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1. is greater 1 2 A se Ti a STS 6 700 645816 08 110 Fig 29 Vertical venting system sealed combustion 1 exhaust 4 100 mm 2 intake 4 100 mm 3 12 300 mm over maximum snow level or 24 600 mm whichever is greater 7746800103 08 1TD Fig 31 Flex Chimney Cap PP vertical venting system sealed combustion 1 exhaust 4 100 mm 2 intake 4 100 mm Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 21 1 672064591 6 101 1N Fig 32 Vertical concentric venting system sealed combustion 1 exhaust 4 100 mm 2 intake 4 100 mm 3 12 300 mm over max snow level or 24 600 mm whichever is greater 4 10 0 MIN 250 mm 0 mm MIN Do not exceed the total equivalent venting length of 100 feet 30 480 mm maximum requirement each for the intake and exhaust piping NOTICE gt Appliance input rates are based on minim
2. y g L Blocking fault No heating operation and no DHW CH f dk T g The return temperature sensor has measured a return temperature higher than 221 F 105 C X L yag at Blocking fault No heating operation and no DHW el a The contacts for the pressure sensor have been interrupted or have shorted y fot y EE Blocking fault No heating operation and no DHW g ae The contacts for the pressure sensor have shorted y CU L y aunt Blocking fault No heating operation and no DHW a a The contacts for the return temperature sensor have shorted y Fy L y auth Blocking fault No heating operation and no DHW a g The contacts for the return temperature sensor have been interrupted EL 2740 Locking fault No heating operation and no DHW The UBA 3 or the KIM is defective JE 3 e Yat Blocking fault No heating operation and no DHW a de The UBA 3 or the KIM is defective Jop yt Operating phase No heating operation and no DHW The system pressure is too low less than 12 psi 0 8 bar H Operating phase No heating operation and no DHW The system pressure is too low less than 12 psi 0 8 bar p Operating phase No heating operation and no DHW The system pressure is too high higher than 58 psi 4 0 bar rE Locking fault No heating operation and no DHW Reset is carried out This code appears after t
3. Fig 49 Opening the control panel 110 130 gt 6720645916 47 1N Chimney sweep button gt fig 50 3 The Chimney sweep button is used to put the boiler into flue gas test service or manual operation mode The BC10 maximum heating water temperature setting applies The flue gas test enables the boiler to be run in full load operation manually for a short period gt table 12 page 31 The service mode enables the boiler to be run in part load operation manually for a short period Measurements and settings can be carried out on the boiler gt table 13 page 31 The manual operation mode enables the boiler to be operated manually for a longer period Use this mode when the control system has not been installed yet or is out of order gt table 14 page 32 Service button gt fig 50 4 The Service button is used to display the current space heating water temperature the current system pressure etc Service Tool connection gt fig 50 5 For further information please contact Buderus LED Burner operation gt fig 50 6 The LED Burner operation lights when the burner of the boiler is active and is extinguished when the burner is switched OFF The LED Burner operation indicates the burner status LED Status Explanation ON Burner Boiler water is being heated operational OFF Burner off The space heating water temper
4. Operating phase Component test phase Locking fault The system has detected an insufficient ionization current during the ignition phase m D Blocking fault The system has detected an insufficient ionization current after 4 start up attempts No heating operation and no DHW yr Blocking fault The system has detected an ionization current before burner start up No heating operation and no DHW Blocking fault An ionization current has been measured after the burner shut down No heating operation and no DHW H Blocking fault The system has detected an insufficient ionization current during the operating phase yr ru nm uo ebe Blocking fault The system has detected an insufficient ionization current during the operating phase No heating operation and no DHW Blocking fault The ionization current is too high No heating operation and no DHW Blocking fault The power supply was interrupted during a locking fault yar p jae fJ f Jar EIN emm Ly ac uc No heating operation and no DHW Blocking fault There was a momentary interruption of power No heating operation and no DHW Blocking fault The UBA 3 is defect No heating
5. eu di Ly Ly LU LE t yr yr S Table 23 Display codes Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 51 Maindisplay Sub display code code Display codes Key to display code Blocking fault There is no bridging cable between contacts 22 and 24 of the UBA3 contact strip Other effects No heating operation and no DHW Blocking fault The sensor test has failed No heating operation and no DHW Blocking fault The safety temperature sensor has detected a flow temperature of over 266 F 130 C No heating operation and no DHW Blocking fault The contacts for the safety temperature sensor have shorted or the safety temperature sensor has detected a flow temperature of over 266 F 130 C No heating operation and no DHW Blocking fault The contacts for the safety temperature sensor have been interrupted No heating operation and no DHW Blocking fault The contacts for the safety temperature sensor have shorted No heating operation and no DHW Blocking fault The contacts for the safety temperature sensor have been interrupted No heating operation and no DHW
6. gt Open the boiler door Turn the vent key through a quarter rotation to undo the boiler door lock gt fig 78 step 1 Push the fastener down gt fig 78 step 2 and open the boiler door NOTICE D gt Ifthe boiler door cannot be opened completely remove it gt 12 2 page 44 6720645916 76 1N Fig 78 Opening the boiler door 11 2 Carry out a visual check for general signs of corrosion gt Check all gas and water bearing pipes for signs of corrosion and for leaks gt Replace any pipes that are corroded gt Carry outa visual inspection of the burner heat exchanger condensate trap automatic air vent and all fittings in the boiler 11 3 Gas valve leakage test gt Check the internal tightness of the gas fitting on the input side with the boiler switched OFF ata test pressure of 5 0 W C 12 4 mbar for natural gas and 8 0 W C 19 9 mbar for LPG gt Check that the appliance is switched OFF gt Open the screw plug on the testing nipple for the gas connection by 2 turns gt fig 79 1 Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 43 EE Maintenance gt Connect the pressure gauge tube to the testing nipple gt fig 79 2 The pressure drop allowed after 1 minute is max 3 8 W C 10 mbar gt Ifthe pressure drop is higher check all sealing locations of the gas fitting for leaks using a foaming product Repeat
7. 4 e Ge eD D ER blue O9 N H H 3 Moz green yellow O1 PE i 44 O be S 20 Brown 120VAC Gio L i i 16 O oy o 3 C d n oa ave orange e ry H i i n O wie H i f O i f i RW i i ar QVC white black o T i H H orange white bh H H i z LEE dee Bt ect T20VAC_ Be N 4 i er 10 VAC blue LO pnl 120VAC_ E H i 28 white H H i S 8 230 VAC Deeg i i i as 120VAC_i O5 H i 1 blue T Ok H i 5 od black i o z gt f H 9 black negro noir H H i a on Pin blue azul blue d H Patla ig brown marr n brun i i 62 O 4 orange white Broche N W green verde vert i H i 61 Q brow 9 a grey gris gris i 70 O J grey O Si orange naranja orange i H S He Eri red rojo rouge i i 7 1 M di Bei white blanco blanc i i i 12 O blue Gi SS yellow amarillo jaune i H i ooo i EE o n a H 39 O orange HAH SC i i i i m L Es H E 4 I H H i 3 Oj e Sa 43 Gd Ke i i Fh OF e gebild i i i i Bae IS i i i 6 OF grey a E ILE Hl E i 4 H oF i H 6 O grey Pi H i H w Pin i H i 50 x H Ei Patilla H H i 78 q K Broche F i H A S i i i Q i e EE i i A 1 i PS S328 88 BESESRRESRSEBRRSSEE amp Se 22 o x 3 ET EECHER DEER Le fied 2 a O Ze 2 Be 27e 23 8eepg2 288 S858 825 g Z SE H amp 5 dk Eiter gebiede Beal LU EE Ee TROER pas becpissioscsta DROS ne EEN AD cnaweewioene OOS External connection for pr onexidn para exper
8. WARNING o Danger of fatal accident due to electric shock gt 120 VAC connections may be present on the external connection board when power is supplied to the boiler gt Open the boiler door gt Remove the screw to release the cover over the electrical connections and pull the cover upwards gt fig 35 H D 6 720 645 916 32 1N Fig 35 Removing the cover 7 1 1 Routing the cable through the boiler gt Route the cable for the low voltage connections through the opening on the left 1 gt Route the cable for the 120 VAC connections through the opening on the left 2 gt Route and attach the cable for the 120 VAC connections using the strain relief clamps 3 gt Only the 120 V electrical connections require a 14 gauge wire 24 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Ke 6 720 646157 33 1N Fig 36 Routing the cable 7 1 2 Low voltage connections A WARNING due to electric shock gt Make sure no power is supplied to the boiler when making connections Electrical connections gt Connect all components to the relevant terminals RC Terminal Room Controller gt Connect a Room or Cascade controller to the orange RC terminal gt fig 37 gt 7 1 4 page 26 FA Terminal Outdoor temperature sensor If outdoor temperature dependant control operation is used an outdo
9. 1 54 39 mm l 1 4 35 mm Ska 74 5 4 138 mm 5 1 130 mm SP 5 1 130 mm i A 6 4 162 mm i 6720645916 02 1TD Fig 2 Dimensions and connections without pump group A LA Flue gas connection inside diameter 4 100 mm The required permanent clearances closet are B AA Air intake connection inside diameter 4 100 mm in front 1 25 mm C WB Wall Bracket not shown rightside 0 D VK Supply G1 union nut with female thread left side 0 E GAS Gas connection to boiler Rp1 female thread above 6 152 mm F RK Return G14 union nut with female thread The position selected for installation MUST allow adequate space for G AKO Condensate outlet 32 mm 1 O D servicing in front of the boiler of at least 16 5 20 5 37 940 mm Maintain an installation clearance from combustible construction from hot water piping of at least 1 25 mm Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 9 KE Dimensions and connections 4 2 With pump group 16 5 420 mm 20 5 520 mm 24 8 630 mm 18 3 465mm 0 25 6 mm o 20 5 520 mm 0 6 152 mm a Sib AIR 4 1 103 5 mm Lech D CEE Tr e CT AAO F E 46 406 mm F PERA S BEES ale Elis EJE o 219 BE Ss EI yz E 8 vige SI Sie D Yio Se E Su O D 8 io D
10. 0 04 0 02 0 00 0 02 inch W C 1 lt i gt 2 7746800103 60 1N Fig 67 Air gas difference at part load 1 2 gt gt turn counterclockwise turn clockwise Enter the result in the commissioning log book gt 15 1 Start up report page 57 If the gas air ratio is incorrect it must be adjusted on the set screw 1 The set screw is located behind the screw on cover 1 Z COG oe Cs gt TL E ay JS ISS 7746800103 61 1N Fig gt 68 Adjusting the gas air ratio Press the Chimney sweep button gt fig 65 3 until the dot disappears from the display 38 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 v Switch OFF the heating system by pressing the main switch of the BC10 basic controller gt fig 65 1 Close the gas valve gt fig 63 page 36 Remove the measuring devices Tighten the screw in the burner pressure measuring nipple Slowly open the gas valve by pushing on the gas valve and turning it rotation in an counterclockwise direction gt fig 61 Switch ON the heating system by pressing the main switch of the BC10 basic controller gt fig 65 1 gt Press and hold the Chimney sweep button gt fig 65 3 approx 2 seconds until the dot in the right hand bottom corner of the display appears gt fig 65 9 gt table 12 page 31
11. VY ry TO RAS Aoo Tor 1 1 4 35 mm 1 54 39 mm _ _ G 5 4 138 mm 5 4 130 mm l 5 1 130 mm 6 4 162 mm ech 6720645916 03 1TD Fig 3 Dimensions and connections with pump group A LA Flue gas connection inside diameter 4 100 mm B AA Air intake with pompadour inside diameter 4 100 mm C WB Wall Bracket not shown D VK Supply G1 union nut with female thread E GAS Gas connection to boiler Rp1 female thread F RK Return G1 union nut with female thread G AKO Condensate outlet 32 mm 1 O D H PF Pump group supply G1 male thread flat seal I Gas connection to pump group 1 NPT female thread J PR Pump group return G1 male thread flat seal Buderus The required permanent clearances closet are in front 1 25 mm rightside 0 left side 0 above 6 152 mm The position selected for installation MUST allow adequate space for servicing in front of the boiler of at least 16 5 20 5 37 940 mm Maintain an installation clearance from combustible construction from hot water piping of at least 1 25 mm 10 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Packaging and transportation EA 5 Packaging and transportation 5 1 Scope of delivery The boiler is delivered factory assembled gt When receiving the delivery check if the packaging is intact gt Check that a
12. 32 9 104 400 39 9 130 500 L50 41 5 130 500 49 8 163 200 L60 50 1 156 600 59 8 195 800 L70 58 7 182 700 69 7 228 400 L80 67 3 208 800 79 6 261 000 L90 75 9 234 900 89 6 293 700 L 84 5 261 000 99 5 326 300 Table 18 Heating capacity as a percentage 0 4 000 ft 9 14 2 Set the space heating water temperature gt Set the upper space heating water temperature limit for heating mode with the space heating water temperature knob gt fig 73 8 gt table 19 This limitation does not apply to DHW preparation Knob position Evplanation 0 No supply to appliance e g only DHW mode 86 190 The temperature in F set on the BC10 cannot be changed with a room controller The supply temperature does not rise above this set temperature maximum supply temperature set point 180 F 82 C Aut The temperature is determined automatically on the basis of the heating curve If no room controller is connected the maximum supply temperature is 180 F 82 C Table 19 Setting of the space heating water temperature Start up procedure ER 10 9 8 S 0 180 150 S 100 sl 120 a 90 N 130 el S Eco 140 HUH e q Se 0 Aut 0 M 2 di FJ eeoe aes 6720645916 47 1N Fig 73 BC10 basic controller 9 14 3 Set the pump run over time gt Set the pump run over time according to the Settings menu gt table 15 page 32 If th
13. Dangerous flue gas can escape if the air supply is insufficient gt Make sure that air vents are not reduced in size or obstructed gt The boiler may only be operated after the defect has been remedied gt Warn the user of the system of the defect verbally and in writing WARNING Lg Danger of fatal accident from explosive fumes gt Only carry out work on gas pipes and fittings if you are properly registered General warnings The following instructions must be observed The boiler must only be used for its designated purpose observing the Installation Instructions e Only use the boiler in the combinations and with the accessories and spares listed Maintenance and repairs must only be carried out by trained professionals Youare only permitted to operate the condensing gas boiler with the combustion air flue gas system that has been specifically designed and approved for this type of boiler Please note that local approval of the flue system and the condensate connection to the public sewer system may be required If boiler installation is provided as replacement heater do not connect new boiler venting to an existing vent system if it is shared with other appliances e 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
14. GB162 80 kW 100kW 100 ft 30 48 m 32 ft 9 76 m 68 ft 20 72 m each for the intake and exhaust piping NOTICE D gt The minimum covering wall thickness is 1 25 4 mm The maximum covering wall thickness is 16 406 mm gt For direct venting properly reassemble and reseal the vent and air intake systems CAUTION A gt Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no restriction leakage corrosion and other deficiencies which could cause unsafe condition c Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously d Test for spillage at the draft hood relief opening after 5 minutes of burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe e Any improper operation of the common venting system should be corrected so the installation conforms
15. Meaning of display setting Unit 199 Sea level 0 4 000 ft Le25 L99 L 100 L configured target load GB162 80 kW Sea level 0 4 000 ft LeB L99 L 100 L configured target load GB162 100 kW F5 Configured target value of the pump run over time min FOO F6O F td 100 IF 5 NOTE Do not set the pump run over time to less than F 5 5 minutes E I DHW flow operating condition setting c Dom ron EZ NOTE If the setting E D is displayed the frost protection of the DHW flow has also been switched off Table 22 BC10 Display settings Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 49 13 Display information 13 5 BC10 Display codes Locking faults the boiler resumes normal operation when the fault The following table contains all codes that can show on the BC10 has cleared display To show the current display code and or sub code press the Blocking faults the boiler is locked and will only restart after a Service button repeatedly manual reset The pump will operate continuously for frost There are 3 main code groups protection Operating codes this code gives the status of the boiler No action is If a blinking code is displayed together with other codes all displayed necessary codes will blink A locking
16. NOTICE 6 4 2 Connecting the pressure relief valve PRV The pressure relief valve is a part of the supplied pump group gt fig 11 1 A listed ASME pressure relief valve supplied with the boiler must be installed at the time of installation No valve is to be placed between the PRV and the boiler No reducing coupling or other restriction may be installed in the discharge line The discharge line must be within 12 305 mm witha minimum of 4 100 mm above a drain and installed such that it allows complete drainage of both the PRV and the line The location of the PRV must be readily accessible for servicing or replacement and be mounted as close to the boiler as possible To install the PRV a suitable fitting connected to an extension on a T fitting can be sweated to the hot water line Support all piping Maintain an installation clearance from combustible construction of at least 1 25 mm from the hot water piping 6 4 3 Making the gas connection DANGER gt Only carry out work on gas lines if you are a qualified gas fitter gt The manual gas shutoff valve is part of the pump group and is installed in accordance with the pump group installation instructions gt Determine proper size gas pipe for the installation using table 4 and table 5 Do not forget the pipe fitting losses and observe proper size of the fittings gt Connect the gas supply pipe to the manual gas shutoff valve so that it i
17. UL approved venting material Item Material United States Canada 4 100 mm PVC schedule ANSI ASTMD1785 BH gas Intake combustion 40 80 venting air pipe and fitting PyC DWV ANSI ASTM D2665 systems CPVC schedule ANS ASTMF441 ULC PP ANSI Cat lV E M amp G Duravent Lapproved cl i ass IIB PolyPro and Polypropylene CPVC Centrotherm Class ll c 3 InnoFlue SW Polypro PP Flex ANSI Cat IV pylene M amp G Duravent approved PolyPro Flex and Polypropylene Centrotherm InnoFlue SW Flex 4 6 100 150 PP Bosch ANSI Cat IV mm concentric Concentric approved Intake combustion Polypropylene air pipe and fitting Pipe cement PVC ANSI ASTM D2564 primer CPVC ANSI ASTM F493 Table6 Approved venting air pipe material 1 For installations in Canada field supplied plastic vent piping must comply with CAN CGA B149 1 latest edition and be certified to the Standard for Type BH Gas Venting systems ULC S636 Components of this listed system shall not be interchanged with other vent systems or unlisted pipe fittings All plastic components and specified primers and glues of certified vent systems must be from a single manufacturer and not mixed with other system manufacturer s vent system parts The supplied vent connector and separate available wall termination kits are certified as part of the GB162 Boiler 18 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Approved vent terminations and f
18. W C W C W C W C W C W C W C Carry out a leakage test in operating conditions 9 9 page39 IT UO U UO UO UO UO 8 Check and adjust the flue gases CO emissions 9 10 page 39 ppm ppm ppm ppm ppm ppm ppm 9 Fillthe heating system oO oO oO oO oO oO oO Pre pressure of expansion vessel also see installation instructions for expansion psi psi psi psi psi psi psi vessel Filling pressure 9 2 page 34 psi psi psi psi psi psi psi 10 Check the air flue gas connection 9 5 page36 I oO oO oO oO oO oO 11 Checking the boiler settings of the control documents for the ITT oO oO oO oO oO oO device in accordance with requirements control device O O O O O O O 12 Final check of the inspection activities documenting the measurement and test results 13 Confirming proper inspection Company Company Company Company Company Company Company stamp stamp stamp stamp stamp stamp stamp signature signature signature signature signature signature signature Table 28 Inspection report 15 3 Service report gt Indicate the maintenance activities that have been carried out enter the values measured and enter your signature and the date Page Date Date Date Date Needs dependant maintenance activities 1 Clean the heat exchanger burner and condensate trap page 45 2 Check and adjust the flue gases CO emissions page 39 NZ W C W C W C W C W C W C CO
19. Z223 1 NFPA 54 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 Installation Codes or applicable provisions of the local building codes DANGER Fire danger due to flammable materials or liquids gt gt Do not store flammable materials and liquids in the immediate vicinity of the boiler WARNING Boiler Damage gt gt Boiler must be clear and free from combustible materials gasoline and other flammable vapors and liquids and corrosive liquids and vapors Never use chlorine and hydrocarbon containing chemicals such as spray chemicals solution and cleaning agents paints glues etc in the vicinity of the boiler gt Do not store and use these chemicals in the boiler room gt Avoid excessive dust formation and build up 16 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Installation 6 CAUTION Boiler damage and operational failures Due to insufficient or improper openings for combustion air and or ventilation of the boiler room Provisions for combustion air and ventilation are always required regardless whether the combustion air is taken from the outside sealed combustion or inside room air for combustion Insufficient ventilation of the boiler room can lead to high air temperatures This can result in boiler damage gt Make sure that intake and exhaust openings are sufficiently sized and no reduction or closure of openings takes place gt When the pr
20. at 80 180 F 27 82 C partial load n a n a 96 1 96 1 BTS 2000 at 80 180 F 27 82 C full load n a n a 90 8 90 8 Heating Maximum flow temperature F C 180 82 Maximum working pressure boiler psi bar 50 3 6 Minimum water circulation volume Gal h l h 0 Flow temperature F C 86 180 30 82 can be set on the BC10 basic controller Resistance at AT 20 K psi bar 3 26 225 4 57 315 Heating circuit volume of heat exchanger Gall 1 3 5 0 Pipe connections boiler without pump group Gas connection in Rp 1 Heating water connection in G 1 union nut with female thread enclosed Condensate connection in mm 1 32 Flue gas values Condensate quantity at 104 86 F 40 30 C Gal h L h 2 4 9 0 2 85 10 8 pH value of condensate pH approx 4 1 Flue gas mass flow rate full load g s 35 3 44 9 Flue gas temperature 176 140 F 80 60 C F C 153 67 149 65 169 76 165 63 full load Flue gas temperature 176 140 F 80 60 C F C 142 61 136 58 142 61 136 58 partial load Flue gas temperature 122 86 F 50 30 C F C 118 48 114 46 124 51 120 49 full load Flue gas temperature 122 86 F 50 30 C F C 93 34 88 31 96 34 88 31 partial load CO content at full load 9 3 0 2 9 6 9 4 0 2 9 7 Free fan feed pressure w c Pa 0 602 150 0 883 220 Flue gas connection Flue gas system room air dependent in mm 4 100 Flue gas system room air independent in
21. case the seal between the condensate collector and the flue pipe at the rear side of the heat exchanger may be leaking gt Connect the flexible condensate drain hose to the condensate collector gt Re install the condensate trap gt Rinse the heat exchanger with clean water gt Reassemble all boiler components in reverse order Burner with burner seal Burner cover with fan and gas valve Gas valve Glow ignitor and ionization electrode gt Startup the boiler gt chap 9 Start up procedure page 33 12 4 Check and adjust the gas air ratio flue gases CO emissions gt 9 10 page 39 12 5 Function check gt Slowly open the gas valve by pushing on the gas valve and turning it VW rotation in an counterclockwise direction gt Switch ON the appliance by pressing the main switch on the BC10 basic controller 1 gt Set the space heating water temperature knob 8 and the DHW temperature knob 10 to the maximum temperatures gt Enter a heat demand via the control unit and check that the boiler starts the heating mode gt Open a hot water tap and check that the boiler starts the DHW mode gt Set the space heating water temperature knob 8 and the DHW temperature knob 10 to the required temperatures 10 9 8 120 N 130 H 6720645916 47 1N Fig 96 BC10 basic controller 48 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 13 Disp
22. content at full load CO content at part load 2 Function check page 48 L oO oO oO oO oO oO 4 Confirming proper inspection Company Company Company Company Company Company Company stamp stamp stamp stamp stamp stamp stamp signature signature signature signature signature signature signature Table 29 Service report Buderus 58 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Spare parts 16 16 Spare parts The following are parts commonly required due to damage or replacements Their failure will affect safety or performance of this appliance For a pictorial representation of the part see the respective position number on the exploded view pictures on page 61 and page 62 Description Product No Description Product No 1 Door USA 8718600178 2 Sealing door 7101382 3 Door lock 7101384 4 Hinge door 7101520 5 Wall mounting bracket 7101386 6 Bracket left 7101388 7 Bracket right 7101390 8 Adjusting foot 7101394 9 Transport slide L R 7101392 10 Drawer modules 7101496 11 Screw 4 2x8 5 10 pc 7100748 12 Condensate collector 7101396 13 Seal condensate collector 7746900152 14 Seal 3 2 80mm 71
23. free area of 12 per 2 000 Btu hr of total input rating of all equipment in the enclosure 4 Where ducts are used they shall be of the same cross sectional area as the free area of the opening to which they connect All Air from Outdoor sealed combustion The closet shall be provided with two permanent openings one commencing within 12 305 mm from the top and one commencing within 12 305 mm from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawlor attic that freely communicate with the outdoors The minimum dimension of air openings shall be no less than 4 101 6 mm CAUTION A Risk of boiler damage due to excessive dustand airborne debris levels gt Donotoperate the boiler when there is a lot of dust in the boiler room e g due to building work gt An air filter must be fitted if the supply of combustion air contains large quantities of dust e g from un paved roads and tracks or dusty workplaces such as quarries mines etc or airborne seeds from plants 6 7 Flue gas adapter CAUTION N gt Do not use lubricants to avoid degradation of the lip rings gt When installing PVC vent pipes remove the upper lip ring and insert 1 gt Incase of open venting use basket 2 on the air intake gt When installing parallel PP venting material remove upper lip ring and insert 1 and use PVC PP PolyPro adapter offered by your local vent su
24. information About these instructions These Installation Instructions contain important information for the safe and professional installation start up and maintenance of the boiler with boiler input rating of 80 kW and 100 kW These Installation Instructions are intended for professional installers who have the necessary training and experience for working on heating and gas systems Cascade installation Special cascade units accessories have been developed to enable this boiler to be installed ina 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 manual Subject to technical modifications Slight changes may be made without prior notice to the illustrations process steps and technical data as a result of our policy of continuous improvement GB162 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 2 max input rate 3 1 Designated use The bo
25. involved in starting up the boiler Complete the commissioning record log book after carrying out all activities described in this chapter gt 15 1 page 57 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 e Do not try to light any appliance e Do not touch any electric 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 instruction e 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 O
26. least 4 ft 1 220 mm below 4 ft 1 220 mm horizontally from or 1 ft 305 mm above any door window or gravity air inlet into any building Vent must be at least 12 305 mm above grade anticipated snow line or roof surface Canada 18 457 mm minimum gt fig 23 Vent termination must be at least 7 ft 2 135 mm above a public walkway gt fig 24 12 305 mm i minimum 12 305 mm minimum EXHAUST es INTAKE Ca 12 305 mm minimum eg 12 305 mm minimum bk keem 12 305 mm minimum 6 720 646916 21 1N Fig 23 Vent and air pipe position 1 of a sealed combustion system Buderus adjacent walls inside corners and 5 ft 1 525 mm below roof overhang gt fig 24 It is not recommended to terminate vent above any door or window condensate can freeze causing ice formations Do not use chimney as a raceway if another boiler or fireplace is vented into or through chimney All PVC and CPVC vent pipes must be glued except for the flue gas adapter Installed you can slide the pipe onto the adapter properly supported and the exhaust pipe must be pitched a minimum of a4 6 35 mm per foot back to the boiler This allows the condensate to drain away All non steel combustion air and vent pipe materials and fittings must comply with the following and must be
27. level is L25 25 with an 80 kW boiler and L 2 0 20 with a 100 kW boiler Higher Increase the modulation rate with the button The maximum setting is L 100 This is equal to the factory setting Step5 Press the button Step 6 IF 5 Pump run over time in minutes starts when the heating mode has ended Adjust as follows or go to step 7 Lower Decrease the time with the button The minimum setting SE O minutes The factory default setting is 5 minutes CAUTION Do not set the post purge time to less than 5 minutes Higher Increase the time with the button The maximum setting is F E O 60 minutes or F d 24 hours Step7 Press the button Step 8 Ei DHW mode status setting Adjust as follows or go to step 9 DHW mode can be switched OFF or ON This setting has priority over other DHW mode settings such as those made on the room thermostat Set the DHW mode with the amp or buttons means ON E __D means OFF NOTE Setting EO also switches OFF the hot water cylinder frost protection Step 9 After 5 seconds or after a power interruption the settings menu ends automatically To end manually press the button Any adjustments that you have made have been confirmed Table 15 Settings Buderus 32 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Start up procedure ER 9 Start up procedure There are several steps
28. screw through rotation in a clockwise direction gt Pushon the control panel to close it 6720645916 71 1N Fig 74 Closing the boiler door 9 15 2 Hand over gt Hand over all relevant documentation to the end user and explain his her responsibilities under the relevant national and regional regulations gt Explain and demonstrate the start up and shut down procedures 10 Shutting down the system CAUTION AN The heating system may freeze if it is not operational in times of freezing gt Protect the heating system against freezing if there is a danger of frost affecting the system Drain the heating system water from the lowest point of the heating system The vent screw at the highest point of the heating system must then be open 10 1 Shut down the appliance using the basic controller Shut down your appliance by means of the Logamatic BC10 basic controller When the system is shut down the burner is automatically switched off Further information about the use of the BC10 basic controller is provided in chap 8 Operation page 30 gt Push on the control panel to open it gt Switch OFF the appliance by pressing the main switch of the BC10 gt fig 73 1 Buderus gt Close the main gas supply or the gas valve gt fig 75 E 6720645916 73 1N Fig 75 Closing the gas valve 10 2 Shutting
29. the KIM is defective y gu t Ja SEI Blocking fault No heating operation and no DHW a SS The UBA 3 or the KIM is defective AG gg Locking fault Minimum outdoor temperature is assumed The contacts to the outdoor temperature sensor have shorted or are interrupted the sensor has been connected incorrectly or is defective AD agal Locking fault No DHW is heated any more The contacts to the DHW temperature sensor have shorted or are interrupted the sensor has been connected incorrectly or is defective Ag mgg Locking fault No DHW is heated any more The contacts to DHW temperature sensor to have shorted or are interrupted the sensor has been connected incorrectly or is defective AG a0 Locking fault No DHW available but there is heating The boiler water does not warm up Sensor lead broken or shorted sensor operation The DHW priority is cancelled connected incorrectly or defective filling pump connected incorrectly or when the fault message appears Switch defective permanent tapping or leak the boiler off and on to reset the boiler AG Eri Locking fault Thermal disinfection was interrupted Thermal disinfection has failed Outlet flow during disinfection period too high sensor lead broken or shorted sensor connected incorrectly or defective filling pump defective AD A 16 Locking fault The boiler no longer receives a heat No connection to EMS EMS bus system is overloaded UBA 3 MC10 is demand The heating system
30. the boiler read the accompanying instructions about water quality before filling the heating system isolated from the gas supply piping system during any pressure testing of that system exceeding 0 5 psi 34 5 mbar The maximum test pressure allowed at the manual gas shutoff valve inlet is 0 5 psi 34 5 mbar gt Cover endangered positions before leak testing gt Donotspray the leak testing agent onto cables plugs or electrical connection lines Do not allow it to drip onto them either WARNING Lg gt The boiler and its manual gas shutoff valve must be DANGER Leaks may be caused to pipes and screw connections during commissioning and maintenance activities gt Carry out a proper leak test gt Only use approved leak detection agents for leak detection gt If0 5 psi 34 45 mbar or less slowly open the gas valve by pushing on the gas valve and turning it rotation in a counter clockwise direction gt fig 52 The gas valve is open when it is in the vertical position gt Shut off the appliance from the power supply gt Check the newconduit section up to and including its connection i e direct sealing location to the gas fitting for leaks using a foaming product The maximum test pressure allowed at the manual gas shutoff valve inlet is 0 5 mbar 0 2 W C NOTICE gt Atinitial start up the boiler will start as soon as the system pressure exceeds 15 psi 1 0 bar gt Ifthe syst
31. the display If a fault occurs the display will immediately show the accompanying fault code The fault code flashes if a locking fault has occurred DHW temperature knob gt fig 50 10 The DHW temperature knob is used to select the required temperature of the hot water in the hot water cylinder The unit is F gt table 20 page 41 LED DHW demand gt fig 50 11 The LED DHW status lights when there is a DHW request and is extinguished when the DHW demand is no longer present 30 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Operation ES 8 2 BC10 operating instructions The menu structure consists of 5 menus You can navigate through the menu structure of the boiler on the BC10 Normal Operation menu gt table 11 using the Reset button the Chimney sweep button the Service Flue Gas Test menu gt table 12 button gt fig 50 2 3 and 4 and the display gt fig 50 9 Service Mode menu gt table 13 Manual Operation menu gt table 14 Settings menu gt table 15 Normal Operation menu Step 1 15 Shows currently measured space heating water temperature in F gt 13 3 page 49 Step 2 Press the button Step 3 P 2 al Shows currently measured system pressure in psi gt 13 3 page 49 Step 4 Press the button Step 5 H Current display code In this case Operating phase Boiler in heatin
32. the pressure test if no leaks are found Replace the gas fitting if the pressure drop is higher than 3 8 W C 10 mbar per minute again See 12 3 2 Remove the burner cover with the fan and the gas valve page 45 for instructions on how to remove 12 Maintenance 6720645916 77 1N CAUTION Risk of electric shock gt Before opening the appliance disconnect the appliance from the power supply using the appliance emergency OFF button or disconnect the relevant circuit breaker of the house from the power grid gt Secure the appliance against accidental restarting Fig 79 Checking the gas fitting for internal tightness 11 4 Measure the ionization current gt 9 12 page 40 11 5 Measure the gas inlet pressure working pressure gt 9 7 page 36 11 6 Check and adjust the gas air ratio gt 9 8 page 38 11 7 Carry out a leakage test in operating conditions gt 9 9 page 39 11 8 Measure the flue gases CO emissions gt 9 10 page 39 11 9 Fil the heating system To ensure a trouble free operation of your boiler check the pH value every year and correct it if necessary See accompanying manual about water quality for more information gt 9 2 page 34 11 10 Check the air flue gas connection gt 9 5 page 36 Buderus page 58 NOTICE gt Thereis no need to lubricate the combustion motor as it is permane
33. time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipmentis to be installed In addition the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors 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 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 30 day period a battery operated carbon monoxide detector with an alarm shall be installed alarm and battery back up may be installed on the next adjacent floor level 6 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 2 APPROVED CARBO
34. with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSAB149 1 Natural Gas and Propane Installation Code 22 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Installation ey WARNING gt Improper venting of the GB162 boiler can result in excessive levels of carbon monoxide which can result in severe personal injury or death The boiler must be vented in accordance with the Venting of Equipment section of the latest edition of ANSI Z 223 1 NFPA 54 Natural Fuel Gas Code and or the Venting systems and air supply for appliances section of the latest version of CAN CGA B149 1 Natural Gas and Propane Installation Code in Canada and in accordance with all applicable local building codes NOTICE gt Toavoid moisture and frost build up and to maintain clearances to openings on adjacent homes 45 and 90 elbows or tees may be attached to the end of the vent termination pipe to direct exhaust plumes away from the adjacent structure The total allowable vent length maximum number of elbows and distance to air intake restrictions must be adhered to 6 9 Multiple boiler vent terminal cleara
35. 0 040 128 2TD Fig 88 Checking the ionization electrode 6720615405 035 1TD NOTICE D The glow ignitor is fragile gt Handle with care Buderus Fig 89 Replacing the ignition unit 1 glow ignitor 2 lonization electrode 3 Rubber seal 4 Cover plate with seal 5 Nut 46 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Maintenance 1 12 3 5 Disconnect the condensate trap 12 3 6 Remove the condensate collector gt Disconnect the condensate trap hose 3 and the rubber sleeve 2 gt Disconnect the flexible condensate drain hose and bend it from the condensate trap 1 backwards gt fig 92 gt Turn the condensate trap a quarter rotation counterclockwise gt fig 90 Kai 6720645916 90 1N Fig 92 Removing the condensate trap hose 6720645916 88 1N gt Open the 2 clamps on the right and left at the bottom of the condensate collector 1 1 Condensate trap gt Pull the condensate collector down step 1 and remove it by pulling 2 Rubber sleeve it towards you step 2 3 Condensate trap hose Fig 90 Disconnecting the condensate trap hose gt Disconnect the condensate trap from the coupling and remove it 1 6720645916 91 Fig 93 Removing the condensate c
36. 01400 15 Upper side condensate collectors 7101402 16 Mounting flue gas pipe 7101398 17 Exhaust pipe 7101404 20 Condensate collector 8718600611 21 Seal condensate collector 73463 22 Dram pipe 7101410 23 Sealing bush white 73449 24 Condensate drain pipe 7101535 25 Fan 7746900382 26 Seal fan 7101450 27 O ring 70x3 2 pc 7101416 28 Venturi 7746901751 29 Seal 2 4 60 mm 73563 30 Gas valve natural gas 8718600291 30 Gas valve LP gas 8718600323 31 Seal 33 x 24x 3 5 10 pc 7098962 32 Gas pipe 7746900397 23 Flange gas valve 8718600286 34 O ring 10 pc 7101504 36 Screw M5 x 20 10 pc 7099650 37 Screw M5 x 16 10 pc 7101484 38 Screw M6 x 20 10 pc 7101486 39 Air inlet pipe 7101462 A0 Sealing 10 pc 7101482 41 Air vent revision set 7101428 42 Clip 7101430 43 Sensor NTC 7746900391 44 Clip 4x2 pc 7746700063 45 O ring 9 19 x 2 62 10 pc 78175s Table 30 Spare parts 46 Pressure sensor 8718600019 47 O ring 14x 1 78 10 pc 7101646 48 Return supply pipe 7101438 49 Connection nipple CH 73080 50 Clm 7746700069 51 O ring 10 pc 7101488 52 Flue gas sensor 7746700420 56 Mounting set with sight glass 8718600172 with glow ignitor with ionization electrode 60 Heat exchanger 7746900383 61 Cover controller BC10 73698 62 Burner 7101444 63 Seal Burner 7101446 65 Burner box 7101448 66 Frontconnection board 7101490 67 BC10USA 78186 68 On off switch 7099041 69 KnobBC10 3
37. 1 P PUMP IUN OVEFTIMG ue ENEE EEN EEN EEN EEN e EEN 8 41 lu 8 R ROOMICONEIOMNER 2 ekege seiegde d e Seed 26 S Safety 8 ietge SE eg eege ee ue deet uge Des RENE ER SENICE MODES Nee deed EEN dere ee ek EE ee 31 ele NN el 30 EE 32 Shutting GOWN EE 42 Signs Of COMOSION age eege ewe catae usecase Ee 43 Space TT 30 T Technical specifications gege e NN cvvetecssecessaverdevesseseess 55 GANS PONLAL OM 9sisie aineiessceinis bcarei Saratsioielncn eieisctuisisiate 8 daieleiole ele EEEa 11 w Working pressure ssssssssssseseessesseoseeosseessesssee 36 55 Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 63 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
38. 119 Low loss header 7746901646 120 plug protector 73948 AM10 7746900020 BCM 1100 100 kW 0 4 000 ft 8718600725 BCM 1101 80 kW 0 4 000 ft 8718600726 Screw 6 3 x 19 10 pc 73986 Table 30 Spare parts Buderus 60 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 6720645916 99 2TD Fig 101 Exploded view Logamax plus GB162 80 kW 100 kw Buderus 61 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 16 Spare parts 6720645916 100 2TD Fig 102 Exploded view pump group Logamax plus GB162 80 kW 100 kW Buderus 62 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Index A Appliance configuration ccseccscesccnceccesccncescesseeees 36 B BCLO basicicontrollen au deteeskk ees eivecddsccaw bes Ne SEN 30 BUET si sis tiacasccdvace ces ER ce cee dence css ENEE EE EE EENS sass 45 c Carbon monoxide content 39 COWES sretao e E N 39 Condensate collector e gg eggt Eug geg age A S EAR A et gek 47 EST Ee Le EE 35 45 46 EE 9 13 24 D DAW circ lation PUMP ssinsssse scisdesieetossasosaeorusesehedenseensces 26 DAW PUMP EE 26 DIMENSIONS sse ccs seas ces caace coeees dese ses svacecseveaenseesvese 9 10 NIE 30 Display CodeS cxssaswceedeses toa svevaaswers seca sca kencedeedv
39. 162 80 kW 100 kW 7746800103 2014 10 31 2 Operation Step 9 Press the button Step10 E This parameter indicates the DHW mode status setting gt 13 4 page 49 Step 1 Dress the button Step 12 2 0 Shows currently measured space heating water temperature in F gt 13 3 page 49 Step13 Dress the button Step14 P22 Shows currently measured system pressure in psi gt 13 3 page 49 Step15 Dress the button Step16 A_ Display code Operating phase The boiler is in service mode gt 13 5 page 50 Step 17 Alter 30 minutes or after a power interruption the flue gas test ends automatically To end manually press and hold the button for more than 2 seconds until the dot disappears Step18 The boiler input rating drops to the preset capacity gt table 15 page 32 Table 13 Service mode Manual Operation menu Step 1 2 0 Shows currently measured space heating water temperature in F gt 13 3 page 49 Step 2 To activate manual operation Press and hold the button for more than 5 seconds Step 3 q Sst A flashing dot in the right hand bottom corner of the display shows manual operation is active This means that the boiler is permanently in heating mode Space heating water temperature is as set on the BC10 basic controller The LED Heating system status lights DHW mode is possible during manua
40. 25 Horizontal venting system sealed combustion 1 exhaust 4 100 mm 2 intake 4 100 mm Buderus 7746800103 05 1TD Fig 26 Concentric horizontal venting system sealed combustion 1 concentric adaptor 4 100 mm 6 150 mm 2 exhaust 4 100 mm intake 6 150 mm 3 place the air intake cap 6 720 645 916 29 2TD v Fig 27 Horizontal venting system sealed combustion 1 exhaust 4 100 mm 2 intake 4 100 mm 20 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Installation 6 aaam 7746800103 07 1TD 3 2 ay 4 K es 6726 645916 27 1N P Fig 28 Vertical parallel venting system sealed combustion 1 exhaust 4 100 mm 2 intake 4 100 mm 3 10 0 MIN 250 mm 0 mm MIN 4 12 300 mm over max snow level or 24 600 mm whichever Fig 30 Vertical venting system non sealed combustion 1 exhaust 4 100 mm 2 intake 4 100 mm 3 12 300 mm over max snow level or 24 600 mm whichever is greater 4 10 0 MIN 250 mm 0 mm MIN H
41. 5 Packaging and transportation cseeeeeeeee 11 9 14 2 Setthe space heating water temperature 41 DI Scope ofdelivery cce eee cece 11 9 14 3 Setthe pump run over me 41 5 2 Transporting the boer 11 9 14 4 Switch DHW mode ON OFF 02e seeeeee 41 9 14 5 Setthe DHW temperature 000 ee 41 6 Installation 12 9 15 Final activities 42 ee a ee We ie ce tn ee 9 15 1 Close the boiler door and the control panel 42 6 1 Requirements for the installation room 12 9 15 2 Hand over 42 6 2 Requirements for the heating system 12 6 3 Installing the boer 12 6 4 Water and Gas Connection 13 10 Shutting down the system 42 E E WE ETC 13 10 1 Shut down the appliance using the basic controller 42 6 4 2 Connecting the pressure relief valve PRV 14 10 2 Shutting down the heating system if there is a risk 6 4 3 Making the gas connection 14 of freezing interruption of use 42 6 4 4 Installing the heating supply and return pipe 14 10 3 Shutting down the heating system in the event of 6 4 5 Installingthe pump cece ee eee ee 15 an emergency 42 6 4 6 Installing the condensate trap 04 15 6 5 Connecting the condensate drain pipe 16 6 5 1 Connecting the expansion vessel in a single boiler 11 Inspection E 43 EEN 16 11 1 Prepare the appliance for inspection 43 6 6 Combusti
42. 8724 70 Draw connection board 7101480 71 Cover control box 7101498 73 Transformer 78191 74 UBA3 8718600083 75 Fuse 5AF 10 pc 8718601966 76 Connection board 7099042 77 Electronic connection red 73776 78 Electronic connection grey 73774 79 Electronic connection grey 13773 80 Electronic connection blue 73775 81 Electronic connection orange 13777 83 Flue gas adapter 73936 84 Measure nipple cap 7101424 86 Cable harness low voltage 7746900392 87 Cable harness high voltage 7746900393 88 Cable harness on off switch 7101476 89 Cable harness earth 7101474 91 Union nut 1 5 pc 73481s 92 Sealing 5 pc 7746700417 93 Nut 1 7099416 95 Gas valve 7746900401 96 Pump UP26 99U 7746900402 98 Level ball valve blue 7746700421 99 Level ball valve red 7746700422 100 Casing 7101514 101 Thermometer 7746900404 102 Manometer 7101506 105 Valve housing return 74549 106 Air release tap 7746900403 Table 30 Spare parts Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 59 16 Spare parts Description Product No 107 Connection pressure gauge 73081 108 Drain pipe 7101410 109 Valve housing supply 7746900406 110 Adapter parallel 4 7746900384 111 Adapter insert 4 7746900385 112 Open venting insert 7746900386 113 Lip ring 114 7746900387 114 Lip ring 103 7746900388 117 Strain relief bracket 7746900398 118 Safety valve ASME 7746900405
43. Ke CH H s zf CH is Ss baal CH CH Q QO ks Kal zf m Condensing gas boiler CAUTION Before putting the boiler into operation read this manual carefully DANGER Improper installation adjustment alteration service or maintenance can cause injury loss of life or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier CAUTION The operating manual is part of the documentation that is delivered to the installation s operator Go through the information in this manual with the owner operator and make sure that he or she is familiar with all the necessary operating instructions NOTICE In the Commonwealth of Massachusetts this boiler must be installed by a licensed Plumber or Gas Fitter Danger 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 Donot 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 Donot try to light any boiler Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions Ifyou cannot reach your gas supplier call the fire department e Installation and service must be performed by a q
44. M REQUIRED When the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for the installation of the equipment and venting shall include 1 Detailed instructions for the installation of the venting system or the venting system components and 2 Acomplete parts list for the venting system design or venting system d MANUFACTURERS REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for the venting of flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting systems shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all instructions For all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or venting design instructions shall remain with the appliance or equipment at the completion of the installation General information ey 3 General
45. N MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of 8 ft above grade directly in line with the exhaust vent terminal for the horizontally vented gas fuelled heating appliance or equipment The sign shall read in print size no less than 1 in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fuelled equipment shall not approve the installation unless upon inspections the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CRM 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CRM 5 08 2 a 1 through 4 The following equipment is exempt from 248 CRM 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most correct edition of NFPA 54 as adopted by the board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURERS REQUIREMENTS GAS EQUIPMENT VENTING SYSTE
46. PERATING INSTRUCTIONS STOP read the safety information above on this label Turn off all electric power to the appliance Set the thermostat or other operating control to lowest setting This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Close main gas shut off valve Wait 5 minutes to clear out any gas Then smell for gas Including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step Open main shut off valve Set the thermostat or other operation control to desired setting Turn on all electric power to the appliance If the appliance will not operate follow the instruction To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Turn off all electric power to the appliance if service is to be performed Set the thermostat or other operating control to lowest setting 3 Close main gas shut off valve PON gt on GR E 708 375A 2172B 6720645916 48 1N Fig 51 Safety sticker Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 33 ES Start up procedure 9 1 Check for gas leaks Prior to the initial start up check that the gas flow pipe work is gas tight this must be confirmed in the start up report 9 2 Fill the heating system To ensure a trouble free operation of
47. When installed in a room with thin walls or a thin floor resonating noise may occur Install noise reducing parts if required gt Donotstore any flammable materials or liquids in the immediate vicinity of the boiler gt Never use anychlorinated detergents or halogenated hydrocarbons e g in spray cans solvents and detergents paints adhesives gt Donot allow too much dust to collect on the boiler 6 2 Requirements for the heating system gt Installing a dirt trap like a y strainer and a desludging device is required This must be installed in the heating system in the immediate vicinity of the boiler in an easily accessible position between the boiler and the lowest point in the return of the system gt Clean the dirt trap at every annual service gt Never use salt bedding type exchangers ion exchangers to soften the water gt The low loss header and boiler connection set must be installed supplied with the boiler Buderus gt When using oxygen permeable pipes plastic e g for floor heating systems you must separate the system using secondary heat exchangers 6 3 Installing the boiler Observe the installation distances of the combustion air flue gas system gt Before starting installation check that the carrying capacity of the wall is sufficient for the boiler weight NOTICE gt To protect the connection orifice you must not remove the styrofoam bottom panel gt Do not lift t
48. a Display codes Maindisplay Sub display code code Key to display code Other effects oy ang Locking fault The room temperature is not possibly The flow temperature sensor has measured a current flow temperature reached higher than 203 F 95 C Du ERN Locking fault The room temperature is not possibly The safety temperature sensor has measured a current flow temperature reached higher than 203 F 95 C Du 285 Locking fault The room temperature is not possibly The return temperature sensor has measured a current return temperature reached higher than 203 F 95 C Tat T 3 TEL Blocking fault No heating operation and no DHW g ort The flue gas sensor temperature is too high Im a p Locking fault No heating operation and no DHW There is no connection between contacts 78 and 50 of the UBA 3 installation base Nyt Tat Blocking fault No heating operation and no DHW g ort The flue gas sensor contacts have shorted nyt Kees al Blocking fault No heating operation and no DHW e CS The flue gas sensor contacts are open J PO Locking fault No heating operation and no DHW The system pressure is too low less than 3 psi 0 2 bar ZF 260 Locking fault The flow temperature sensor has not after burner start up detected any temperature increase in the heating systems w
49. acasens 50 BIER 42 E Emergeny es ENER ER ENER EE ENEE AER EE EEN SE ENEE RER 42 F Fatt eegene eg geg vere scanmett acer nengeveeuaes 49 50 Flow temperature o ges ere eg Set Age esche Ee de Se SENG 55 Flue aS CONNECTION ageet ss EEN EES ENEE ANN 36 55 Flue gaS best 23285 cee ek e dES d EE ERR dE EE see EES 31 Freeze damage wicssvaivewecnenchevtvece bner Cerir RENE SEON 42 Freeze protection e aaeN EES SN ENEEREENEEE EE EE EN ENEE RER EE 8 FUNCTION MOGUIE si si cescucudevesseves seveies dudsveaVencusesseedaves 26 Blieder 39 G GaS CONNECHON ss csscvsascsesceseetedessvecsissevseestes E EEREN ESSE 14 Gas SU BENEKE Ed EE de dE ER EE g 35 Gas tightness ege ebeeieie Zeg eege deu ged SEN Ee ENER ee 35 Gas all CH WEE 38 H Heat exchanger ccssascsseiwsstevesbeswtavevssueservanesvtabies 45 48 Heating Capacity sssscscscssssssssessesessccssasescsseseesessasavaess 41 Heating system Water cscseccessctsccssccscdseccodscteccescdsssetacs T Hydraulic resistance NN 56 l lgnitionUnit sieri dE ERENNERT EEN 46 Inspection report ssscsiesccssasccssasecscsescveessesssesassesvass sees 58 Installation TOOM ss seg geg dE wal vendewetwesetwed ned eewsauseness 12 lonization C OM e 40 Index L Ike aK ABE LOSE uereg leese 34 39 43 iere ER M Main power SWITCH Sex gege vies chasdeeteatevebis cies KENE E Ne 30 Manual operationisniscivescescansocasdewsadecuceestessorauceraetans 32 Neue eenegen E gege eege DEEN EE eu EN N Ou ele e E 3
50. ain gt Open the gas valve again by pushing on the gas valve and turning it rotation in a counterclockwise direction Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 37 ES Start up procedure 9 8 Check and adjust the gas air ratio WARNING N Damage to the boiler by incorrect adjustment of the gas air ratio gt Adjust gas air ratio ONLY with part load gt Adjust gas air ratio ONLY based on the gas air pressure differential and never based on measured flue gas values such as CO CO gt NOy WARNING AN A leaking testing nipple causes explosive fumes gt Check the testing nipples used for gas tightness gt Only use approved detection products to locate leaks CAUTION Due to short circuits gt Cover any hazardous locations prior to locating the leaks gt Donot spray the leak detection product on cable runs plugs or electrical wiring Do not let it drip onto them either gt Open at least 2 thermostatic radiator valves if present Do not switch ON the boiler gt Push on the control panel to open it gt witch OFF the heating system by pressing the main switch of the BC10 basic controller gt fig 65 1 gt Close the gas valve gt fig 63 gt Turn the vent key through a rotation to undo the boiler door lock gt fig 54 detailed picture gt Push the fastener down gt fig 54 and open the boiler door gt Open the screw pl
51. as system installation instructions been observed Buderus 9 6 Checking the appliance configuration NOTICE D The burner must only be put into use with the correct orifice gt table 16 gt Consult the relevant gas utility company for the type of gas supply gt Check that the actual gas supply is in accordance with the type of gas supply specified on the gas classification label gt fig 62 9 or E ai 6720645916 59 1N Fig 62 Checking the gas classification label Gas orifice diameter in inch mm 0 331 8 40 0 193 4 70 Type of gas supply Altitude in ft m GB162 80kW Natural gas 0 4 000 0 1 220 0 4 000 0 1 220 Table 16 Gas orifice diameter 9 7 Measure the gas inlet pressure working pressure gt Open at least 2 radiator valves if present Do not switch ON the boiler gt Push onthe control panel to open it gt Switch OFF the power supply to the appliance gt Close the gas valve in a clockwise direction gt fig 63 L AI 6720645916 60 1N Fig 63 Closing the gas valve gt Turn the vent key through a quarter rotation to undo the boiler door lock gt fig 54 page 34 gt Push the fastener down and open the boiler door 36 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 gt Open the screw plug on the testing nipple for the gas inlet
52. ater ap 211 Locking fault S The heating water temperature difference measured between the flow temperature sensor and the safety temperature sensor is too high ER a p Locking fault The flow temperature sensor has measured a heating water temperature increase of over 40 F s 5 C s Locking fault The temperature difference measured between the flow temperature sensor and the return temperature sensor is more than 122 F 50 C Jy 2g Locking fault The pump has stopped or is running without water dU 262 Locking fault No feedback from the pump JH 754 Locking fault The tacho signal from the fan has failed during the operating phase Jr Tat Blocking fault No heating operation and no DHW e eat No current of air after a certain time IF ERE Operating phase The appliance has been switched off for a couple of seconds because it had been running without any interruption for 24 hours This is a safety check a ee me Blocking fault No heating operation and no DHW d e The tacho signal from the fan is not present during the pre operative or operating phase L y Blocking fault No heating operation and no DHW ap 2 thr 3 j The fan is running too slowly Ek Blocking fault No heating operation and no DHW The fan is running too fast AL y 2 Ht Blocking fault No heating operation and no DHW SR The flow temperature sensor has detected a flow temperature of over 221 F 105 C
53. ature has reached the target value and there is no heat demand Fig 50 BC10 basic controller 1 Main power switch 2 Reset button 3 Chimney sweep button 4 Service button 5 Service Tool Connector 6 LED Burner operation 7 LED Central heat demand 8 Space heating water temperature knob 9 Display 10 DHW temperature knob 11 LED DHW demand The BC10 basic controller has the following components Main power switch gt fig 50 1 The main power switch is used to switch the boiler ON and OFF Reset button gt fig 50 2 If a fault has occurred you may have to restart the boiler by pressing the Reset button This is only required in the event of a locking fault Blocking faults are reset automatically as soon as their cause has been corrected The display shows during the reset operation Buderus Table 10 Meanings of LED Burner operation indications LED Central heat demand gt fig 50 7 The LED Central heat demand lights when there is a heat demand and is extinguished when the heat demand is no longer present Space heating water temperature knob gt fig 50 8 The Space heating water temperature knob is used to set the upper space heating water temperature limit The unit is F Display gt fig 50 9 The appliance display values display settings and display codes can be read out from
54. code will always show on the first screen of the BC10 Display codes Maindisplay Sub display code code Key to display code Other effects J A Operating phase Communication test while starting up This display code flashes 5 times within 5 seconds while starting up to indicate that the communication between the UBA 3 and the BC10 basic controller is being tested If a new UBA 3 or a new KIM was fitted this code will flash for max 10 seconds Perd Blocking fault No heating operation and no DHW If this code continues to flash on the display there is a fault in the communication between the UBA 3 and the BC 10 basic controller F 7H Operating phase The boiler is in flue gas test or service mode H agg Operating phase The boiler is in heating mode HL agg 2 Operating phase The room temperature is too high The boiler is in manual operation mode H ag 1 Operating phase The boiler is in DHW mode H ag t Operating phase Pump run over time via the external hot water cylinder 130 seconds at minimum speed The LED Burner operation is off 0R an 41 Operating phase The room temperature is not possibly The switch optimization program is activated reached This program is activated if there has been a DHW request from an RC regulator more frequently than once eve
55. does not heat defective any longer AG pap Locking fault No heating operation and no DHW Water pressure sensor generates a fault code The digital water pressure sensor is defective Age Pis Locking fault BC10 settings are no longer taken over by No communication with BC10 Contact problem at BC10 or BC10 is RCxx devices defective Ate g5 _ Locking fault The water flow to the downstream heating The contacts to the switch sensor have shorted or are interrupted the circuits may be faulty now they can no sensor has been connected incorrectly or is defective longer be provided with the required heat capacity Ate A tb Locking fault Heating circuit pump 1 is activated 5 WM10 not available or no communication WM10 or bus circuit connected continuously incorrectly or defective WM10 is not recognized by the RC thermostat Ata a5 Locking fault Both RC35 and RC20 activate heating Conflicting addresses Both RC20 and RC35 are registered as Master circuit 1 and DHW Depending on the heating programs set and the required room temperatures the heating system can no longer work correctly DHW mode does not work well Table 23 Display codes Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 53 Maindisplay Sub display Display codes code code Key to display code Other effects Aci Boe Locking fault Since th
56. down the heating system if there is a risk of freezing interruption of use If conditions are such that the heating system has to be shut down for a long period while there is a risk of freezing the water must be drained from the heating system gt Push onthe control panel to open it gt Switch off OFF appliance by pressing the main switch of the BC10 gt fig 73 1 gt Close the main gas supply or the gas valve gt fig 75 gt Drain the heating water at the lowest point of the heating system using the drain cock or the heating body gt fig 76 The automatic air vent at the highest point of the heating system radiator must be open Vo ow 6720645916 74 1N Fig 76 Draining the heating system example 10 3 Shutting down the heating system in the event of an emergency You must immediately close the main shutoff valve or gas shutoff valve and disconnect the power from the appliance gt Close the main shutoff valve 42 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 11 Inspection Offer your customer an annual inspection and maintenance contract The activities to be included in an annual inspection and maintenance contract can be found in the inspection gt 15 2 page 58 and service reports gt 15 3 page 58 WARNING Lg Do not use this boiler if any part has been under water gt Immediately call a qualified service technician to inspect the boil
57. e heating system is room temperature controlled and not controlled parts of the heating system risk freeze damage e g radiators in the garage set the pump run over time to 24 hours 9 14 4 Switch DHW mode ON OFF gt Set the DHW mode according to the Settings menu gt table 15 page 32 When DHW mode is switched OFF C Dt the freeze protection for the hot water cylinder if present is switched OFF 9 14 5 Set the DHW temperature gt Set the DHW temperature knob gt fig 73 10 to the required temperature of the hot water in the hot water cylinder gt table 20 Knob position SEN ELC 0 DHW mode is OFF only heating mode ECO Economy mode The DHW will only be reheated to 140 F 60 C if the temperature has significantly fallen This reduces the number of burner starts and saves energy As a result the water may be a bit colder initially 86 140 The temperature set on the BC10 is a temperature that cannot be changed using a RC thermostat Aut The temperature is set on the thermostat e g RC35 If no thermostat is connected the maximum DHW temperature is 140 F 60 C Table 20 Setting of the DHW temperature Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 41 EJ Shutting down the system 9 15 Final activities 9 15 1 Close the boiler door and the control panel gt Close the boiler door gt fig 74 and lock the fastener by turning the vent
58. e wall according to the installation instructions of the module gt Make an EMS bus connection cable using a 2 core cable and the connector enclosed with the module gt fig 46 Important Use the connector of the same color as the connections on the module 6 720 646157 43 1N Fig 46 EMS bus polarity NOTICE D Pay attention to the polarity when using an EMS bus connection cable gt Connect the wire from terminal 1 to terminal 1 and from terminal 2 to terminal 2 gt fig 44 and fig 45 gt Connect the EMS bus connection cable to the orange RC connection of the external connection board 1 zU FA WA FW EV DWV OO 6 720 646157 44 1N Fig 47 External connection board Room controller RC and EMS bus connection color orange gt Toconnect other modules see 7 2 1 Logamax plus GB162 80 kW 100 kw 7746800103 2014 10 7 3 Electrical wiring diagram A CAUTION Wiring errors can cause improper and dangerous operation gt Label all wires prior to disconnection when servicing gt Verify proper operation after servicing Logamax plus GB162 80 kW 100 kW 45 Oe orangewhite O wie 120VAC_ oi brown O13 L L green yellow H Si e i 8 19 20 21 22 3
59. ed gt Covering non metallic vent pipe and fittings with thermal insulation shall be prohibited gt Aminimumclearance of 4 ft 1 220 mm horizontally from and in no case above and below unless a 4 ft 1 220 mm horizontal distance is maintained from electric meters gas meters regulators and relief equipment 7 2135 mm 5 1525 mm 1220 mm 1220 mm 1 2 3 4 6 720 645916 22 1N Fig 24 Ventand air pipe position 2 of a system with combustion air supply from the room non sealed 1 Height at Least 1ft 305 mm above grade and snow line 2 Exhaust terminal must be at least 3 ft 915 mm above forced air inlet within 10 ft 3 050 mm 3 Forced Air Inlet 4 Gravity Air Inlet Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 19 ES Installation Below are approved examples of vertical and horizontal venting installation NOTICE D gt Place pipe supports every 5 ft 1 525 mm of horizontal and vertical run beginning with support near boiler gt The condensate must be drained in accordance with the applicable rules gt 6 5 page 16 gt Periodic cleaning of the vent terminal and air intake screens is mandatory gt Avoid locating vent terminals near equipment or construction which can be subject to degradation from exhaust gases 6720645916 23 1TD gt Sat Fig
60. ed freeze protection that switches the boiler ON at a space heating CH water temperature of 45 F 7 C and switches it OFF at a CH flow temperature of 59 F 15 C This feature does not protect the central heating system from freezing If there is arisk of radiators or pipe sections freezing up we recommend setting the pump run over time to 24 hours gt 13 4 page 49 3 5 Tools materials and further equipment For the installation and maintenance of the boiler you will need the standard tools for space heating gas and water fitting In addition a hand truck with a fastening belt is useful 3 6 Disposal gt Dispose of the boiler packaging in an environmentally sound manner gt Dispose of components of the heating system e g boiler or control device that must be replaced in an environmentally responsible manner Buderus 8 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Dimensions and connections KE 4 Dimensions and connections 4 1 Without pump group 16 5 420 mm 18 3 465 mm 0 25 6 mm 0 20 5 520 mm 0 20 5 520 mm 6 152 mm l I 4 1 103 5 mm ine Gas RS EE yy SS Cc ZY nae E 16 406 mm LO 2 H Fle EIS E ai E E o ball S SS S elle S g E S 8 D j D E F GEET Gier E 1 E 1 G A 24 8 630 mm
61. ee e g for floor heating safety 6 DWV green Connection for external 3 way valve 7 PK green External heating pump 120 VAC for use with non Buderus pump group 8 PS grey DHW tank pump 120 VAC 9 PZ lilac DHW recirculation pump 120 VAC 10 Netz white Main power connection 120 VAC Table9 External connection board connections EV Terminal External switching contact An external switch contact can be used i e to safeguard a floor heating system so that the heating water temperature will not become too high etc When the external switch contact is opened the boiler will be switched off for heating operation and for domestic hot water operation The pump continues to run for the run over time set on the boiler gt Remove the cable from the EV terminal gt fig 37 gt Connect the external switch contact to the red EV terminal gt fig 37 DWV Terminal 3 way valve gt Do not use this connection 7 1 3 D 120 VAC connections NOTICE gt Use the 120 VAC connections for specific hydraulic configurations and a corresponding controller Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 25 7 Electrical connections 6 720 646157 35 1N Fig 38 120 VAC Connections 1 PK 2 PS 3 PZ 4 120VAC PK Terminal External pump gt Connect the external heating or system pump for situations where the pump of the Buderus pump group is not used to the g
62. em pressure falls below 3 psi 0 2 bar the boiler will stop and generate a fault code gt Push and open the control panel cover gt Turn the Space heating water temperature knob 8 and DHW temperature knob 10 counterclockwise to the 0 position 10 9 8 6720645916 47 1N Fig 53 BC10 basic controller gt Turn the vent key a quarter rotation to undo the boiler door lock gt fig 54 detailed picture Push the fastener down gt fig 54 step 2 and open the boiler door gt Remove the insulation cover of the pump group gt fig 54 step 4 4 3 i BE 5 2 6720645916 49 1N Fig 52 Open the gas valve 1 pressure relief valve 2 supply water valve 3 pump 4 manual gas shutoff valve 5 return water valve Buderus gt Fig 54 Opening the boiler door 6720645916 51 1N To purge the boiler every radiator in the heating system must have a purge facility In some situations it may even be necessary to provide extra purging facilities at certain locations The boiler itself has an automatic air vent 34 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 gt Loosen the cap of the automatic air vent gt fig 55 by turning rotation counterclockwise 6720645916 52 1N Fig 55 Opening the automatic air vent gt Op
63. en the heating supply and return isolating valves on the pump group gt fig 56 The open position is parallel to the pipe gt Fillthe heating system to a pressure of about 20 psi 1 5 bar L 6720645916 53 1N Start up procedure ER The pressure in the heating system which is measured directly at the boiler must be at least equal to the required pre pressure of the expansion vessel plus 7 psi 0 5 bar This minimum pressure must not be less than 12 psi 0 8 bar if the heating system is cold The maximum pressure in the heating system measured directly at the boiler must not exceed 30 psi 2 6 bar or 50 psi 3 5 bar when the optional 50 psi 3 5 bar pressure relief valve is used gt 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 9 3 Fill the condensate trap with water gt Fill the condensate trap with water gt fig 58 For disconnecting the condensate trap gt 12 3 5 page 47 G 6720645916 55 1N Fig 58 Filling the condensate trap with water WARNING N Danger of fatal accident due to poisoning gt Ifthe condensate trap is not filled with water flue gas can escape and put people s lives at risk Fig 56 Opening the isolating valves here open position gt Read the pressure PSI from the press
64. er and to replace any part of the control system and any gas control which has been under water CAUTION Insufficient or improper cleaning and maintenance can A cause damage to the installation gt Inspect and clean the appliance once a year gt Carry out maintenance as required Immediately remedy faults This will avoid further damage to the system CAUTION Risk of electric shock gt Before opening the appliance gt disconnect the appliance from the power supply using the appliance emergency OFF button or disconnect the relevant circuit breaker of the house from the power grid gt Secure the appliance against accidental restarting gt Periodically examine the venting systems and cleaning of the screens in the vent terminal gt Also periodically inspect the low water cutoffs including flushing of float types and clean the condensate collections and disposal system 11 1 Prepare the appliance for inspection INSTRUCTION FOR THE INSTALLER D gt If gas pipes have to be disconnected from the gas burner fitting the burner cover must only be opened by a specialized professional gt Switch OFF the appliance by pressing the main switch of the BC10 gt Close the gas valve 1 Inspection EA gt Close the isolating valves 2 T g il oor 1 O AAN IRZ KY Ier 2 Fig 77 Closing the valves here in closed position 6720645916 75 1N
65. ere is no actual room temperature RC20 HK1 temperature sensor The integrated temperature sensor of the information room influence and remote control control unit of heating circuit 1 is defective optimization of the switch times do not work The EMS works on the basis of the values last set on the remote control Ap A tb Locking fault Since there is no actual room temperature The contacts to the heating circuit flow sensor have shorted or are information room influence and interrupted the sensor has been connected incorrectly or is defective optimization of the switch times do not work FER AON Locking fault Heating circuit pump 2 is activated The contacts to the heating circuit flow sensor have shorted or are depending on the preset value The power interrupted the sensor has been connected incorrectly or is defective to the mixer is switched off and the mixer stays in the state it was last put in can be adjusted manually FER HIE Locking fault Heating circuit 2 cannot be operated MM10 not available or no communication The heating circuit addresses on the MM10 and the RC35 do not match up the MM10 or the bus circuit is connected incorrectly or is defective MM10 is not recognized by the RC35 correctly MM10 and the mixer automatically goes into emergency operation Heating circuit pump 2 is activated continuously Monitor data in the RC35 is invalid
66. g mode gt 13 5 page 50 Step 6 After 5 seconds the display returns to step 1 or Step 7 Press the button Table 11 Normal operation Flue Gas Test menu Step 1 2 0 Shows currently measured space heating water temperature in F gt 13 3 page 49 Step 2 To activate the flue gas test Press and hold the button for more than 2 but not longer than 5 seconds Step 3 20 The non flashing dot in the right hand bottom corner of the display shows the flue gas test has been activated the boiler is in heating mode at a capacity of 100 for a maximum of 30 minutes space heating water temperature is as set on the BC10 basic controller DHW mode is not possible Step 4 Press the button Step 5 Hd dl Shows currently measured system pressure in psi gt 13 3 page 49 Step 6 Press the button Step 7 H Display code Operating phase The boiler is in flue gas test mode gt 13 5 page 50 Step 8 Press the button Step 9 2 0 Shows currently measured space heating water temperature in F gt 13 3 page 49 Step10 After 30 minutes or after a power interruption the flue gas test ends automatically To end manually press and hold the button for more than 2 seconds until the dot disappears Table 12 Flue gas test Service Mode menu Step 1 2 0 Shows currently meas
67. gnal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing damage are not taken NOTE indicates that damage to property may occur CAUTION indicates possible minor to medium personal injury WARNING indicates possible severe personal injury DANGER indicates a potential for loss of life Important Information Important information neither indicating personal injury nor damage to property are marked with this symbol They are separated by lines above and below the text Additional symbols Symbol Explanation gt Sequence of steps gt Cross reference to other points in this document or to other documents Listing list entry Listing list entry 2nd level Table 1 1 2 Safety instructions Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING N A fire or explosion may result causing property damage personal injury or death gt Ifthe information in these instructions is not followed exactly DANGER A if flammable gas explodes gt Beware if you smell gas there may be an explosion hazard gt Donotstore or use gasoline or other flammable vapors and liquids in the vicinity of this or any other boiler Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 5 2 Regulations and guidelines WARNING
68. gt After the LED Burner operation gt fig 65 6 has lit wait for 1 minute until the boiler is burning at full load gt Press the Chimney s weep button gt fig 65 3 to clear the reading gt table 12 page 31 gt Check that the boiler performance is still at the required value gt table 15 page 32 vvv v v 9 9 Carry outa leakage test in operating conditions WARNING AN Leaks may be caused to pipes and screw connections during commissioning and maintenance activities gt Carry out a proper leak test gt Only use approved leak detection agents for leak detection gt Press and hold the Chimney sweep button gt fig 65 3 approx 2 seconds until the dot in the right hand bottom corner of the display gt fig 65 9 appears gt table 12 page 31 gt After the LED Burner operation gt fig 65 6 has lit up wait for 1 minute until the boiler is burning at full load gt Use a foaming product to check all sealing locations in the total gas circuit of the burner while the burner is active gt Press the Chimney sweep L button gt fig 65 3 to clear the reading gt table 12 page 31 9 10 Check and adjust the flue gases CO emissions gt Openat least 2 radiator valves if present Do not switch ON the boiler gt Pushon the control panel to open it gt Switch OFF the appliance by pressing the main switch of the BC10 basic co
69. hanger burner and condensate trap The boiler heat exchanger has a self cleaning coating 1 Ir KL D ee CAUTION A To avoid a short circuit gt Donot spray the cleaning agent onto the burner the hot surface ignitor the ionization electrode or other electric components 12 3 1 Remove the gas valve gt Undo the gas fitting screw connection 1 and pull the 4 connectors 2 from the gas valve 6720645916 80 1N Fig 82 Undoing the connections to the gas fitting 6720645916 81 1 Fig 83 Removing the connectors from the fan gt Pull the air suction tube from the fan gt fig 84 Co S 6720645916 82 1N Fig 84 Pulling the air suction tube from the fan gt Carefully open the 4 snap retaining clips on the burner cover gt fig 85 The retaining clips may be under tension gt Remove the retaining clips Fig 85 Opening the retaining clips Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 45 12 Maintenance gt Remove the burner cover with the gas air unit gt fig 86 NA Pai 6720645916 84 1N NOTICE D If the seat of the cover plate
70. have a resolution of at least 1 pA Fig 72 Measuring the ionization current gt Switch ON the appliance by pressing the main switch of the BC10 basic controller fig 70 1 gt Activate the Service mode in accordance with the Service mode menu gt table 13 page 31 gt Set the capacity to minimum part load according to the Service mode menu gt table 13 page 31 gt After the LED Burner operation gt fig 70 6 has lit wait for 1 minute until the boiler is burning at part load gt Measure the ionization current The ionization current must be gt 5 pA DC at part load operation gt Enter the result in the start up report gt 15 1 page 57 gt Ifthe result is not as it should be gt 9 10 page 39 or check the ionization electrode gt 12 3 4 page 46 gt Press and hold the Chimney sweep button gt fig 70 3 approx 2 seconds until the dot in the right hand bottom corner of the display gt fig 70 9 appears gt table 12 page 31 gt Switch OFF the appliance by pressing the main switch of the BC10 basic controller fig 70 1 gt Remove the multi meter and reconnect the monitoring cable gt Switch ON the appliance by pressing the main switch of the BC10 basic controller fig 70 1 gt Check that the boiler performance is still at the required value gt table 13
71. he Reset button on the display was pressed for 5 seconds Table 23 Display codes 1 Any display code with a dot in bottom right hand corner 2 Any display code with a blinking dot in bottom right hand corner 3 Any display code starting with the letter E except EL Buderus 54 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Technical specifications 14 14 Technical specifications 14 1 Technical specifications of GB162 boilers at sea level 0 4 000 ft General specifications GB162 80 NG GB162 80 LP GB162 100 NG GB162 100 LP Gas category Natural gas Propane Natural gas Propane Rated thermal load btu h 72 000 290 000 62 000 270 000 72 000 333 000 62 000 315 000 Rated heating capacity btu h 64 100 255 200 55 200 237 600 64 100 293 000 55 200 277 200 heating curve 176 140 F 80 60 C Rated heating capacity btu h 71 300 281 300 61 400 261 900 71 300 326 300 61 400 308 700 heating curve 122 86 F 50 30 C Boiler efficiency at max capacity 88 88 heating curve 176 140 F 80 60 C Boiler efficiency at max capacity 97 98 heating curve 122 86 F 50 30 C CSA Output btu h 261 000 243 000 295 000 279 000 De ration altitudes 2 000 4 000 ft 1 000 ft 2 3 2 2 2 1 2 0 AFUE at 80 180 F 27 82 C 93 8 93 9 n a n a BTS 2000
72. he boiler by the door covering the control panel gt chap 5 2 Transporting the boiler page 11 gt Protect the boiler and the combustion air flue gas orifice against pollution during installation gt Remove the packaging and dispose of it in an environmentally manner gt Measure the installation height gt chap 4 Dimensions and connections page 9 gt Mark both holes with the wall bracket gt fig 8 using a spirit level gt Install the wall bracket with 2 screws gt fig 8 6 720 646157 07 1TD Fig 8 Installing the wall bracket gt With 2 people lift the boiler by holding it by its back and by the transport rail at its bottom and install it on the wall bracket gt fig 6 page 11 gt The boiler can be moved sideways to get the correct position 12 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 gt Level the boiler with the set screw and a spirit level gt fig 9 6 720 646157 08 1 Fig 9 Aligning the boiler with the set screw gt Remove the protective covers from the bottom of the boiler gt fig 10 6 720 646157 09 1TD Fig 10 Removing the covers boiler bottom NOTICE D gt Some residual water from final testing may leak away 6 4 Water and Gas connection 6 4 1 General The water and gas connections to the boiler a
73. he wall bracket gt Click the function module s into position in the wall bracket gt fig 42 6 720 646157 39 1N j 6 720 646157 41 1N Fig 42 Clicking the function module into position gt Remove the drawer gt Remove the covers of both free connectors on the function module connection cables gt fig 43 6 720 646157 40 1N Fig 43 Removing the covers Fig A4 Interconnecting modules NOTICE gt The module may have the letters RC or EMS above the connection gt fig 45 1 gt Connect the free connector of the EMS bus connecting cable gt fig 44 to the first module gt fig 45 gt If more modules are used the EMS bus connection for the second module may be branched off from the first module using the cable enclosed with the module gt fig 44 and fig 45 1 Module 1 a Module 2 i 6 720 646157 42 1N Fig 45 Connecting several modules NOTICE Pay attention to the polarity when using an EMS bus connection cable gt Connect the wire from terminal 1 to terminal 1 and from terminal 2 to terminal 2 gt fig 44 and fig 45 Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 27 28 Electrical connections 7 2 2 Installing function modules outside the boiler gt Install the module on th
74. header when installing a single boiler so correct flows are guaranteed It is not necessary to install a low loss header for cascade systems gt Install the pump gt fig 13 8 in the return circuit gt fig 13 2 6 4 6 Installing the condensate trap 6 720 646157 014 1TD WARNING AN Danger of fatal accident due to poisoning gt Ifthe condensate trap is not filled with water flue gas can escape and put people s lives at risk gt Fill the condensate trap supplied with the boiler with water gt fig 14 6 720 646157 13 1TD Fig 14 Filling the condensate trap with water Fig 15 Installing the condensate trap gt Connect the condensate trap hose 3 and the rubber sleeve 2 to the condensate trap 1 6 720 646157 15 1TD Fig 16 Installing the condensate trap hose Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 15 Le Installation 6 5 Connecting the condensate drain pipe NOTICE D gt The condensate must be drained from the boiler in accordance with local state or federal rules and regulations NOTICE D gt Use materials approved by the authority having jurisdiction In the absence of such authority PVC and CPVC pipe must comply with ASTM D1785 F441 or D2665 Cement and primer must comply with ASTM D2564 or F493 For Canada use ULC certified PVC or CPVC pipe fittings and ceme
75. ied with GB162 80 kW 100 kw Additional required accessories not in delivery content Asingle boiler must be installed with the Buderus low loss header LLH to regulate the flow The low loss header must be ordered separately The low loss header delivery comes also with the AM10 modulating outdoor reset control Multiple boiler cascade installations can use the Buderus cascade frame accessories Please contact Buderus for further informations gt When receiving the delivery check if the packaging is intact gt Check that all items are included in the delivery gt fig 5 gt Always lift and carry the boiler with 2 people as shown in fig 6 or use a hand truck or special equipment 6 720 646157 05 1TD Fig 6 Lt and carry the boiler correctly Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 11 Le Installation CAUTION Damage to the unit by lifting or carrying incorrectly gt Donot hold the boiler by the door covering the control panel gt fig 7 6 720 646157 06 1TD Fig 7 Incorrect way of lifting and carrying the boiler 6 Installation 6 1 Requirements for the installation room DANGER N gt Install the heating system in a frost free room gt Ifthe boiler is operated dependent on room air the installation room must have the required air vents Do not obstruct these vents The air vents must always be free gt
76. iler was designed to heat water in a central heating system and generating domestic hot water It is suitable for connection to fully pumped sealed water systems only with a maximum supply temperature set point off 180 F 82 C The boiler can be installed either as a single system or as part of a multiple system cascade system This boiler may not be installed in places 4 000 ft above sea level Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 7 La General information 3 2 Heating system water quality The quality of the system water is very important Poor water quality can damage heating systems due to scale formation and corrosion For further details please see the accompanying Water quality requirements for Logamax plus GB162 80kW 100 kW manual CAUTION Risk of system damage due to unsuitable heating system water gt If oxygen permeable pipes are used e g for under floor heating systems the systems must be separated from one another by plate heat exchangers Unsuitable heating system water promotes sludge and corrosion formation This can result in heat exchanger malfunction and damage 3 3 Pump test If the boiler has not been operational for approx 2 days the pump will automatically run for 10 seconds every 24 hours This pump test is first carried out 24 hours after the main power has been connected to the boiler 3 4 Freeze protection The boiler has integrat
77. ith the following code GREEN AND YELLOW EARTH BLUE NEUTRAL BROWN LIVE As the colors of the wires in the mains lead of the appliance may not correspond with the colored markings identifying the terminals in your connector proceed as follows The wire colored green and yellow must be connected to the terminal on the connector marked with the letter E or by the earth symbol or colored green or green and yellow The wire colored brown must be connected to the terminal marked with the letter L or colored red The wire colored blue must be connected to the terminal marked with the letter N or colored black WARNING THIS APPLIANCE MUST BE EARTHED Ensure that your appliance is connected correctly if you are in any doubt consult a qualified electrician For location of individual components see service section and the exploded views in this manual Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 29 ER Operation 8 Operation 8 1 BC10 basic controller The boiler is fitted with a control unit the BC10 basic controller This controller can be used to control the heating system gt Pushonthe control panel gt fig 49 to get access to the BC10 basic controller gt fig 50 CAUTION gt Limit the space heating water temperature to the maximum flow temperature of the floor heating circuit gt Apower interruption discontinues manual operation Frost damage may occur
78. l operation Step A Press the button Step 5 Pg Shows currently measured system pressure in psi gt 13 3 page 49 Step 6 Press the button Step 7 H Bi Display code Operating phase gt 13 5 page 50 The boiler is in manual operation mode During manual operation the Settings menu table 15 from step 2 can be used to temporarily change the target boiler performance NOTE If the boiler output has been changed temporarily this must be set again after ending manual operation according to the Settings menu gt table 15 page 32 Step8 Press the button Step 9 2 0 Shows currently measured space heating water temperature in F gt 13 3 page 49 Step 10 After a power interruption manual operation ends automatically To end manually press and hold the button for more than 2 seconds until the dot disappears Table 14 Manual operation Step 1 2 0 Shows currently measured space heating water temperature in F gt 13 3 page 49 Step 2 To open the Settings menu Press and hold the buttons for more than 2 seconds Step 3 L This shows the Settings menu is open You can adjust the setting of this parameter Step 4 IL Target output Adjust as follows or go to step 5 Lower Decrease the modulation rate with the button The minimum setting for boilers at sea
79. l valve EES The gas orifice diameter is marked on the gas orifice in mm Hydraulic resistance of the boiler psi mbar 7 25 500 6 53 450 5 80 400 5 08 350 100 kW 435 300 re e e e e e e e be e e 3 63 250 290 200 E BOW ee I l 2 18 150 l d l 1 45 100 l I d l 0 73 50 I l o o f 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 L h VE 2 2 2 4 4 6 6 8 8 11 0 13 2 15 4 17 6 19 8 22 0 GPM 6720645916 98 1N Fig 100 Boiler resistance curve 1 Volume flow 2 Pressure drop Buderus 56 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Reports ry 15 Reports 15 1 Start up report gt Enter your signature and the date after completing the start up activities Start up activities Page Measurement results Remarks 1 Check for gas leaks page34 O 2 Pi the heating system page 34 O Pre pressure expansion vessel refer to the installation psi instructions for the expansion vessel Heating system filling pressure psi 3 Fillthe condensate trap with water page35 O 4 Write down the gas characteristics Heat input btu ft 2 Heat output btu PM 5 Bleed the gas supply valve page 35 O 6 Check the air flue gas connection page36 7 Checking the appliance configuration page 36 O 8 Measure the gas inlet pressure working pressure page 36 W C 9 Carr
80. lay information 13 1 Removing the control panel To make it easier to use the buttons on the control panel when the boiler door is open and to make it easier to read the values in the display you can disassemble the control panel from the boiler door and hang it from the boiler frame gt Open the boiler door gt Loosen the 2 screws of the control panel at the rear side of the boiler door 1 6720645916 95 1N Fig 97 Loosening the screws gt Loosen the cable tie 1 gt Remove the control panel gt fig 98 Display information SS gt Use the 2 hooks to hang the control panel from the boiler gt fig 99 6720645916 97 1N Fig 99 Hanging the control panel from the boiler frame 13 2 Replacing the control panel gt Take the control panel from the boiler frame gt Install the control panel in the boiler door by following the procedure in 13 1 Removing the control panel page 49 in reverse order 13 3 BC10 Display readings Display readings Display reading Key to display reading Unit Range 15 Current space heating water F o 90 temperature Fig 98 Removing the control panel 13 4 BC10 Display settings Pee Current system pressure psi P O00 P 58 Table 21 BC10 Display readings Display readings Display setting
81. leaks the seal can burn away gt Check the cover plate for tightness NOTICE H Since the effectiveness of the seals in the ignition unit is reduced the gas condensing boiler may become damaged gt Therubber seal gt fig 89 3 and the cover plate with seal gt fig 89 4 need to be replaced every 4 years Fig 86 Removing the burner cover with the gas air unit 12 3 3 Remove the burner and the burner seal gt Remove the burner seal 1 and replace it if necessary gt Remove the burner plate 2 and clean it on all sides using compressed air or asoft brush When re installing the burner plate make sure that the notch is on the right hand side gt fig 87 detailed picture 6720645916 85 1N Fig 87 Removing the burner plate and the burner seal 12 3 4 Checking ignition unit DANGER gt Close the gas valve prior to working on components in contact with gas gt Check for gas tightness after carrying out work on components in contact with gas gt Check the individual components of the ignition unit gt fig 89 for wear or contamination gt fig 88 gt If required replace the ionization electrode and or glow ignitor gt After checking or replacing the ionization electrode and or the glow ignitor fit a new cover plate and rubber seal lt SS 7 746 80
82. ll items are included in the delivery 7746800103 01 1TD Fig 4 Items supplied with unit Nr Parts Boiler with casing Wall bracket Condensate trap with hose Technical documents set Supply and return union nuts with sealing rings Screws and plugs for wall bracket Union nut for gas connection DHW sensor Pump group Qty Packaging 1 box on AJ GW N e Kal ejej eje ojl oN o ejej tal k 1 box L a Fig 5 Additional accessories 7746800103 02 1TD 1 Low loss header single installation only 2 AM LO modulating outdoor reset control 5 2 Transporting the boiler CAUTION The boiler may be damaged when it is improperly secured gt Onlytransport the boiler using the right transportation equipment such as a hand truck with a fastening belt or special equipment for maneuvering steps gt During transportation the boiler must be secured on the transportation equipment to prevent it from falling off gt Protect all parts against impacts if they are to be transported gt Observe the transportation markings on the packaging CAUTION The unpacked boiler may be damaged when not protected against contamination gt Leave the protective covers on the connections gt Cover the flue gas connections at the top of the boiler with plastic film Table 3 Items suppl
83. lue material Installation ey Flue System Vent air intake Roof terminals trade name terminal s 4 6 100 150 Concentric PP Bosch Order No mm M amp G Duravent PolyPro 7738004825 concentric 90 elbow with PVC stainless steel ANSI ASTM D1785 or inlet screen Z Flex Heat Fab 90 elbow with PP M amp G Duravent PolyPro inlet screen or Centrotherm Innoflue Flue System Vent air intake Roof terminals tradename Terminalts 4 6 Concentric PVC IPEX System 636 no 100 150 mm CVK 4 6 M amp G Duravent PolyPro M amp G Duravent Order 100 150 mm _ concentric and No 4PPS VK TC or PP Centrotherm Innoflue SW Centrotherm ICRT4679 concentric 4 100 mm M amp G Duravent PolyPro M amp G Duravent order No PP Flex Chimney Cap APPS FCT or Centrotherm Innoflue Centrotherm ISCP04 SW Flex Chimney Cap Wall terminals 4 100 mm 4 100 mm 4 100 mm Flue System trade name PVC parallel stainless steel PolyPro Twin pipe termination PP Parallel PVC to ANSI ASTM D1785 Vent air intake terminal s ANSI ASTM D1785 or Field Controls M amp G Duravent Order No 4PPS HTP IPEX no CVK Table 7 Approved vent terminations and flue material DW Table 7 Approved vent terminations and flue material D NOTICE gt Use of cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenolsulfone in venting systems shall be prohibit
84. lve Venturi Burner cover Flow temperature sensor lonization electrode Sighting glass Glow igniter Safety temperature sensor Heat exchanger Pressure sensor Return temperature sensor Universal Burner Automatic Version 3 UBA 3 Draw with function module integration options Cover shield Condensate trap Pump group scope of delivery 37 38 39 40 41 42 43 44 The pump group also includes an insulation cover see also pump group installation instructions Isolating valve blue CH boiler return with pump drain cock check valve and thermometer Manual gas shut off valve yellow GAS Isolating valve red CH boiler flow with drain cock pressure gauge and thermometer Pressure gauge Isolating valve Thermometer optional accessory Drain valve Safety valve 30 psi 2 bar or 50 psi 3 45 bar optional Low loss header single appliance only 45 Low loss header not illustrated Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 3 Contents 7 2 1 Installing function modules in the boiler 26 Contents 7 2 2 Installing function modules outside the boiler 28 7 3 Electrical wiring diagram 0 00 sees 29 1 Explanation of symbols and safety information 5 1 1 Guideline to symbols 5 8 Operation 30 1 2 Safety instructions 0 0 00 0 ccc c eee eee 5 81 BC10 basic controlle
85. m by pressing the main switch of the BC10 basic controller gt fig 70 1 gt Press onthe control panel to close it 9 11 Function test gt During initial start up and annual inspection and or needs oriented servicing make sure that all control regulating and safety devices are in full working order and if applicable check them for correct adjustment gt The gas and water circuits must be tested for leaks gt 9 1 page 34 gt 9 10 page 39 Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 39 ey Start up procedure 9 12 Measure the ionization current gt Presson the control panel to open it gt Open atleast 2 radiator valves if present Do not switch ON the boiler gt Switch OFF the appliance by pressing the main switch of the BC10 basic controller gt fig 70 1 10 9 8 6720645916 47 1N Fig 70 BC10 basic controller gt Turn the vent key through a quarter turn to undo the boiler door lock gt fig 54 step 1 gt Push the fastener down fig 54 step 2 and open the boiler door gt Undo the plug and socket connection of the monitoring cable gt fig 71 SS N 6720645916 67 1N Fig 71 Removing the ionization electrode plug and socket connection Buderus gt Connect the multimeter in series gt fig 72 Select the yADC range onthe multi meter The multi meter must
86. mm 4 100 4 100 parallel Table 24 Technical specifications of GB162 boilers at sea level Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 55 General specifications GB162 80 NG GB162 80 LP GB162 100 NG GB162 100 LP Electrical data Mains connection voltage VAC Hz 120 60 Electrical protection rating IPX4D Fuses Amp 5 Electrical power consumption W 104 156 full load without a pump group Electrical power consumption W 29 29 partial load without a pump group Boiler dimensions and weight Height 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 lb kg 154 70 Other specifications Pump group pump UP 26 99 Table 24 Technical specifications of GB162 boilers at sea level Gas orifice Type of gas supply Factory pre setting of the gas control valve Thermal Type of diameter Natural gas Delivered factory set Natural Gas powen gas Altitude inmm Set number LP gas Suitable for propane after conversion also see gas boiler _ supply in kwh m inch with orifice the instruction Conversion to another type of GB 162 Natural 0 4 000 8 40 7746900399 gas supply 80 kW gas 0 1 220 0 331 Information on gas type instruction plate 100kW LPG 0 4 000 4 70 7746900499 Set to gas category Propane 0 1 220 0 193 Table 26 Factory setting of the gas contro
87. nce Vertical terminations The combustion air inlet pipe must terminate in a downward position using 2 x 90 elbows The combustion air inlet pipe shall terminate at least 3 ft 914 mm horizontally from the center line of the exhaust vent this is to prevent cross contamination of flue gases into the combustion air stream Terminate all exhaust vents at the same height and all combustion air inlets at the same height while maintaining the minimum 36 914 mm height clearance from the exhaust to the down turned 90 elbow and combustion air inlet Exhaust vent termination edge shall be at least 24 610 mm from the edge of the air inlet pipe of an adjacent heater Exhaust vent terminations shall be placed at a minimum of 12 305 mm center to center gt fig 33 and fig 34 Air intake terminations may be placed adjacent to each other The combustion air inlet is part of the direct vent system and not classified as a forced air inlet 6 720 645 916 030 1N Fig 33 Vertical terminations 1 minimum 12 305 mm 2 minimum 36 914 mm 3 minimum 36 914 mm 4 minimum 12 305 mm 5 minimum 36 915 mm 6 minimum 24 610 mm Horizontal terminations Combustion air inlet elbow must terminate at least 12 305 mm below exhaust elbow or outlet but not exceed 15 381 mm maximum separation gt fig 34 Horizontal termination shall not extend beyond 18 from the building based on minimum 12 305 mm requi
88. nt 7746800103 62 1TD Fig 17 Connecting the condensate trap 1 Condensate trap 2 Air gap gt 1 25 4mm SEN 6 720 645916 017 Fig 18 Condensate drainage pipe gt Install the condensate drain pipe taking the following into account Anair gap of at least 1 25 4 mm must be maintained between the boiler condensate trap hose and the condensate pipe work gt fig 17 and fig 18 Ifthe condensate outlet of the boiler is lower than the drain a condensate pump must be used The condensate produced by the boiler has a pH value between 3 and 4 gt Install a neutralization unit if required by the local code Buderus 6 5 1 Connecting the expansion vessel ina single boiler system CAUTION N Damage to the installation due to faulty pressure relief valve gt The expansion vessel must be of sufficient capacity gt Connect the expansion tank to the boiler return If a check valve is available connect the expansion vessel to the CH side of the check valve in the return circuit 1 7746800103 04 1TD Fig 19 Connecting the expansion vessel in a single boiler system 1 Expansion vessel 2 Gas supply 3 Air gap lt 1 25 4 mm 6 6 Combustion Air and Ventilation Openings Provisions for combustion and ventilation air must be made in accordance with section 5 3 Air for Combustion and Ventilation of the National Flue Gas Code ANSI
89. ntly lubricated INSTRUCTION FOR THE INSTALLER H gt Record the activities in the service report gt 15 3 12 1 Prepare the heating system for maintenance INSTRUCTION FOR THE INSTALLER H gt If gas pipes have to be disconnected from the gas burner fitting the burner cover must only be opened by a specialized professional gt Switch OFF the appliance by pressing the main switch of the BC10 gt Close the gas valve 1 gt Close the isolating valves 2 6720645916 75 1N Fig 80 Closing the valves here in closed position 12 2 Remove the boiler door gt Unscrew the control panel from the boiler door and hang it on the boiler frame gt 13 1 page 49 gt Unscrew the bolt from left hand top hinge of the boiler door and remove it together with the washer fig 81 gt Slightly lift the door and pull it from the hinge gt Put the door upright in a safe position NOTICE gt The cover over the electrical connections does not have to be removed from the boiler 44 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 6720645916 79 1N Maintenance ey 12 3 2 Remove the burner cover with the fan and the gas valve gt Pullthe mains connector 1 from the fan gt Pull the connector of the harness 2 from the fan while pushing on the connector lock to loosen it Fig 81 Removing the boiler door 12 3 Clean the heat exc
90. ntroller gt fig 65 1 gt Remove the cover from the flue gas measuring point gt fig 69 1 Start up procedure a gt Connect the flue gas analyzer to the left hand measuring point insert it roughly 2 gt fig 69 6720645916 63 1N Fig 69 Measuring the flue gases CO emissions gt Press and hold the L button gt fig 70 3 approx 2 seconds until the dot in the right hand bottom corner of the display gt fig 70 9 appears gt table 12 page 31 gt After the LED Burner operation gt fig 70 6 has lit wait for 1 minute until the boiler is burning at full load gt Measure in the flue gas measuring port the CO percentage The CO values in air free condition must be less than 400 ppm or 0 04 vol Values of 400 ppm or more indicate an incorrect burner adjustment gt 9 8 page 38 adirty gas burner or heat exchanger or burner faults gt You must determine and remove the cause gt chap 12 Maintenance page 44 gt Press the Chimney sweep button gt fig 70 3 to clear the reading gt table 12 page 31 gt Switch OFF the heating system by pressing the main switch of the BC10 basic controller gt fig 70 1 gt Remove the flue gas analyzer and fit the cover back onto the flue gas measuring point gt fig 70 1 gt Switch ON the heating syste
91. oblemis not resolved donot operate the boiler gt Please note these restrictions and its dangers to the operator of the boiler NOTICE gt When one expects contaminated combustion air near swimming pools chemical cleaning operations and hair salons sealed combustion operation is recommended All Air form inside the Building non sealed combustion The closet shall be provided with 2 permanent openings communicating directly with an additional room s The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have aminimum free area of 12 per 1 000 btu h of total input rating of all gas utilization equipment in the confined space but no less than 1 002 One opening shall commence within 12 305 mm of the top and one opening shall commence within 12 305 mm of the bottom of the enclosure The minimum dimension of air openings shall be not less than 4 101 6 mm 1 Where directly communicating with the outdoors each opening shall have a minimum free area of 12 per 4 000 Btu hr of total input rating of all equipment in the enclosure 2 Where communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 12 per 4 000 Btu hr of total input rating of all equipment in the enclosure 3 Where communicating with the outdoors through horizontal ducts each opening shall have a minimum
92. ollector 6720645916 89 1N Fig 91 Disconnecting the condensate trap gt Check the condensate collector for damage and replace it if required gt Rinse the condensate trap to clean it gt Ell he condensate trap with water and reinstall it NOTICE gt The condensate trap has a bayonet connector After inserting it the condensate trap must be turned Y4 rotation clockwise to click into position Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 47 ES Maintenance gt Clean the condensate collector mechanically using compressed air or a soft brush and rinse it with clean water gt fig 94 6720645916 92 1N Fig 94 Cleaning the condensate collector 12 3 7 Clean the heat exchanger CAUTION AN Incorrect handling can damage the boiler gt Donot use metal brushes or similar hard cleaning tools gt Handle the glow ignitor with care it is made from fragile ceramic material gt Cover the boiler interior using a blanket or a cover to prevent dirt entering the boiler WARNING AN If the condensate collector is installed incorrectly gt Flue gas or condensate may leak gt Clean the heat exchanger with compressed air or a soft brush gt fig 95 6720645916 93 1N Fig 95 Cleaning the heat exchanger Buderus gt Refit the condensate collector and make sure that the 2 retaining clips close smoothly If this is not the
93. on Air and Ventilation Openings 16 11 2 Carry outa visual check for general signs of 6 7 Fluegasadapter 0 cee eee eee eee eee 17 COFFOSION 0 es ee eee e ee eee eect eee ee eee ees 43 6 8 Installation of the Exhaust and Air Intake system 18 11 3 Gas valve leakage test 43 6 9 Multiple boiler vent terminal clearance 23 11 4 Measure the ionization otemt 44 11 5 Measure the gas inlet pressure working pressure 44 11 6 Check and adjust the gas air ratio 44 7 Electrical connections cceeceecceceees 24 11 7 Carry outa leakage test in operating conditions 44 7 1 External connection board connections 24 11 8 Measure the flue gases CO emissions 44 7 1 1 Routing the cable through the boiler 24 11 9 Fillthe heating system 0ceee ees 44 7 1 2 Low voltage connections 2 200200 25 11 10 Check the air flue gas connection 44 7 1 3 120VAC connections 2 eee eee 25 CAA Controller eege nen 26 7 2 Installing function modules accessories 26 Buderus 4 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Explanation of symbols and safety information eS 12 Maintenance lt eege SE A4 12 1 Prepare the heating system for maintenance 44 12 2 Removethe boiler door 44 12 3 Clean the heat exchanger burner and condensate
94. operation and no DHW Blocking fault The UBA 3 is defect Operating phase The external switch contact is open No heating operation BAA Start up phase The boiler starts up after activation of the mains power supply or completion of a system reset This code is displayed for a maximum of 4 minutes Table 23 Display codes Buderus 52 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Maindisplay Sub display code code Display codes Key to display code Display information Ea Other effects y GAL y 33454 Blocking fault No heating operation and no DHW e g The UBA 3 or the KIM is defective y JH L y ERD Blocking fault No heating operation and no DHW 8 The UBA 3 or the KIM is defective yg H L Be Jat Blocking fault No heating operation and no DHW e SS The UBA 3 or the KIM is defective y gL L e J44 Blocking fault No heating operation and no DHW a a The contacts for the gas valve have been broken Se Jor t Taal Blocking fault g a The UBA 3 or the KIM is defective y gP L Ja 394 Blocking fault No heating operation and no DHW a ai The UBA 3 or
95. or temperature sensor must be connected gt Connect the outdoor temperature sensor to the blue FA terminal gt fig 37 WA Terminal Potential free heat demand With this connection the room temperature based modulating function of the boiler is not used This has anegative effect on comfort and energy consumption The boiler will now only modulate up to the preset space heating water temperature gt Connect the potential free heat demand contact On Off thermostat or relay panel end switch to the green WA terminal gt fig 37 The maximum allowed resistance of this circuit is 100 Q D FW Terminal DHW temperature sensor gt Connect the external DHW temperature sensor to the grey FW terminal using the harness enclosed with the DHW temperature sensor D NOTICE gt The RC and WA terminals cannot be used simultaneously NOTICE gt Itis not possible to connect more than 1 DHW temperature sensor in the boiler gt Connect a DHW temperature sensor suitable for this particular boiler 1 RC FA WA FW EV DWV RC FA WA FW III colocolo e 2 4 5 6 7 8 9 10 6 720 646157 34 1N Fig 37 External connection board connections no abbr color component 1 RC orange Roomcontroller RC and EMS bus 2 FA blue Outdoor temperature sensor 3 WA green Potential free On off thermostat 4 FW grey DHW temperature sensor 5 EV red External switch contact potential fr
96. page 31 9 13 Test the Ignition Safety shut off device gt Switch OFF the appliance by pressing the main switch of the BC10 basic controller gt fig 70 1 gt Disconnect the plug and socket connection of the monitoring cable gt Switch ON the appliance by pressing the main switch of the BC10 basic controller gt fig 70 1 gt Press the Chimney Sweep L button and hold it for approx 2 seconds until the display shows the decimal point gt Check if the boiler does 1 start up attempt and 3 restart attempts After each start up attempt the boiler will signal a start up failure A 6A code can be seen in the display 40 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 After the last start up attempt the boiler will lock out The 6A code is blinking in the display gt Connect the plug and socket connection of the monitoring cable gt Press the Reset button gt Check if the boiler starts up gt Press the Chimney Sweep L button return to normal operating conditions 9 14 Boiler settings 9 14 1 Set the heating capacity gt Set the required heating capacity on the BC10 according to the Settings menu See table 18 when making these settings Rated heating capacity 5 based on natural gas Display sea level indication GB162 80 kw GB162 100 kw kw btu h kW btu h L20 20 0 68 300 L30 24 3 78 300 29 9 97 900 L40
97. pplier 6 720 645916 19 1N Fig 20 Connecting the flue gas adapter parallel gt When installing concentric PP venting material remove upper lip ring and insert gt fig 20 1 and place air intake cap 1 7 746 800 103 09 1D Fig 21 Placing air intake cap Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 17 Le Installation 6 8 Installation of the Exhaust and Air Intake system NOTICE gt Consult local and state codes pertaining to special building code and fire department requirements Adhere to national code requirements gt Observe the listed maximum lengths of vent system which are boiler model dependent The maximum permissible lengths are listed in table 8 page 22 D Vent must be 3 ft 915 mm above any forced air intake within 10 ft 3 050 mm gt fig 24 Do not extend exposed vent pipe outside the building beyond recommended distance Condensate could freeze and block vent pipe Vent should terminate at least 3 ft 915 mm away from Optional vent kits are 1 Parallel or concentric horizontal with approved wall terminal or vertical 6 720 645916 20 1N Fig 22 Vent pipes The termination shall be at least 4 ft 1 220 mm for the U S and 6 ft 1 830 mm for Canada away from a gas utility meter service regulator or the like for room air applications only The termination shall terminate at
98. pressure by 2 turns gt fig 64 1 Start up procedure ER gt Press the Chimney sweep amp button gt fig 65 3 to clear the reading gt table 12 page 31 Fig 64 Measuring the gas supply pressure gt Reset the digital pressure gauge to 0 NOTICE D gt Throughout the measuring operation keep the digital pressure gauge in the same position horizontal or vertical in which it was reset to O gt Connect the pressure gauge connection tube to the positive port of the testing nipple gt fig 64 2 gt Slowly open the gas valve by pushing on the gas valve and turning it rotation in an counterclockwise direction gt fig 61 page 36 The gas valve is open when it is in the vertical position gt Switch ON the appliance by pressing the main switch of the BC10 basic controller gt fig 65 1 gt Press and hold the Chimney sweep button gt fig 65 3 approx 2 seconds until the dot in the right hand bottom corner of the display gt fig 65 9 appears gt table 12 page 31 gt After the LED Burner operation gt fig 65 6 has lit up wait for 1 minute until the boiler is burning at full load gt Statically measure the gas supply pressure and enter it in the start up report gt 15 1 page 57 To obtain the best performance of the appliance the gas supply pressure must be LPG inch W C Statically measu
99. r 30 8 2 BC10 operating instructions 008 31 2 Regulations and guidelines ceceeeececeees 6 2 1 Massachusetts Installations Only 6 9 Start up procedure ccccccecsccceesssesseees 33 9 1 Check for gasleaks 00 0 ccc cece eee eae 34 3 General information H geg ih EE a A 9 3 Fill the condensate trap with water 35 3 1 Designated use 7 32 Heating svstemiwaterauality 7 9 4 Bleed the gas supply valve 0 cee eee 35 MS ee ee pe RS hres eae ow ae te ee 9 5 Check the air flue gas connection 36 3 3 PUMP TES ste 5 c SE aurea SA SES aint 8 3 4 Freeze protection cc cece cece eee eens 8 oo EE SE configuration BER a g 9 7 Measure the gas inlet pressure working pressure 36 3 5 Tools materials and further equipment 8 i RE 3 6 Disposal tie e AA ebe Zeeche 8 oe EE peal ratio Ee 9 9 Carry out a leakage test in operating conditions 39 9 10 Check and adjust the flue gases COemissions 39 4 Dimensions andconnections seceeeeeeees 9 9 11 Function test 2 ee sees eee eee eee 39 4 1 Without pump group ccceeeeeeeeeeee 9 9 12 Measure the ionization current 40 4 2 Withpumpgroup cesceeeeeeeeeeees 10 9 13 Test the Ignition Safety shut off device 40 9 14 Boiler settings 41 9 14 1 Setthe heating capacity 41
100. r gt Loosen the screw step 1 gt Pullopen the drawer step 2 gt Installa 120 VAC cable to the boiler mains connection 7 1 4 Controller NOTICE gt It is not possible to connect more than 1 room controller The following controls can be connected to the boiler Logamatic RC35 room controller Logamatic 4323 controls Control with contact for potential free heat demand Error reporting module EM10 0 10 V input can be used to convert a0 10V signal to a modulating signal MCM boiler cascade module up to 16 boilers To install additional modules in the boiler see 7 2 Installing function modules accessories page 26 Installing an RC35 controller as an outdoor reset control in the boiler gt Open the control panel cover gt Remove the cover 1 gt Install the RC35 in the slot 2 Buderus amp 1 6 720 646157 37 1N Fig 40 Opening the drawer 26 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 gt Install the wall bracket in the relevant slots in the drawer gt fig 41 6 720 646157 38 1N Electrical connections gt Slide the drawer back into the boiler gt Connect the free 120 VAC mains cable gt fig 43 to the module 1 If more modules are used the 120 VAC supply for the second module can be taken from the first module using the cable enclosed with the module Fig 41 Installing t
101. re made using the pump group gt fig 4 page 11 This pump group includes the circulation pump and a pressure relief valve Installation ey 6 720 646157 10 1TD Fig 11 Pump group 1 pressure relief valve 2 supply water valve 3 manual gas shutoff valve 4 circulation pump 5 aas niet 6 return water valve 7 pump group cover NOTICE gt Ifyoudonotuse the included pump group you have to install a separate circulation pump under the boiler This pump must be selected so that the volume flow through the boiler is sufficient to handle the maximum boiler input rating gt 6 4 5 page 15 gt Install the pump group on the boiler in accordance with the pump group installation instructions Asingle boiler must be installed with the low loss header to regulate the flow gt Install the low loss header 1 E E Fig 12 Low loss header 6 720 646157 11 1TD Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 13 a Installation gt Avoid installing the boiler above radiation levels If the boiler is installed above radiation sections a low water cutoff shall be installed and wired to the boiler Follow local code or in case of use of alow water cutoff be aware to use an air vent in order to prevent the boiler from shutting down unnecessarily D
102. red gas supply pressure Natural gas inch W C mbar mbar Min 5 12 4 8 19 9 Nom 8 19 9 11 27 4 Max 10 5 26 1 13 32 3 Table 17 Gas supply pressure 1 Measured statically perpendicular to flow at full load gt Press the Service button gt fig 65 4 repeatedly until the temperature reading is shown in the display 10 9 8 B68 L egc iti 1 2 3 6720645916 47 1N Fig 65 BC10 basic controller 1 Main switch 2 Reset button 3 Chimney sweep button 4 Service button 5 Connection possibility for the diagnosis connector 6 LED Burner operation 7 LED Central heat demand 8 Space heating water temperature knob 9 Display 10 DHW temperature knob 11 LED DHW demand WARNING Lg Aleaking testing nipple causes explosive fumes gt Check the testing nipples used for leaks gt Only use approved detection products to locate leaks NOTICE D gt Ifthe supply pressure is too low check the gas supply pipe or contact the relevant gas utility company if the required supply pressure is not available gt Ifthe supply pressure is too high a gas pressure regulator must be integrated upstream of the gas fitting Contact the gas utility company gt Close the gas valve gt Remove the gauge connection tube and tighten the screw plug on the testing nipple ag
103. red separation between intake and exhaust Exhaust vent vertical rise shall not extend beyond 39 991 mm from building penetration to termination elbow gt fig 34 Condensate could freeze and block vent pipe en en Se e Sen Se Terminate all exhaust vents at the same height and all combustion air inlets at the same height while maintaining the minimum 12 305 mm vertical height clearance from between exhaust and combustion air inlet Exhaust vent termination edge shall be at least 12 305 mm laterally from the edge of the air inlet pipe of an adjacent heater The combustion air inlet is part of the direct vent system and not classified as a forced air inlet Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 23 7 Electrical connections 6 720 645 916 031 1N Fig 34 Horizontal terminations 1 minimum 12 305 mm 2 maximum 15 381 mm 3 maximum 18 457 mm 4 minimum 12 305 mm 5 minimum 12 305 mm 6 maximum 39 991 mm Buderus 7 Electrical connections Devices such as pumps outdoor sensor and 3 way valve are all connected to the external connection board The electrical connections to the boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 If installed in Canada electrical connections should conform with CSA C22 1 Code part 1 7 1 External connection board connections
104. reen PK terminal gt fig 38 The maximum allowed connected load of the pump 100 Watts PS Terminal DHW pump gt Connect the DHW pump to the grey PS terminal gt fig 38 The maximum allowed connected load of the pump 100 Watts PZ Terminal DHW circulation pump gt Connect the DHW circulation pump to the lilac PZ terminal gt fig 38 The maximum allowed connected load of the pump 100 Watts Mains connector WARNING Connecting incoming power gt Ground the boiler electrically in accordance with local codes or in absence of local codes with the National Electrical Code ANSI INFPA 70 and or the CSA C22 1 Electrical Code 40 45 50 GER a 50 Pr Ja 55 i Eco 60 D o aut H aut f o o J IF eoeas 6 720 646157 36 1N Fig 39 Installing the room controller 7 2 Installing function modules accessories NOTICE gt Refer to the installation instructions of the relevant function modules for information about installation and combination possibilities The following function modules accessories can be connected to the boiler Heat demand 0 10 V module EM10 Error reporting module EM10 Switch module WM10 Mixing module MM10 The function modules accessories can be installed in 2 ways in the boiler max 2 see 7 2 1 outside the boiler see 7 2 2 7 2 1 Installing function modules in the boile
105. ry 10 minutes This means that the boiler cannot be restarted until at least 10 minutes have elapsed since initial burner start up OA 305 2 Operating phase The boiler cannot start up temporarily after a DHW request has ended DI 7H4 Pre operative phase The boiler prepares for a burner start up whenever a heat demand or a DHW request arises DE 365 U Beadiness for operation The boiler is in standby mode There is a current heat demand but too much energy has been supplied OH 74 Readiness for operation The boiler is in standby mode There is no current heat demand OL 7H4 Ignition phase The gas valve is activated ou 274 1 Start up phase The boiler starts up after activation of the mains power supply or comple tion of asystem reset This code is displayed for a maximum of 4 minutes oy ag4 1 Operating phase The room temperature is not possibly The flow temperature sensor has detected that the current flow reached temperature is higher than the flow temperature setting on the BC10 or that it is higher than the flow temperature calculated according to the heating curve or that it is higher than the flow temperature calculated for the DHW mode Table 23 Display codes Buderus 50 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 Display information E
106. s free from any strain Length of pipe in Gas volume Capacity in ft 3 hr feet m 4 e 1 1 10 3 05 278 520 1 060 1 600 20 6 1 190 350 730 1 100 30 9 15 152 285 590 890 40 12 2 130 245 500 760 50 15 25 115 215 440 670 75 22 88 93 175 360 545 100 30 5 79 160 305 480 150 47 25 64 120 250 380 Table A Gas pipe capacity for different pipe sizes 1 Maximum pipe capacity in ft 3 hr based on a specific gravity of 60 42 mbar and a inlet gas pressure of 14 W C 35 mbar or less and a pressure drop of 3 W C 20 mbar Buderus Steel pipe diameter in inches mm Equivalent length for Pipe Fittings in feet m Type of pipe fitting Tee flow thru branch Gate valve Gas cocks Equivalent length in feet m 90 Elbow 19 2 1 0 64 4 1 1 25 0 5 0 15 1 25 0 38 1 25 2 6 0 79 5 2 1 59 0 6 0 18 1 60 0 49 1 32 3 5 1 07 6 9 2 11 0 8 0 24 2 15 0 66 1 38 4 0 1 22 8 0 2 44 0 9 0 27 2 50 0 76 Table 5 Equivalent length for pipe fittings in feet 6 4 4 Installing the heating supply and return pipe 7746800103 03 1TD Fig 1 2 3 4 5 6 7 8 9 13 Connecting the boiler supply and return Supply Return Isolating valves Drain cock Gas valve Pressure relief valve Condensate trap Pump Non return valve 10 Dirt filter for example
107. scale cartridge or y strainer 11 Gas supply 12 Airgap gt 1 25 4 mm 13 Low loss header single boiler installation D NOTICE gt When using plastic pipes observe the supplier s instructions especially those referring to recommended jointing techniques and the notes relating to the heating system water on page 8 14 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 NOTICE gt To prevent contamination in the heating system we recommend you integrate a dirt filter gt fig 13 10 in the return pipe near the boiler In an old system it is a requirement to install a dirt filter Also install shutoff valves to enable filter cleaning immediately upstream and downstream of the dirt filter scale cartridge or y strainer Installation 6 gt Connect the condensate trap 1 to the condensate outlet The condensate trap has a bayonet connector insert and turn Y4 rotation clockwise to click into position gt Connect the supply pipe with a flat rubber seal installed to the Supply connection gt fig 13 1 making sure it is not under stress Use a supply pipe with a minimum diameter of 1 38 mm gt Connect the return pipe with a flat rubber seal installed to the Return connection gt fig 13 2 making sure it is not under stress Use a return pipe with a minimum diameter of 1 38 mm 6 4 5 Installing the pump Always use the supplied Buderus pump group and the low loss
108. t conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 gt Install CO detectors per local regulations Boiler requires yearly maintenance gt chap 12 Maintenance page 44 Operating Limits of the boiler Max boiler temperature 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 applicable codes and regulations When replacing an existing boiler it is important to check the condition of the entire hot water distribution system to ensure safe operation 230 F 110 C 2 1 Massachusetts Installations Only a For all side wall side horizontally vented gas fuelled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the
109. the power supply connection The technical rules laid down by the gas utility company concerning the connection of the gas burner fitting to the local gas main The instructions and standards concerning the safety equipment for the water space heating system The Installation Instructions for building heating systems The boiler must be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the boiler or to lower floors of the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the boiler The pan must not restrict combustion air flow The boiler must be installed such that the gas ignition system components are protected from water dripping spraying rain etc during boiler operation and service Donot restrict or seal any air intake or outlet openings Ifyou find any defects you must inform the owner of the system of the defect and the associated hazard in writing The boiler must not be installed on carpeting Buderus What to do if you smell gas Donottry to light any boiler Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e Ifyou cannot reach your gas supplier call the fire department 2 Regulations and guidelines The installation mus
110. tos t cnicos 1 OO SEIT Connexion erprise d entretien s Gees OOO g LGE W Gi EV peoi f a e Eege 1 2 2 IR e els 7 SITZ E CIE SES es See orange bua green gray ei turgo naranja azul verde gris rojo turquesa green grey Ver orange bleu vert gris rouge turquoise verde gris Ve blanco gris lilas blanc 6 720 646157 45 1N Fig 1 2 3 4 5 6 7 8 48 Electrical wiring diagram 81 pole connector AC 0 10 24 and 16 pole connector AC 120 V 230V Connection for pump in connection kit accessory Fan Gas valve Transformer Glow ignitor Earth Electrical connections 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 3 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 Main power connection 120 V 60 Hz max permissible 5 A Mains switch 120 VAC function module Ground 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 IMPORTANT The wires in this mains lead are colored in accordance w
111. trap 45 12 3 1 Remove the gas valve ccc cece eee ees 45 12 3 2 Remove the burner cover with the fan and the gas valve 45 12 3 3 Remove the burner and the burner seal 46 12 3 4 Checking ignition unit 46 12 3 5 Disconnect the condensate rap 46 12 3 6 Remove the condensate collector 47 12 3 7 Cleanthe heat exchanger 48 12 4 Check and adjust the gas air ratio flue gases COZ MISSIONS Eege e 48 12 5 Function check 0 eee e cece eee eee 48 13 Display information ceceseeececeeees 49 13 1 Removing the control pang 49 13 2 Replacing the control pang 49 13 3 BC10 Display readings 49 13 4 BC10 Display settings 0c eee eee 49 13 5 BC10 Display code 50 14 Technical specifications eceeeeeecees 55 14 1 Technical specifications of GB162 boilers at sea level 0 4 0001 55 15 Repofts s ciaccedencutekeden teepiaesen veto reemer ves 57 15 1 BREED ESO NEE KENE EEN 57 15 2 Inspection report 0 ccc cece eee eee ees 58 15 3 Servicereport 58 1G Spare Parts eg erg sinc viele Sivas NEEN NENNEN 59 E EE 63 1 Explanation of symbols and safety information 1 1 Guideline to symbols Warnings Warnings are indicated in the text by a warning triangle N and a gray background In case of danger from electric shock the exclamation point on the warning triangle is replaced with a flash Si
112. ualified installer service agency or the gas supplier 6720645916 00 1N Notice e This manual is available in the English and French language e This manual must be retained for future reference A d An ered CERTIFIED CERTIFIED a a www ahridirectory org Installation instructions Logamax plus GB162 80 kw GB162 100 kW Read carefully before carrying out installation and maintenance K LI d eru S Fig 1 Logamax plus GB162 with pump group Buderus 2 Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 BC10 basic controller receptacle Installation option for room controller e g RC35 Cover with user manual compartment BC 10 basic controller can be expanded e g by the RC35 room controller Connection box low voltage and 120 VAC connections Fan harness and mains lead of the pump Condensate drain outlet Condensate collector Boiler front door Automatic air vent Retaining clips Air intake for the fan Gas pipe Flue gas pipe Door lock Flue gas sensor Flue measuring point Measuring point for air intake Flue gas connection Air intake connection Fan Gas va
113. ug on the testing nipple for the burner pressure by 2 turns gt fig 66 1 7746800103 59 1N Fig 66 Checking the gas air ratio at minimum load gt Set the pressure gauge to 0 Buderus NOTICE D gt Throughoutthe measuring operation keep the digital pressure gauge in the same position horizontal or vertical in which it was reset to 0 Use a connection tube to connect the positive port of the pressure gauge to the testing nipple for burner pressure gt fig 66 2 Slowly open the gas valve by pushing on the gas valve and turning it rotation in an counterclockwise direction gt fig 61 Switch ON the heating system by pressing the main switch of the BC10 basic controller gt fig 65 1 Activate the Service mode in accordance with the Service mode menu gt table 13 page 31 Set the capacity to minimum part load according to the Service mode menu gt table 13 page 31 After the LED Burner operation gt fig 65 6 has lit wait for one minute until the boiler is burning at part load Read the differential pressure The differential pressure De Pair must be 0 02 inch W C 5 Pa 0 02 inch W C 5 Pa read out on pressure gauge 0 04 O inch W C 10 0 Pa gt fig 67 a a 15 10 5 0 5 Pa 0 145 0 10 0 05 0 00 0 05 mbar 0 06
114. um vent length operation Longer vent lengths up to maximum will reduce the input proportionally Equivalent Friction losses feet m 45 elbow 4 PVC CPVC 4 1 22 90 elbow 4 PVC CPVC A 2s 4 plastic pipe per foot PVC CPVC 1 0 30 parallel vent kit 2 0 61 concentric PVC terminal 4 6 100 150 mm 20 6 1 45 elbow 4 100 mm PolyPro Elbow 12 22 45 elbow 4 6 100 150 mm PolyPro Elbow 3 7 1 14 90 elbow 4 100 mm PolyPro Elbow 11 8 3 6 90 elbow 4 6 100 150 mm PolyPro Elbow 5 6 1 72 4 100 mm PolyPro Pipe per foot 3 3 1 0 concentric 4 6 100 150 mm PolyPro Pipe per foot 3 3 1 0 4 100 mm PolyPro Flex pipe per foot 6 9 2 1 parallel PolyPro Wall terminal 4 100 mm 13 8 4 2 concentric PolyPro Wall terminal 4 6 100 150 mm 20 3 6 2 concentric PolyPro Roof terminal 4 6 100 150 mm 26 0 7 9 PolyPro Roof terminal Flex Chimney Cap 3 3 1 0 Table 8 Friction Loss Equivalent in piping and fittings Buderus See table 8 for the Friction Loss Equivalent in piping and fittings Example When you end up using 3 x 45 elbows and the concentric roof terminal then the total venting length may not exceed 68 ft 20 72 m 3 x 45 elbow 3x4 ft 1 22 m 12 ft 3 66 m concentric roof terminal 4 6 20 ft 6 10 m Total friction loss equivalent 32 ft 9 76 m Total venting length for this example is
115. ure gauge on the pump group or on the control panel of the BC10 gt fig 57 100 120 90 130 Eco LZ 140 I I 0 Aut ch CI egen 6720645916 54 1N Fig 57 Reading the pressure gauge 9 4 Bleed the gas supply valve gt Close the gas valve gt fig 59 CIE 6720645916 56 1N Fig 59 Closing the gas valve Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 35 ES Start up procedure gt Open the screw plug on the testing nipple of the gas supply pressure and for purging 1 by 2 turns and install a hose Fig 60 Bleeding the gas flow pipe gt Slowly open the gas valve by pushing on the gas valve and turning it counterclockwise through rotation gt fig 61 The gas valve is open when it is in the vertical position 6720645916 58 1N Fig 61 Opening the gas valve gt Purge the gas supply into a well ventilated area gt Close the gas shutoff valve when no more air is present gt fig 59 gt Remove the hose and tighten the screw plug on the testing nipple again NOTICE D gt Test the tightness of the measuring nipple s used 9 5 Check the air flue gas connection Check the following points Is the prescribed flue gas system used gt 6 8 page 18 Have the configuration instructions from the relevant flue g
116. ured space heating water temperature in F gt 13 3 page 49 Step 2 To activate service mode 1st step Press and hold the button for more than 2 but not longer than 5 seconds Step 3 2 0 The non flashing dot is shown in the right hand bottom corner of the display shows the boiler is now in Flue gas test mode Step 4 To activate service mode 2nd step Simultaneously press and hold the buttons for more than 2 seconds Step 5 L Display shows the maximum capacity setting during heating mode in gt 13 4 page 49 In this case L 100 Service mode has been activated You can now adjust the boiler performance to partial load i e to check the gas air ratio or the ionization current Step6 Press and hold the button until the display shows L 25 Display setting with a 80 kW boiler and 20 with a 100 kW boiler Minimum capacity setting during heating mode in gt 13 4 page 49 The boiler will reduce its performance to 25 or 20 respectively within a couple of seconds The space heating water temperature set on the BC10 basic controller control panel applies now Check the gas air ratio or the ionization current and if necessary set the gas air ratio according to 9 8 or 9 10 Step 7 Press the button Step 8 IF 5 This parameter shows the pump run over time in minutes that starts when the heating mode has ended gt 13 4 page 49 Table 13 Service mode Buderus Logamax plus GB
117. y outa leakage test in operating conditions page 39 O 10 Check and adjust the flue gases CO2 emissions page 39 ppm 11 Carry outa function test page 39 O Measure the ionization current page 40 uA 12 Measure the pH value Fill in the record book 13 Boiler settings page41 O 14 Final activities page42 O Close the boiler door and the control panel Hand over Confirming proper start up Company stamp signature date Table 27 Start up report Buderus Logamax plus GB162 80 kW 100 kW 7746800103 2014 10 57 Ea Reports 15 2 Inspection report gt Indicate the inspection activities that have been carried out enter the values measured and enter your signature and the date Date EICH Date Date Date Inspection activities See paragraph 1 Check the general condition of the heating oO oO oO oO oO oO oO system 2 Carry outa visual inspection and function test of oO oO oO oO oO UO UO the heating system 3 Checking the gas and water bearing system TT TT TT TT TT TT TT components for Operational tightness 9 9 page 39 Visible corrosion 11 2 page 43 Signs of wear Ell the condensate trap 9 3 page 35 4 Measure the ionization current 9 12 page 40 uA uA WA TA uA TA uA 5 Measure the gas inlet pressure working 9 7 page 36 pressure W C W C W C W C W C W C W C 6 Check and adjust the flue gases CO emissions 9 10 page 39

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