the lid on the connection tray in reverse order O Install the UBA 3 in reverse order of removal GENES Pin 1 e Close the boiler door as instructed in section 77 OOS OOOOCOOOSO00S000000500m 28 Pin 81 000800800 0 0 0 0 0 0 o 0 0 55 ps y n e Switch on the power supply to the heating system see KIM O section 79 AA em 16 16 pin high voltage connector e Set the multimeter to Measure resistance 1 Check the power supply cord and the low voltage cord for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the black contacts high voltage connector pins 3 4 7 and low voltage connector pins 1 25 27 28 52 80 81 on the UBA 3 mounting base 3 Check the power supply cord and the low voltage cord for internal short circuiting The electrical resistance measured between two random wires must be infinite Measure the electrical resistance
117. moved Chimney sweep button The Chimney sweep button 3 is used to activate a flue gas test the service mode or manual operation The flue gas test enables the boiler to be run in full load oper ation manually for a short period See also section 20 Flue Gas Test menu page 13 The service mode enables the boiler to be run in part load operation manually for a short period The service mode should be used to carry out measurements and settings on the boiler See also section 21 Service Mode menu page 14 10 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements The manual operation mode enables the boiler to be run manually for a long period Manual operation should be used for situations where the controller has not been installed yet or where the controller is out of order See also section 22 Manual Operation menu page 15 A maximum heating system supply temperature in accordance with the setting of the space heating water temperature knob section 14 8 on the BC 10 applies during the flue gas test service and manual operation DAMAGE TO THE INSTALLATION A with floor heating by the pipework being over heated e Use the space heating water temperature knob 8 to limit the maximum heating system supply temperature to the permitted heating system supply temperature of the floor heating circuit This is usually approximately 104 F 40 C DAMAGE TO THE
118. n and no gt section 66 DHW Main Sub a display a display code code SL 10 GA dg eR O t A EIES BE ccd aes es ee BE 306 A Ie E BL ecg JEP J269 11 If 1H 308 ees E IE y Fat J26 1 nit ft O Ja By 1 BBE ELO Ez Jax fea yan EE gaf 3212 EI Eu EI O EE Buderus 26 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Main displa code a y ap y Jau AG t AD t AD t AB Ae t Ade Aci Adc 4 Sub display code a sea or Jaa Display code LED on UBA 3 Reset Meaning i required Locking fault code The UBA 3 section 1 Yes flashing 32 or the KIM is defective 4 6 7 8 1 Hz Locking fault code The UBA 3 section 1 Yes flashing 32 or the KIM is defective 4 6 7 8 1 Hz Blocking fault code The contacts for the out No Off door temperature sensor are open or have shorted Blocking fault code The contacts for the No Off DHW temperature sensor are open or have shorted Blocking fault code The contacts for the No Off DHW temperature sensor 2 are open or have shorted Blocking fault code DHW mode was active No Off for 4 hours with
119. n reverse order of removal e Close the boiler door and install the casing of the pump group in reverse order of removal e Switch on the power supply to the heating system see section 79 DANGER OF FATAL ACCIDENT ZN due to electric shock e Switch off the power supply to the heating system see section 72 e Open the boiler door and remove the casing of the pump group as instructed in section 73 Remove the UBA 3 as instructed in section 82 e Remove the cover from the connection tray see section 114 81 pin low voltage connector g a Pin 1 HAHAHA 2 Pn PaGeo GOED a P 1 16 pin high voltage connector 3 nev e Set the multimeter to Measure resistance 1 e Connect the multimeter 2 e Check the tacho cable of the pump for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the black contacts low voltage connector pins 67 and 68 on the UBA 3 mounting base 3 e Check the tacho cable of the pump for internal short circuit ing The electrical resistance measured between two ran dom wires must be infinite See section 131 Measure the electrical resistance over the pump tacho cable to ground The electrical resistance must be infinite for every individual wire e Disconnect the pump tacho cable plug Attach the
120. nce for both the heating operation and the DHW mode will be limited Blocking fault code The supply temperature sensor section 1 24 has not measured any heating water temperature increase after a burner start Operating code blocking fault code The temperature difference of the heating water measured between the supply section 1 24 and safety temperature sen sors section 1 28 is too much Locking fault code The pressure sensor section 1 30 failed to measure a pressure increase on the heating side during any of four attempts Blocking fault code The supply temperature sensor section 1 24 has measured a heating water temperature increase of more than 9 F sec 5 C sec Blocking fault code The temperature differ ence measured between the supply tempera ture sensor section 1 24 and the return temperature sensor section 1 31 is more than 90 F 50 C Operating code The pump speed was found to be too high or too low while starting up OU The modulating function of the pump is switched off The pump continues to run but the pump speed is fixed Operating code The tacho signal of the pump is missing LED on UBA 3 Reset required No Off 5 7 Yes flashing 4 6 7 8 1 Hz Yes flashing 4 6 7 8 1 Hz Yes flashing 4 6 7 8 1 Hz Yes flashing 4 6 7 8 1 Hz No Off No Off No Off Yes flashing 4 6 7 8 1 Hz No Off 5 7 No Off 5 7
121. nd 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 loss 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 80 kW 100 kW Installation Instructions User s Manual Service Instructions Please contact us if you have any suggestions for improvement or corrections Subject to technical modifications Slight changes may be made without prior notice to the illustra tions process steps and technical data as a result of our policy of continuous improvement General EA This document consists of various sections They have been divided into subsections Every subsection is marked with a grey frame An ID number is always provided in the top left hand corner References in the document are based on these ID numbers In addition a subsection may be divided into various numbered operating steps Reference to a certain operating step is always made within the same subsection If an operating
122. nd pressure relief valve Pressure gauge Isolating valve Thermometer optional accessory Drain valve Pressure relief valve 30 PSI 2 bar or 50 PSI 3 45 bar optional Product Description L The pump group also includes an insulation cover see also pump group installation instructions Low loss header scope of delivery single appliance only 44 Low loss header not illustrated Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 3 m Contents Section page Product description co cccoccrcra ca a uaiiie niita 2 A rati r VIE ERE EAE ae cae 5 General information 0 000 c eee eee 5 Layout of this document 0 00 00 ce eee eee 5 Remedying faults using this document 0 00 6 Logamax plus GB162 0 cette 6 2 Safety and general instructionS o oooooo 7 Safety and general instructions 0 00 c eee eee eee 7 3 Regulations and guidelines o ooooooomo o 9 General regulations 0 0 0 0 cece eee 9 Regulations in Massachusetts 00 00 00 cece o 9 4 Operator as 10 GOnelal vuestra a pd Seek eae 10 Menu structure coi ri a bee eerie es 12 Normal Operation menu 00 000 eee eee 13 Flue Gas Test menu 0 eee 13 Service Mode menu 0c eee eee 14 Manual Operation menu 0 0 cee eee eee 15 SetingS MENU veis ii a A Pay ede aoe 15 Operation epi
123. nd repairs must only be carried out by trained professionals You are only permitted to operate the condensing gas boiler with the combustion air flue gas system that has been specif ically 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 You must also observe The local building regulations stipulating the installation rules at the time of installation The local 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 con cerning the connection of the gas burner fitting to the local gas main The instructions and standards concerning the safety equip ment 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 adja cent 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
124. ndicated in section 92 e Check that the tacho plug of the pump valve has been installed correctly see section 90 Has the tacho plug of the pump been installed correctly Diagnosis The tacho plug of the pump has not been installed correctly Action Install the tacho plug of the pump correctly see section 90 e Check the electrical resistance of the tacho cable of the pump as indicated in section 89 Is the pump tacho cable okay Diagnosis The wire harness is defective Action Replace the wire harness or the affected part e Check the pump power supply cord as instructed in section 89 Is the pump power supply cord okay e Check the pump for contamination as instructed in section 87 Is the pump dirty Diagnosis The pump is dirty Action Clean the pump see section 87 e Attempt to rectify the fault by temporarily replacing the pump see section 92 Has the fault been remedied Yes No Yes No Yes No Yes No Yes No Yes No Yes No Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements The modulating function of the pump is switched off The pump continues to run but gt Step 4 gt Step 3 gt Section 67 gt Step 6 gt Step 7 gt Section 67 gt Step 10 gt Step 9 gt Section 67 gt Step 13 gt Step 12 gt Section 67 gt Step 15 gt Step 12 gt Step 17 gt Step 18 gt Section 67 gt
125. nent or connect the pipes correctly Step 12 e Check to see if any other external part of the drinking water system is a possible cause Step 13 Is such a cause detected Yes Step 14 No Section 67 Step 14 Diagnosis Another external part of the drinking water system is a possible cause of the fault gt Section 67 Action Take the affected components out of service Step 15 e Check the DHW mode as indicated in section 23 that the DHW temperature is adjusted to a high enough setting according to section 81 that the DHW supply has not been shut off by the timer switch program of the RC regulator Consult the operating instructions of the RC regulator Step 16 Are the settings okay Yes Step 18 No Step 17 Step 17 Diagnosis The settings are not OK Action Adjust the settings gt Section 67 Step 18 Open the stop tap of the cold water inlet pipe and a hot water tap Step 19 Check that the LED DHW demand on the BC10 is lit see section 14 11 Step 20 Is the LED lit Yes gt Step 27 No Step 21 Step 21 E Check the DHW temperature sensor see section 93 Step 22 Is the DHW temperature sensor okay Yes gt Step 24 No Step 23 Step 23 Diagnosis The DHW temperature sensor is defective Section 67 Action Replace the DHW temperature sensor see section 96 Step 24 e Check the DHW temperature sensor lead as indicated in section 94 Step 25 Is the wire okay Yes
126. ng circuit address 3 and the corresponding room thermostat Blocking fault code The supply temperature No Off sensor of heating circuit address 2 indicates a fault Symptoms Ea Other symptoms No heating operation and no DHW No heating operation and no DHW A minimum outdoor tempera ture of 40 F 40 C is assumed This may cause the room temperature to be too high Heating operation but no hot water Heating operation but no hot water Heating operation but no hot water The tank has not been disin fected No heating operation and no DHW No heating operation and no DHW The BC10 settings are not shown on the RC thermostat Heating system supply tem perature at heating circuit addresses too low The heating circuit pump is run continuously The mixer is not activated any more and stays in its last posi tion Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Diagnosis gt section 66 gt section 66 gt section 64 gt section 65 Buderus 27 EA Symptoms Display code LED on Other symptoms Diagnosis UBA 3 Main Sub 4 Reset display display Meaning a required code code Ad
127. ng code The boiler is in heating mode See also section 29 Display codes and other symptoms page 21 and further Have at least 5 seconds passed without a button being pressed and or has the main voltage been interrupted Yes Step 1 No Step 8 O Press the button Step 1 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Activate flue gas test Yes Step 3 No Step 1 To activate the flue AON Press and hold the E button for more than 2 but not longer than 5 seconds 15 Display reading Current heating system supply temperature in F As soon as a non flashing dot is shown in the bottom right hand corner of the display the flue gas test has been activated This means that the boiler is in heating mode at a capacity of 100 for a maximum period of 30 minutes The maximum heating system supply temperature set on the control panel now applies DHW mode is not possible during the flue gas test O Press the button P 22 Display reading Currently measured heating system water pressure in PSI See also section 27 Display readings page 21 O Press the es button A Operating code A flue gas test is being carried out or the boiler is in service mode Flue gas test The boiler is in heating mode at a capacity of 100 for a maximum of 30 minutes The maximum heating system supply temperature set on the control panel now appli
128. nization circuit ground lead 79 Checking the gas valve power supply plug 79 Checking the gas valve activation o ooocooooooooo 79 Checking the gas valve electrical resistance of the power SUPPIV COM os ceci a a aa eae 80 Checking the gas valve internal electrical resistance 80 Replacing the gas valve 1 2 eee 81 Checking the ON OFF controller 00 0 e eee eee ee 82 Checking the RC regulator 0 0 cece eee eee 82 Checking an external switch contact 000 eee 83 Measuring the difference between the static and dynamic gas supply pressures 0 cece cee ee eee 83 Bleeding the gas supply pipe 0000 02 eee 84 Measuring and adjusting the gas air ratio 84 Checking the transformer internal electrical resistance 85 Checking the transformer power supply cord and low voltage cord 86 Replace transformer 00 0 cece eee ee eee eee eens 86 Checking the wire harness connections 87 Checking the cotrol panel supply voltage o 87 Replacing the automatic air purging system 88 Replacing cleaning the burner 02 0 e eee eee ee eee 88 Replacing cleaning the siphon 0 00 c eee eee eee ee 89 Checking replacing the pressure sensor pollution 89 Replacing cleaning the heat exchanger 0 89
129. nsor see section 95 Step 7 e Check the movement of the servomotor of the three way valve Step 8 Does the servomotor of the three way valve move Yes No Step 9 e Check that the three way valve has been installed correctly Step 10 Has the three way valve been installed correctly Yes No Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements gt Step 3 gt Step 4 gt Section 67 gt Step 7 gt Step 6 gt Step 9 gt Step 12 gt Step 18 gt Step 11 Buderus 53 ea Diagnosis Step 11 Diagnosis The three way valve has not been installed correctly Action Install the three way valve correctly Step 12 e Check that the three way valve is being activated Step 13 Is the three way valve activated Yes No Step 14 Diagnosis The servomotor of the three way valve is defective Action Replace the servomotor of the three way valve Step 15 Check the wiring of the three way valve Step 16 Is the wiring of the three way valve okay Yes No Step 17 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part Step 18 Check the interior of the three way valve for contamination and or damage Step 19 Is the three way valve okay Yes No Step 20 Diagnosis The three way valve is defective Action Replace the three way valve scat Jeet 101 prg Ao i S pan Pes Locking fa
130. nting base for breaks The electrical resistance measured separately for every wire must be approx 0 2 Measure between the connection tray and the black contacts low voltage connector pins 63 and 64 on the UBA 3 mounting base 3 Actions e Check the cable of the DHW temperature sensor between the connection tray and the UBA 3 mounting base for internal short circuiting The electrical resistance measured between two random wires must be infinite e Measure the electrical resistance over the DHW temperature sensor cable to ground The electrical resistance must be infi nite for every individual wire Attach the relevant sensor plugs O Install the UBA 3 in reverse order of removal O Install the lid on the connection tray in reverse order e Close the boiler door in reverse order e Switch on the power supply to the heating system see section 79 e Drain the boiler see section 75 e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 N CAUTION Note that some water may escape when the sensor is removed Keep a bucket and a cleaning rag ready e Disconnect the supply temperature sensor plug 1 Remove the clamp spring of the supply temperature sensor by moving it in the direction indicated by the arrow 2 Remove the supply temperature sensor 3 Buderus Logamax plus GB162 80 kW 100 kW Sub
131. nuously thus minimizing the risk of the heating system freezing up Step 13 0 H Operating code The boiler is in standby mode No current heat requirement See also section 29 Display codes and other symptoms page 21 Step 14 Start of pump over run time for the heating system The pump over run time for the heating system can be adjusted as per section 23 Factory adjusted setting 5 minutes Step 15 Has the preset pump over run time expired Step 16 Is there a DHW heating system which has generated a heat demand Step 17 Is there a current heat demand from the room or external temperature dependent controller Step 18 Is the current heating system supply temperature lower than 45 F 7 C Step 19 The pump stops Step 20 Has the pump been out of use for more than 24 hours Step 21 Is there a DHW heating system which has generated a demand Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Operation EN Yes Step 13 No Step 12 gt Step 1 Yes Step 19 No Step 16 Yes Step 29 No Step 17 Yes gt Step 48 No Step 18 Yes Step 65 No Step 15 Yes Step 24 No Step 21 Yes gt Step 29 No Step 22 Buderus 17 EA Operation Step 22 Is there a current heat demand from the room or external temperature dependent controller Yes Step 48 No gt Step 23 Step 23 Is the current heating sy
132. oints The heating boiler is fitted with a control panel the BC10 basic controller The BC10 can be used to control the heating system In addition it is possible to call up display readings settings and codes on the display of the BC10 The display settings can be changed after calling them up See chapter 5 Symptoms on page 21 Ta e Briefly press the access cover of the BC10 to open it The control panel is located on the left behind the access cover 2 The Operating Instructions are located in a compartment on the back of the access cover 1 Buderus The control panel has the following elements 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 10 DHW temperature knob 11 LED DHW demana SMRNBARAHN gt Main power switch The main power switch 1 is used to switch the mains power to the heating boiler on and off Reset button With certain faults you may have to restart the boiler by pressing the Reset button 2 This is only required in the event of a locking fault can be recognized by a flashing error code in the display During a reset the display shows E Blocking errors which can be recognized by a non flashing error code are reset automatically as soon as their cause has been re
133. on on the display of the BC10 section 1 4 Step 1 Does the boiler work normally Yes Step 2 No Step 11 Step 2 e Check that there is 7 8 to 15 2 VDC on both contacts 1 and 2 of the connector between the BC10 and the bottom plate of the BC10 see section 124 and section 131 Step 3 Is there a voltage Yes Step 4 No Step 8 Step 4 e Check the contact between the BC10 section 1 4 and its slot by pushing on the BC10 Step 5 Is there any indication on the BC10 display within a few minutes Yes Step 6 No Step7 Step 6 Diagnosis There is insufficient contact between the BC10 section 1 4 and its slot Section 67 Action replace BC10 and or its slot Step 7 Diagnosis The control panel BC10 is out of order gt Section 67 Action Replace BC10 See the Installation and servicing instructions of the BC10 Step 8 e Check the corresponding component of the wire harness see section 131 Step 9 Is the wire harness free of damage Yes Section 66 No Step 10 Step 10 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 11 Check that the plug is in the grounded socket Step 12 Is the plug in the grounded socket Yes Step 14 No Step 13 Step 13 Diagnosis The plug is not in the grounded socket gt Section 67 Action Insert the plug into the grounded socket see section 79 Step 14 e Check that the main power
134. ons N DANGER OF FATAL ACCIDENT FIRE due to flue gas escaping After carrying out these activities check the system for leaks on the flue gas side e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 Disconnect the plug of the flue gas sensor as instructed in section 97 Remove the cap from the measuring nipple of the combus tion air supply as instructed in section 97 Remove the flue gas sensor 1 e Install the new flue gas sensor in reverse order e Attach the plug of the new flue gas sensor in reverse order e Close the boiler door in reverse order e Switch on the power supply to the heating system see section 79 Buderus A DANGER OF FATAL ACCIDENT LIAS due to electric shock e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Disconnect the plug of the glow ignitor 1 e Set the multimeter to Measure AC voltage Minimum mea suring range 120 VAC 2 e Switch on the power supply to the heating system see section 79 e Put the boiler in flue gas test mode see section 20 e Check that approx 120 VAC is measured on the plug 3 while the operating code O E is displayed e Switch off the power supply to the heating system see section 72 e Attach the
135. operly registered WARNING Dangerous flue gas can escape if the air supply is insufficient e Make sure that air vents are not reduced in size or obstructed e The boiler may only be operated after the defect has been remedied e Warn the user of the system of the defect ver bally and in writing gt E A Heating system requirements Installing a dirt trap like a y strainer and a desludging device is required This must be installed in the heating system in the immediate vicinity of the boiler in an easily accessible posi tion between the boiler and the lowest point in the return of the system Clean the dirt trap at every annual service Never use salt bedding type exchangers ion exchangers to soften the water The low loss header and boiler connection set must be installed supplied with the boiler When using oxygen permeable pipes plastic e g for floor heating systems you must separate the system using sec ondary heat exchangers Buderus 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 please see the accompanying Water quality requirements for Logamax plus GB162 80 kW 100 kW manual CAUTION AN Risk of system damage due to unsuitable heating system water e f oxygen permeable pipes are used e g for underfloor heating systems the systems
136. or use with Buderus controls LED DHW demand The LED DHW demand 11 lights up as soon as water is being heated as the result of a hot water demand and is extin guished as soon as the heating system for DHW mode is switched off Buderus The boiler menu structure can be browsed on the BC10 using the Reset Chimney sweep or Service buttons section 17 2 3 and 4 and the display section 17 9 The boiler menu structure consists of 5 menus Normal Operation menu section 19 page 13 Flue Gas Test menu section 20 page 13 Service Mode menu section 21 page 14 Manual Operation menu section 22 page 15 Settings menu section 23 page 15 12 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Operation ES 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Continue in Normal Operation menu Yes Step 3 No Step 1 O Press the wom button P 22 Display reading Currently measured heating system water pressure in PSI See also section 27 Display readings page 21 Press the ome button H Random operating code In this case Operati
137. oring and is then modulated up or down The degree of modulation of the pump will hardly vary during DHW mode the pump will be running almost continuously at 100 Step 34 Is there still a heat demand Yes Step 35 No Step 40 Step 35 Is the heating system supply temperature 45 F 25 C higher than the preset DHW temperature or higher than Yes Step 36 200 F 93 C No Step 33 Step 36 oY Operating code The supply temperature sensor has measured a current heating supply temperature higher than the supply temperature setting on the control panel section 1 4 or higher than the supply temperature calculated according to the heating curve or higher than the supply temperature calculated according to the DHW mode Step 37 The LED Burner operation is extinguished Step 38 The fan unit section 1 20 continues to run for max 30 seconds Step 39 Has the heating system supply temperature fallen sufficiently Yes gt Step 29 No Step 39 Step 40 The gas valve section 1 21 is closed and the burner is shut down Step 41 The LED Burner operation is extinguished Step 42 The LED DHW demand is extinguished Step 43 OH Operating code The boiler is in standby mode There is no current heat demand Start of pump over run time via the tank for a period of approx 60 seconds Start of air side purging phase of the fan unit section 1 20 for approx 30 seconds See also section 29 Display codes and
138. ors etc Action Open more thermostatic valves Step 7 e Check the safety temperature sensor as indicated in section 93 Step 8 Is the safety temperature sensor okay Step 9 Diagnosis The safety temperature sensor is defective Action Replace the safety temperature sensor see section 95 Step 10 Check the safety temperature sensor cable as indicated in section 94 Step 11 Is the wire okay Step 12 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part Step 13 e Check the pump as indicated in section 87 Step 14 Is the pump okay Step 15 Diagnosis The pump is defective Action Replace the pump see section 92 Diagnosis 3 Yes No Yes No Yes No Yes No Yes No gt Step 5 gt Step 4 gt Section 41 gt Step 7 gt Step 6 gt Section 67 gt Step 10 gt Step 9 gt Step 13 gt Step 12 gt Section 67 gt Section 66 gt Step 15 gt Section 67 yap amp Jaa Locking fault code The contacts of the safety temperature sensor section 1 28 are open t T y ll Locking fault code The contacts of the supply temperature sensor section 1 24 have J Y E J g ef shorted t tt Hyg e a Locking fault code The contacts of the supply temperature sensor section 1 24 are open t tt L IL Locking fault code The contacts of the return temperature sensor section 1 31 have JE Hy E fz y of shorted
139. out any interruption while a heat demand occurred as well The DHW heating system has been switched off after this period of 4 hours while the boiler is in heating mode Blocking fault code Thermal disinfection has No Off been switched off Blocking fault code The UBA 3 bus is over No Off loaded Blocking fault code The water pressure indi No Off cation of the heating system does not work Blocking fault code No communication No Off between the room thermostat and the control panel section 1 4 Blocking fault code The room thermostat No Off sensor indicates a fault Blocking fault code No communication with No Off the RC35 takes place Blocking fault code Select RC35 as one of No Off the heating circuit addresses Blocking fault code Activate at least one No Off heating circuit address via the service menu Blocking fault code The switch module sen No Off sor indicates a fault Blocking fault code No communication with No Off the switch module Blocking fault code Two RC room thermo No Off stats are connected they have been assigned the wrong heating circuit addresses Blocking fault code There is no communica No Off tion between heating circuit address 1 and the corresponding room thermostat Blocking fault code There is no communica No Off tion between heating circuit address 2 and the corresponding room thermostat Blocking fault code There is no communica No Off tion between heati
140. pening the gas valve section 1 21 Locking fault code Flames ionization cur rent were detected after switching off the burner section 1 23 Blocking fault code Insufficient flame activity ionization current was measured during the burner procedure Locking fault code The glow ignitor section 1 29 was activated too long for more than 10 minutes Locking fault code The power supply was interrupted during a locking fault yan Je tap HEY J y 1 yy y yi HE Jeet HEF 3213 Yau 42206 Suu Jrz o jay t fees Blocking fault code The main voltage has briefly been interrupted Locking fault code The UBA 3 section 1 32 is defective Locking fault code The UBA 3 section 1 32 is defective Operating code The external switch contact has opened Operating code Display test while starting up immediately after switching on the main voltage This code is displayed fora maximum of 1 second Locking fault code The KIM is too new for the UBA 3 section 1 32 Locking fault code The UBA 3 section 1 82 or the KIM is defective Locking fault code The UBA 3 section 1 32 or the KIM is defective Locking fault code The UBA 3 section 1 32 or the KIM is defective Locking fault code The contacts of the gas valve section 1 21 are open Locking fault code The UBA 3 section 1 3
141. pin high voltage connector e Remove the tacho cable plug see section 86 2 e Set the multimeter to Measure resistance 1 e Connect the multimeter e Check the fan unit tacho cable for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the black contacts low voltage connector pins 16 17 44 and 45 on the UBA 3 mounting base 3 e Check the fan unit tacho cable for internal short circuiting The electrical resistance measured between two random wires must be infinite See also section 131 e Remove the multimeter e Connect the tacho cable plug in reverse order O Install the UBA 3 in reverse order of removal Install the lid on the connection tray in reverse order e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 62 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements DANGER OF FATAL ACCIDENT 4 i due to electric shock DANGER OF FATAL ACCIDENT FIRE y from explosive fumes All work on gas pipes and fittings must be carried out by authorized gas technicians e While carrying out these activities check all sealing rings and gaskets for damage deformation and signs of aging and replace if required e After carrying out these activities check the system for
142. played Yes Step 28 No gt Step 25 Step 28 Connect a digital pressure gauge see section 119 Open the gas stop valve see section 81 and put the boiler into operation see section 20 Check that the gas valve is opened while switching over from the operating code E to the operating code L_ The opening of the gas valve while switching over from the operating code O to the operating code OL can be recognized by the pressure reading changing to approx 0 02 inch W C Step 29 Does the pressure reading change to approx 0 02 inch W C while switching over from the operating code Yes Step 43 o L to the operating code OL No Step 30 Step 30 e Check the plug and socket connection of the gas valve see section 109 Step 31 Is the plug and socket connection okay Yes Step 33 No Step 32 Step 32 Diagnosis The plug and socket connection has come loose gt Section 67 Action Replace the plug and socket connection on the gas valve see section 109 Step 33 e Check that a voltage is supplied to the gas valve while the operating code L is displayed see section 110 Step 34 Is voltage supplied to the gas valve Yes Step 35 No Step 36 Step 35 Diagnosis The gas valve is defective Action Replace the gas valve see section 113 gt Section 67 Step 36 e Check the gas valve power sup
143. plug of the glow ignitor in reverse order e Close the boiler door in reverse order e Switch on the power supply to the heating system see section 79 74 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Disconnect the plug of the glow ignitor 1 O Set the multimeter to Measure resistance 2 e Check that the electrical resistance of the glow ignitor is between 50 and 300 Q 3 Attach the plug of the glow ignitor in reverse order e Close the boiler door in reverse order e Switch on the power supply to the heating system see section 79 DANGER OF FATAL ACCIDENT 4 due to electric shock DAMAGE TO THE INSTALLATION EX To prevent damage do not insert the multimeter measuring electrodes too far into the holes of the plug and socket connection e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 Remove the UBA 3 as instructed in section 82 Remove the cover from the connection tray see section 114 e Disconnect the plug of the glow ignitor as instructed in section 101 1 ELUKE 73111 vunueren pin eo ed dodo dp odo Pin 16
144. ply cord as indicated in section 111 Step 37 Is the power supply cord okay Yes Section 66 No Step 38 Step 38 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 39 e Check that the overall gas supply network is of sufficient capacity Step 40 Is the overall gas supply network of sufficient capacity Yes Step 42 No Step 41 Step 41 Diagnosis The gas supply network is not of sufficient capacity gt Section 67 Action Increase the capacity of the gas supply network Step 42 Diagnosis The cause of the fault is to be found outside the boiler and the gas pipe gt Section 67 The gas supply pressure regulator may be defective Action Contact the gas utility company Step 43 Check that the gas air ratio is approximately 0 02 inch W C while switching over from the operating code HE tothe operating code L see section 119 Step 44 Is the gas air ratio while switching over from the operating code O to the operating code L_ approximately Yes Step 46 0 02 inch W C No Step 45 Step 45 Diagnosis The gas air ratio setting is not okay Action Adjust the gas air ratio see section 119 gt Section 67 Step 46 Check that the correct orifice has been installed see section 113 and 135 Step 47 Has the correct orifice been installed Yes Step 49 No Step 48
145. r The boiler is suitable for connection to fully pumped sealed water systems ONLY The boiler can be installed either as a single system or as part of a multiple system cascade system with a maximum of 8 boilers connected together These boilers may not be installed in places over 4 000 ft above sea level Hazard definitions The following defined terms are used throughout the documen tation to bring attention to the presence of hazards of various risk levels Notices give important information concerning the operation of the product DANGER Indicates the presence of hazards that will cause severe personal injury death or substantial property damage WARNING Indicates the presence of hazards that can cause severe personal injury death or substantial property damage CAUTION Indicates presence of hazards that will or cause minor personal injury or property damage CAUTION Risk of electric shock Indicates presence of hazards due to electric shock NOTICE Indicates special instructions on installation opera tion or maintenance that are important but not related to personal injury or property damage E gt e gt gt Safety and general instructions MEN 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 accesso ries and spares listed Maintenance a
146. r of the BC10 on the front of the boiler as instructed in section 69 e Remove the BC10 by depressing the lock on the left hand side e Switch on the power supply to the heating system see section 79 e Put the main power switch on the control panel in position 1 On see section 80 e Set the multimeter to Measure DC voltage e Check that there is between 7 8 and 15 2 VDC on both left hand contacts of the connector on the bottom plate of the BC10 O Install the BC10 in reverse order e Close the cover of the BC10 on the front of the boiler in reverse order Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 87 Actions Drain the boiler as indicated in section 75 e Open the boiler door as instructed in section 73 V Pull the clamp spring forwards 1 and remove the automatic air purging system 2 e Note The top of the automatic air purging system has two cut outs 3 Install the new automatic air purging system so that the clamp spring engages in both cut outs Fill and purge the heating system and put the boiler into oper ation see section 78 Buderus e Disassemble the gas air unit including the burner cover as indicated in section 86 Remove the burner gasket 1 and replace it if necessary Remove the burner 2 e
147. ressure indication on the display of the BC10 section 1 4 Step 1 e Check that the plug and socket connection of the pressure sensor is connected See section 128 1 Step 2 Is the plug and socket connection okay Yes Step 4 No Step 3 Step 3 Diagnosis The plug and socket connection of the pressure sensor is not correct gt Section 67 Action Reconnect the plug and socket connection see section 128 1 Step 4 e Check the wiring between the pressure sensor plug and the UBA 3 mounting base by measuring see section 131 Step 5 Is the wiring okay Yes Step7 No Step6 Step 6 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 7 Diagnosis The pressure sensor is defective Action Replace the pressure sensor see section 128 Step 8 Has a pressure indication appeared on the display Yes gt Section 67 No Section 66 Operating code The switch optimization program is activated This program is activated if OA E there has been a hot water request from an RC regulator or an ON OFF controller more frequently than once every 10 minutes This means that the boiler cannot be restarted until at least ten minutes have elapsed since initial startup of the burner Step 1 Has the maximum heating system supply temperature setting just been changed Yes Step 2 No gt Step 3 Step 2 Diagnosis The maximum heating system supply tempera
148. rror After laying down the diagnosis the fault can be remedied by means of chapter 7 Actions on page 56 The Logamax plus GB162 condensing gas boiler is a fully up to date central heating boiler designed to provide a high level of convenience maximum energy savings optimum care for the environment and advanced safety features all in a single device This is why the boiler is equipped with the very latest electron ics The electronic system consists of the UBA 3 Universal Burner Automat 3 see section 1 32 and the connected con trol panel the BC10 Basic Controller 10 see section 1 4 The main task of this electronic system is to control and ensure the safe operation of the central heating boiler In addition itis possible to call up display readings settings and codes on the display of the BC10 The display settings can be changed after calling them up Also see section 23 and section 28 The working of the boiler during normal operation mode is explained in more detail in chapter 4 Operation on page 10 This chapter provides a step by step explanation of the boiler operation under normal operating conditions Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Please observe these instructions in the interest of your own safety Designated use The boiler was designed for heating water for a central heating system and generating domestic hot wate
149. ruction If you cannot reach your gas supplier call the fire department C Use only 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 attempted 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 gt pia Om Peo nm TO TURN OFF GAS TO APPLIANCE 1
150. rupted Step 2 Is this the case Yes Step 3 No Step 4 Step 3 Diagnosis The fault is caused by the presence of windmills generators or other equipment which may gt Section 67 cause the main voltage to be interrupted Action Place the affected equipment out of service Step 4 e Use a main voltage monitoring device to check over a long period of time whether the main voltage is actually interrupted briefly Step 5 Has the main voltage actually been briefly interrupted Yes gt Step 6 No Section 66 Step 6 Diagnosis The cause of the fault lies in the electrical system gt Section 67 Action Solve the problem in the electrical system 89 S Operating code The external switch contact has opened Step 1 e Check that an external switch contact has been connected to the device see section 116 Step 2 Is an external switch contact connected Yes Step 9 No Step3 Step 3 e Check that a connection is present see section 116 Step 4 Is there a connection Yes Step 6 No Step5 Step 5 Diagnosis There is no connection Action Restore the connection to the connection box see section 116 1 gt Section 67 Step 6 e Check the wire harness between the connection tray and the UBA 3 mounting base according to section 131 Step 7 Is the wire harness okay Yes Section 66 No Step8 Step 8 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section
151. s Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 91 yeENnueW sy UL smaa papo dxa ay pue UO DAS a91119s Bas sjuauodulo9 eNPIAIPU jo uO1Je90 104 ULI1D11 99 9 palyijenb e ynsuos yqnop Aue ul ase noA y p93 1109 paj9auuos s aoue dde noA yey aansuy G3GNNOUYD 39 1SNIN 3INVIIddAV SIHL ONINYVM YORI p310 09 JO N 1999 OU YIM PayJEW peura ay 0 pajoauuos aq JSNLW an q palojo9 am ay pal P910 09 JO 7 1919 OU YIM PeyeLU JEUIW8 ay 0 pajoauuos eq JSNW UMOI paJojos alim ay mos pue usa1B Jo u 16 pasooo JO joqw s punou y Aq 10 4 Jey Y YM payeu 1OJOBULOD ay UO eulua ay 0 pajoauuoo aq JSN mo e pue UBEJ6 paJojoo M ay SMO OJ Se pas9o1d 10 99UUO09 JNOA ul sjeurua ayy BulAjnuap Shue pajojo9 ayy yum puods a1109 Jou Aew aoueldde y jo Jo peaj sureu ay ul salim ay JO S10 09 ay sy 317 NMOYa8 1VH LNAN 3079 f HLEV3 MOTIAA ANY N3389 9pos Bulmo oy Y YM eouepio908 ul P1009 ae pee sujeul SIU Ul SOIM ay 1NV LHOdIANI O A A AN CROATA NAO UR NN NANA meee A NN NN NN AN RO RAN DA NANA NO PR ANA NN as E 8 O mola4 uaa 6 Jo 8 i oozw zou zee LO umolq i sO eniq i cam c 2 h OO no L O Mofie jueslb 000 000 900 00 Q Q glo Q i i Mi 2 S S ss S H H o O olol fo o i i A N NIN A DUO O i H ssigenzss 255 85585R i c LS of i H F e fg 5 85 Joge 5 gt 1 1 773 5 595
152. s check the system for leaks on the flue gas side e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 O 0 OSG e Disconnect the plug of the flue gas sensor 1 72 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Remove the cap from the measuring nipple of the combus tion air supply e Pull the plug of the flue gas sensor upwards e Set the multimeter to Measure resistance 1 e Check the electrical resistance of the flue gas sensor by mea suring it 2 e Check the flue gas temperatures by measuring them in the flue gas measuring nipple see section 1 16 e Compare the resistance values measured and flue gas tem peratures measured to the values in section 134 e Replace the flue gas sensor if the reading fluctuates by more than 10 with respect to the reference value e g infinitely high resistance in the event of a line break or resistance of 0 Q in the case of a short circuit e Attach the plug of the flue gas sensor in reverse order Install the cap on the measuring nipple of the combustion air supply e Close the boiler door in reverse order e Switch on the power supply to the heating system see section 79 due to electric shock e Switch off the power supply to the heating sys
153. s test or during service mode H Operating code The boiler is in heating Off mode Operating code The boiler is in manual oper Off ation mode Operating code The boiler is in DHW mode Off DA Operating code The switch optimization pro Off The target room temperature gt section 35 gram is activated This program is activated if possibly is not reached a hot water request from an RC regulator or an ON OFF controller occurs more frequently than once every 10 minutes This means that the boiler cannot be restarted until at least ten minutes have elapsed since initial startup of the burner OA Operating code The heating boiler cannot Off start up temporarily after DHW mode has ended Buderus 22 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Symptoms Ea Display code LEDon Other symptoms Diagnosis a UBA 3 Main Sub displa displa Meanin A e Pa MEW 9 required code code oc Operating code The heating boiler prepares Off for a burner start up whenever a heat demand has occurred The fan unit section 1 22 and the pump are started The glow ignitor section 1 29 is activated DE Operating code The time proportional pro Off gram is activated The time proportional program is activated as soon as the required modulating control per formance is lower than the bottom limit of the devic
154. s and hold the button for more than 2 seconds until the dot disappears Bude rus Yes Step3 No gt Step 1 Yes Step1 No gt Step 8 gt Step1 Yes Step3 No gt Step1 gt Step 1 No gt Step 12 Yes Step 13 gt Step 5 gt Step 1 14 Operating step with number Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improyements Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Cross reference to subsection or operating step Buderus EN General Buderus 6 FAULTS CAN BE REMEDIED USING THIS DOCUMENT BY FOLLOWING A 3 STEP PLAN IT IS IMPORTANT THAT THE SAME SEQUENCE IS FOLLOWED EVERY TIME Step 1 Symptoms Step 2 Diagnosis Step 3 Action Step 1 chapter 5 Symptoms Symptom every indication which may be relevant in order to recognize faults or errors An important symptom is the display indication on the BC10 basic controller of the boiler but all other symptoms must also be taken into consideration In most cases the display indica tion e g the locking fault code Jeb can easily be read from the BC10 basic controller but the user of the boiler must also be asked whether other symptoms have occurred Exam ples of such symptoms are the boiler makes whistling noises in the morning or the room does not reach the required temper ature The display
155. s at sea level is L 25 25 for an 80 kW heating boiler and L 20 20 for a 100 kW heating boiler Higher Increase the target boiler performance with the 8 button The maximum setting is L _ _ 100 Otherwise this concerns the factory adjusted setting Step 7 O Press the button Step 8 F 5 Display setting Target pump run over time after heating mode has elapsed in minutes Set the second parameter as soon as the display shows F 5 Recommendation Do not set a pump run over time of less than F 5 5 minutes Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 15 EA Operation Step 9 Set the pump run over time after heating operation has ended Yes Step 10 No Step 11 Step 10 Lower Decrease the target pump run over time after the end of heating operation with the nese button The minimum setting is F 0 minutes The factory default setting is 5 minutes Higher Increase the target pump run over time after the end of heating operation with the button The minimum setting is F_ d 24 hours Step 11 Press the Q button Step 12 C Display setting required DHW mode position on off See also section 28 Display settings page 21 Set the third parameter as soon as the display shows E Step 13 Set the DHW mode status Yes Step 14 No Step 15
156. s indicated in section 105 Step 2 Is the onization electrode okay Yes Section 66 No Step 3 Step 3 Diagnosis The ionization electrode is defective Action Replace the ionization electrode see section 103 gt Section 67 Buderus 48 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Diagnosis En 1 Locking fault code Flames ionization current have been detected after switching off the JE C S 3 a El burner section 1 23 gt Step 1 e Connect a digital pressure gauge see section 119 Open the gas stop valve see section 81 and put the boiler into flue gas test mode see section 20 End the heat demand in accordance with the flue gas test section 20 wait for the LED Burner operation to extinguish and then check that burner pressure is still available gas air ratio of 0 02 inch W C Step 2 Is burner pressure still available gas air ratio of 0 02 inch W C Yes Step 6 No Step 3 Step 3 O Check the ionization electrode as indicated in section 105 Step 4 Is the ionization electrode okay Yes Section 66 No Step5 Step 5 Diagnosis The ionization electrode is defective Action Replace the ionization electrode see section 103 gt Section 67 Step 6 e Close the gas stop valve as indicated in section 74 Remove the digital pressure gauge and close the gas air ratio measuring nipple Open the gas stop valve see section 81 and put the boiler
157. s test see section 20 Install the vent screw on the pump in reverse order e Install the casing of the pump group as indicated in section 77 e Close the cover of the BC10 in reverse order 64 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements DANGER OF FATAL ACCIDENT 4 i due to electric shock DAMAGE TO THE INSTALLATION To prevent damage do not insert the multimeter measuring electrodes too far into the holes of the plug and socket connection e Switch off the power supply to the heating system see section 72 Remove the casing of the pump group as indicated in section 73 Undo the pump power supply cord plug as instructed in A 1 and B 1 73111 arverer e Set the multimeter to Measure AC voltage Minimum mea suring range 250 VAC 1 e Switch on the power supply to the heating system see section 79 Actions Put the boiler in flue gas test mode see section 20 e Check that there is 120 VAC on the two contacts L and N of the pump power supply cord plug while operating code HE is displayed or while the locking fault code Jet Jesh is displayed The locking fault code may be displayed after appr 4 minutes O Stop the flue gas test as instructed in section 20 e Attach the pump power supply cord plug O Install the casing of the pump group in reverse order of removal
158. shes to clean the various parts and components Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 89 i USER INSTRUCTION If the boiler door cannot be opened all the way making it difficult to remove the heat exchanger if required you may remove the door Suspend the BC10 from the radiator as instructed in section 68 Unscrew the hinge pin of the hinge 1 and remove it including its washer Pull the door upwards a bit and then pull it out of the hinge Carefully put the door down e See the Installation and servicing instructions of the boiler for detailed maintenance information e Switch off the power supply to the heating system see section 72 e Open the boiler door and remove the casing of the pump group as instructed in section 73 e Close the gas stop valve and service valves as indicated in section 74 e Disassemble the burner including the gas air unit including as indicated in section 126 e Remove the glow ignitor and the onization electrode as indi cated in section 103 e Remove the supply safety and return sensors as instructed in section 95 e Remove the pressure sensor as instructed in section 128 e Remove the automatic air purging system as instructed in section 125 Buderus e Pull the condensate draining pipe down and bend it back wards Ad
159. sode ee ada pol be 17 5 SYMpPtomMS iii as 21 SYMPtOMS i424 sc2veegide awe tases seek idee wh deans 21 Removing the control panel 00 0000 eee ee eee 21 Display readingS isi si cc0ecs cca ce eet e eee Rae e eee x 21 Display settings 0 00 00 eee 21 Display codes and other symptoms 0000 21 6 DiaQnOSiS ie ci sie tee ee ee Hae isti oe eee Ore 30 Diagnosis gae ica atada aia 30 7T ACUONS seco ii is A da EEE 56 Hanging the control panel from the boiler 56 Shutting down ooocococcoco eee 56 Switching off main power ooococococcoc ee 56 Closing cover of the BC10 eee eee eee 57 Switching off power supply 00 0 c eee eee eee 57 Opening boiler door a an eee eee 57 Closing isolating valves 2 0 0 cc cee eee 57 Draining the system 0 0 6 eee 57 Opening isolating valves 2 0 00 cece tees 58 Closing boiler door 0 cece eee eee ee 58 Filling and bleeding the system 0 0 00 0 0000008 58 Switch on power supply 00 0 eee ee eee eee 59 Switching on main power 00 0 0 eee eee eee 59 Initial Startup aida sd sake arate eco Das 60 Checking replacing fuses 0 cece ete 61 Checking the fan unit operation 120 VAC 04 61 Checking the fan unit power supply cord 120 VAC 62 Checking the fan unit tacho cable oooooooocooooo 62 Checking and or replacing the f
160. stem supply temperature lower than 45 F 7 C Yes Step 65 No Step 20 Step 24 The pump is run for 10 seconds in order to prevent it from seizing up Step 25 Have ten seconds elapsed Yes Step 19 No Step 26 Step 26 Is there a DHW heating system which has generated a demand Yes Step 29 No gt Step 27 Step 27 Is there a current heat demand from the room or external temperature dependent controller Yes Step 48 No Step 28 Step 28 Is the current heating system supply temperature lower than 45 F 7 C Yes Step 65 No gt Step 25 Step 29 The LED DHW demand on the control panel section 1 4 lights up Step 30 OL Operating code The boiler prepares for a burner start up whenever a heat demand arises The fan unit section 1 20 and the pump are started The glow ignitor section 1 27 is activated Step 31 GL Operating code The gas valve section 1 21 is activated o See also section 29 Display codes and other symptoms page 21 Step 32 Maximum four ignition attempts are carried out Does the ionization current exceed 1 4 microamperes within these Yes Step 33 4 ignition attempts No Step 12 Step 33 H Operating code The device is in DHW mode See also section 29 Display codes and other symptoms page 21 The LED Burner operation on the control panel section 1 4 lights up The startup load on the boiler is approx 50 for the purposes of flow monit
161. step involves the taking of a yes no decision the right hand side of the table indicates which operating step or subsection you should proceed with cross reference Q Step 2 Step 3 Step 4 Step 5 Step 6 Step7 Step 8 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 2 Step y LS Operation Section Subsection with ID number ding C frently measured heating system flow temperature in C See also section 30 Display readings page 22 Continue in Normal Operation menu Press the button P i6 H Have Display reading Currently measured heating system water pressure in bar See also section 30 Display readings page 22 Press the button Random operating code In this case Operating code The boiler is in heating mode See also section 32 Display codes and other symptoms page 22 and further at least 5 seconds passed without a button being pressed and or has the mains voltage been interrupted Press the 5 button EX EX activat P i a Display reading Currently measured heating system flow temperature in C See also section 30 Display readings page 22 Activate flue gas test To activate the flue gas test Press and hold the 2 button for more than 2 but not longer than 5 seconds Display reading Current heating system flow temperature in C
162. sured any Operating code blocking fault code The temperature difference of the heating water measured between the supply section 1 24 and safety temperature sensors section 1 28 is too Blocking fault code The supply temperature sensor section 1 24 has measured a heating Blocking fault code The temperature difference measured between the supply temperature sensor section 1 24 and the return temperature sensor section 1 31 is more than Hh Locking fault code The supply temperature sensor section 1 24 has measured a heating J A E JE Bf system supply temperature higher than 221 F 105 C t tt 1 Locking fault code The safety temperature sensor section 1 28 has measured a heating J F E J af supply temperature higher than 221 F 105 C g tt 1 Locking fault code The return temperature sensor section 1 31 has measured a return JE E H Ef water temperature higher than 221 F 105 C t tt Step 1 Are the service valves open as instructed in section 78 Step 2 Diagnosis The service valves are closed Action Open the service valves see section 78 Step 3 Is the pressure in the heating system at least 14 PSI Step 4 Diagnosis The heating system pressure is too low and is less than 14 PSI Action Fill and bleed the heating system see section 78 Step 5 Check that the boiler has been purged correctly see section 78 Yes No Yes No Logamax plus GB162
163. switch is in position 1 as indicated in section 80 Step 15 Is the main power switch in position 1 On Yes Step 17 No Step 16 Step 16 Diagnosis The main power switch is not in position 1 On gt Section 67 Action Turn the main power switch in position 1 ON see section 80 Step 17 els there 120 VAC on the grounded socket Step 18 Is there 120 VAC on the grounded socket Yes Step 20 No Step 19 Step 19 Diagnosis There is not 120 VAC on the grounded socket Section 67 Action Remedy the problem in the electrical system Step 20 O Measure the resistance of the 120 VAC power supply cable Step 21 Is the resistance of the 120 VAC power supply cable within the specified limits Yes Step 23 No Step 22 Step 22 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part Section 67 Step 23 Test the fuse on the rear of the UBA 3 using a multimeter see section 82 Step 24 Is the fuse working correctly Yes Section 66 No Step 25 Buderus 30 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Step 25 Step 26 Step 27 Step 28 Step 29 Step 30 Step 31 Step 32 Step 33 Step 34 Step 35 Step 36 Step 37 Step 38 Step 39 Step 40 Step 41 Step 42 Step 43 Step 44 Step 45 Step 46 Step 47 Step 48 Step 49 Step 50 Step 51 Step 52 Step 53 Step 5
164. t Step 44 Step 44 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 45 Check the ionization electrode as indicated in section 105 and section 107 Step 46 Is the ionization electrode okay Yes gt Step 48 No gt Step 47 Step 47 Diagnosis The ionization electrode is defective gt Section 67 Action Replace the ionization electrode see section 103 Step 48 e Check whether flue gas is being recirculated by visually checking the boiler for discolouring or temporarily running the boiler without air intake Note This is only allowed if the conditions in the installation room permit this Step 49 Is flue gas being recirculated Yes Step 50 No gt Step 51 Step 50 Diagnosis Flue gas is recirculated by the boiler Action Remedy the cause of the recirculation gt Section 67 Step 51 e Temporarily remove the combustion air supply and exhaust gas outlet connections from the top of the device Put the device into operation as instructed in section 20 Note Ensure that there is sufficient air supply during this test Check that the fault has been rectified Step 52 Has the fault been remedied Yes Step 53 No gt Step 54 Step 53 Diagnosis The cause of the fault is to be found in the air inlet flue gas outlet system gt Section 67 Action Switch off the device and remedy the fault Step 54 e Check whether the fault can be r
165. target boiler performance DHW mode is possible during manual operation CAUTION If the boiler performance has been changed temporarily it must be reset after ending manual operation according to the Settings menu section 23 page 15 Step 9 O Press the noe button Step 10 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Step 11 Has the main voltage been interrupted Yes Step 1 No Step 12 Step 12 Deactivate manual operation Yes Step 13 No Step 5 Step 13 To deactivate manual operation gt Step 1 O Press and hold the E button for more than 2 seconds until the dot disappears Step 1 15 Display reading Currently measured heating system supply temperature in F See also section 27 Display readings page 21 Step 2 Open the Settings menu Yes Step 3 No Step 1 Step 3 To open the Settings Be amp Press and hold the buttons for more than 2 seconds Step 4 Display setting target boiler performance as a See also section 28 Display settings page 21 As soon as the display shows k the Settings menu is open The boiler performance can be set using the first parameter shown on the display Step 5 Adjust boiler performance No Step7 Yes Step 6 Step 6 Lower Decrease the target boiler performance with the nese button The minimum setting for boiler
166. tem see section 72 e Open the boiler door as instructed in section 73 Remove the UBA 3 as instructed in section 82 Remove the cover from the connection tray see section 114 A DANGER OF FATAL ACCIDENT AA e Disconnect the plug of the flue gas sensor as instructed in section 97 o ELOK E 73111 wrens pin OO Pin 16 16 pin high voltage connector e Set the multimeter to Measure resistance 1 e Check the safety sensor cable for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the black contacts low voltage connector pins 65 and 66 on the UBA 3 mounting base 3 e Check the flue gas sensor cable for internal short circuiting The electrical resistance measured between two random wires must be infinite Measure the electrical resistance over the flue gas sensor cable to ground The electrical resistance must be infinite for every individual wire e Attach the plug of the flue gas sensor in reverse order e Install the lid on the connection tray in reverse order O Install the UBA 3 in reverse order of removal e Close the boiler door as instructed in section 73 e Switch on the power supply to the heating system see section 79 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 73 Acti
167. tep 18 Is the pump dirty Yes Step 19 No Step 29 Step 19 Diagnosis The pump is dirty Action Clean pump see section 91 gt Section 67 Step 20 e Check the pump activation as instructed in section 88 Step 21 Is the activation okay Yes Step 22 No Step 23 Step 22 Diagnosis The pump is defective Action Replace pump see section 92 gt Section 67 Step 23 E Check the pump power supply cord as instructed in section 89 Step 24 Is the pump power supply cord okay Yes Section 66 No Step 25 Step 25 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 26 e Check the pump as indicated in section 87 Step 27 Is the pump okay Yes Step 33 No Step 28 Step 28 Diagnosis The pump is defective Action Replace the pump see section 92 Step 29 Is this a heating system which can run while fully sealed e g a heating system with only radiator thermostat Yes Step 30 valves TRAs or zone valves or low loss header No gt Section 66 Step 30 e Check whether there is a bypass or a low loss header in the heating system which ensures a supply through the boiler at all times Step 31 Is there a bypass or a low loss header in the heating system Yes Step 33 No Step 32 Step 32 Diagnosis There is no bypass nor a low loss header gt Section 67 Action Install a bypass or a low loss header in the heating system Buderus 38
168. thor ity having jurisdiction or in the absence of such requirements to the latest edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 In Canada installation must be in accor dance with the requirements of CAN CSA B149 1 Natural Gas and Propane Installation Code Where required by the authority having jurisdiction the installation must conform to the Stan dard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Install CO detectors per local regulations Boiler requires yearly maintenance Operating Limits of the boiler Max boiler temperature 230 F 110 C Max operating pressure 30 psi 2 6 bar with optional pressure relief valve 50 psi 3 45 bar The hot water distribution system must comply with all applica ble codes and regulations When replacing an existing boiler it is important to check the condition of the entire hot water distri bution system to ensure safe operation Massachusetts Installations Only a For all side wall side horizontally vented gas fueled equip ment 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 seven 7 feet above fin ished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBO
169. ting operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Diagnosis gt section 45 gt section 46 gt section 47 gt section 45 gt section 48 gt section 49 gt section 37 gt section 50 gt section 51 gt section 37 gt section 52 gt section 53 gt section 53 gt section 53 Buderus EA Symptoms Display code a Meaning General fault code A blocking or locking boiler fault has occurred Blocking fault code Insufficient flame activity ionization current was measured during the first second or third burner ignition attempt section 1 23 Locking fault code Insufficient flame activity ionization current was measured during the fourth burner ignition attempt section 1 23 Locking fault code Flames ionization cur rent were measured after a heat demand occurred but before o
170. ting system see section 72 e Open the boiler door as instructed in section 73 e Loosen the screw 1 Remove the cover from the connection tray 2 e Remove the ON OFF controller from the wall RC FA WA FW EV DWV colo ope 1 e Connect the ON OFF controller to the green plug WA 1 in the connection tray of the boiler using a short length of two pole electric cable e Switch on the power supply to the heating system see section 79 e Adjust the selector for the DHW temperature setting on the control panel to position 0 see section 70 1 e Setthe ON OFF controller to heat demand operation If the boiler runs in heating mode H for approx 3 minutes the cause of the fault lies outside the heating boiler e Switch off the power supply to the heating system see section 72 e Attach the ON OFF controller to the wall in reverse order of removal e Connect the ON OFF controller to the boiler in reverse order e Install the lid on the connection tray in reverse order e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 e Adjust the selector for the DHW temperature setting on the control panel to the required position as instructed in section 81 1 Buderus e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Remove the cover from
171. tion 109 Step 21 Check the gas valve power supply cord as indicated in section 111 Step 22 Is the power supply cord okay Yes Step 28 No Step 23 Step 23 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part gt Section 67 Step 24 e Check that the overall gas supply network is of sufficient capacity Step 25 Is the overall gas supply network of sufficient capacity Yes Step 27 No Step 26 Step 26 Diagnosis The gas supply network is not of sufficient capacity gt Section 67 Action Increase the capacity of the gas supply network Step 27 Diagnosis The cause of the fault is to be found outside the boiler and the gas pipe work gt Section 67 The gas supply pressure regulator may be defective Action Contact the gas utility company Step 28 Adjust the gas air ratio see section 119 Step 29 Is the gas air ratio okay Yes Step 31 No Step 30 Step 30 Diagnosis The gas air ratio setting is not okay Action Adjust the gas air ratio see section 119 gt Section 67 Step 31 Check that the correct orifice has been installed see section 119 and 135 Step 32 Has the correct orifice been installed Yes Step 34 No Step 33 Step 33 Diagnosis The wrong orifice has been installed Action Install the correct orifice see section 119 and 135 gt Section 67 Step 34 Check the following elements for contamination damage and or incorr
172. tion 72 e Open the boiler door as instructed in section 73 Remove the UBA 3 as instructed in section 82 Remove the cover from the connection tray see section 114 e Disconnect the supply temperature sensor plug see section 93 1 81 pin low voltage connector d u 3 Lu oonponappopodsaoooododoanga Pin 1 77 oonponansppanioedaoddaddBdd 28 Pin81 SOOOODOOCCSCOOO0000CCRn0000 55 gt l m m l Q O pin OO Pin 16 16 pin high voltage connector gt FLUKE 73111 emer e Set the multimeter to Measure resistance 1 e Check the supply temperature sensor cable for breaks The electrical resistance measured separately for every wire must be approx 0 Q 2 Measure between the plug and the black contacts low voltage connector pins 13 and 14 on the UBA 3 mounting base 3 e Check the supply temperature sensor cable for internal short circuiting The electrical resistance measured between two random wires must be infinite O Measure the electrical resistance over the supply tempera ture sensor cable to ground The electrical resistance must be infinite for every individual wire e Disconnect the safety temperature sensor plug as instructed in section 93 1 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 69 81 pin low voltage connector
173. to each other or the contacts of the return temperature sensor have shorted to ground t tt E 1 Locking fault code The contacts of the return temperature sensor section 1 31 are open TO piy T tt Step 1 e Check the supply safety and return temperature sensors indicated in section 93 Step 2 Are the supply safety and return temperature sensors okay Step 3 Diagnosis The supply safety and or return temperature sensors are defective Action Replace the supply safety and or return temperature sensors see section 95 Step 4 e Check the cables of the supply safety and or return temperature sensors indicated in section 94 Step 5 Are the wires okay Step 6 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part Yes No Yes No Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements gt Step 4 gt Step 3 gt Section 66 gt Step 6 gt Section 67 Buderus 45 2 Diagnosis EA pz ETO Jr first second or third burner ignition attempt section 1 23 fourth burner ignition attempt section 1 23 Blocking fault code Insufficient flame activity ionization current was measured during the Locking fault code Insufficient flame activity ionization current was measured during the Step 1 Is the heating system propane gas fired Yes Step 2 No Step5 Step 2 e Contact
174. train which have been disconnected for leaks Use a foaming agent which has been approved for gas leak testing e f a gas leak is found switch off the power supply to the heat ing system see section 72 close the gas stop valve as indi cated in section 74 and deal with the cause of the gas leak e Close the boiler door as instructed in section 77 e Switch on the power supply to the heating system see section 79 e Switch off the power supply to the heating system see section 72 e Open the boiler door as instructed in section 73 e Disconnect the plug of the ionization electrode 1 76 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements e Select the uA DC range on the multimeter The multimeter must have a resolution of at least 1pA 1 e Connect the multimeter to the ionization circuit in series 2 e Switch on the power supply to the heating system see section 79 e Put the boiler in service mode see section 21 e During service mode adjust the capacity to L 25 25 with an 80 kW boiler or L 20 20 with a 100 kW boiler e Check that the ionization current is at least 3 uA microam peres during service mode operating code A J The actual value in practice is 5 40 yA e Switch off the power supply to the heating system see section
175. ture setting has just been changed gt Section 67 Action Set the maximum heating system supply temperature to the target value and switch off the power supply to the boiler by removing the plug from the grounded socket and reinserting it Step 3 Are the service valves open as instructed in section 78 Yes Step5 No Step 4 Step 4 Diagnosis The service valves are closed Action Open the service valves as instructed in section 78 gt Section 67 Step 5 e Check that the connections of the room thermostat to the boiler and the room thermostat are correct Step 6 Has the thermostat cable been connected correctly Yes Step 8 No Step 7 Step 7 Diagnosis The thermostat cable has not been installed correctly gt Section 67 Action Connect the thermostat cable correctly Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 35 ea Diagnosis Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 EKS Visually check the thermostat cable for breaks and loose contacts if possible and measure the electrical resis tance using a multimeter Is the thermostat cable okay Yes No Diagnosis The thermostat cable is defective Action Replace thermostat cable e Check that enough thermostatic valves are open on the radiators convectors etc Are enough thermostatic valves open on the radiators convectors etc Yes No Diagnosis There
176. ty temperature sensor have shorted to ground or the contacts of the safety tempera ture sensor have measured a supply water temperature of over 266 F 130 C Locking fault code The contacts of the safety temperature sensor section 1 28 are open Locking fault code The contacts of the sup ply temperature sensor section 1 24 have shorted Locking fault code The contacts of the sup ply temperature sensor section 1 24 are open Operating code The Service Tool was con nected at the time indicated Operating code Component test phase using the Service Tool Blocking fault code There is no communica tion between RCC and UBA 3 section 1 32 Reset required No Yes 4 6 7 8 No 5 7 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 Yes 4 6 7 8 No No No LED on UBA 3 Off flashing 1 Hz Off flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz flashing 1 Hz Off Off Off Symptoms Ss Other symptoms No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No heating operation and no DHW No hea
177. uct Description Fig 1 Logamax plus GB162 with pump group Buderus 2 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 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 measuring point Measuring point for air intake Flue gas connection Air intake connection Fan Gas valve Venturi Burner cover Flow temperature sensor lonization electrode Sight glass Glow ignitor Safety temperature sensor Heat exchanger Pressure sensor Return temperature sensor Universal Burner Automatic Version 3 UBA 3 Drawer with function module integration options Cover shield Condensate trap Pump group scope of delivery 36 37 38 39 40 41 42 43 Isolating valve blue CH boiler return with pump drain valve check valve and thermometer Manual gas shutoff valve yellow GAS Isolating valve red CH boiler supply with drain valve pressure gauge thermometer a
178. ult code The pressure sensor contacts section 1 30 are open Locking fault code The pressure sensor contacts section 1 30 have shorted Blocking fault code The water pressure indication does not work properly Section 67 gt Step 14 gt Step 15 gt Section 67 gt Section 66 gt Step 17 gt Section 67 gt Section 66 gt Step 20 gt Section 67 Operating code The water pressure of the heating system is beyond the measuring range of the pressure sensor section 1 30 Step 1 e Check the plug and socket connection of the pressure sensor See section 1 30 Step 2 Is the plug and socket connection okay Yes No Step 3 Diagnosis The plug and socket connection has come loose Action Renew the plug and socket connection Step 4 e Check the wiring between the pressure sensor plug and the UBA 3 mounting base by measuring the electrical resistance see section 131 Step 5 Is the wiring okay Yes No Step 6 Diagnosis The wire harness is defective Action Replace the wire harness or the affected part Step 7 e Use another pressure gauge than the pressure gauge on the control panel to check whether the heating system water pressure measured at the height of the boiler is too high and is more than 83 PSI Step 8 Is the water pressure of the heating system too high Yes No Step 9 Diagnosis The water pressure of the heating system is too high Action Drain the heating system until the water
179. upply pressures as indicated in section 117 Step 9 Are the static and dynamic gas supply pressures correct Yes Step 16 No Step 10 Step 10 Check that there is no obstruction in the gas pipe between the device gas stop valve and gas valve Step 11 Did you find an obstruction Yes Step 12 No Step 13 Step 12 Diagnosis There is an obstruction in the gas pipe Action Remove the obstruction gt Section 67 Step 13 e Check that there is no obstruction in other parts of the gas pipe Step 14 Did you find an obstruction Yes Step 15 No gt Step 24 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 49 ea Diagnosis Step 15 Diagnosis There is an obstruction in the gas pipe Action Remove the obstruction gt Section 67 Step 16 Has the gas supply pipe and the gas tank if relevant been purged Yes gt Step 18 No Step 17 Step 17 Diagnosis The gas supply pipe and the gas tank if relevant has not been purged gt Section 67 Action Purge the gas supply pipe and the gas tank if relevant see section 118 Step 18 e Check the plug and socket connection of the gas valve see section 109 Step 19 Is the plug and socket connection okay Yes Step 21 No Step 20 Step 20 Diagnosis The plug and socket connection has come loose gt Section 67 Action Replace the plug and socket connection on the gas valve see sec

Service manual - GB162-80kW/100kW - US(en)

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