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Service manual - Logamax plus GB142 (USA/CA) - en

1. A F E g g zg g Z S S j tS O 5 cul D cf SE F A cA ce T c oa a fig 10 UBA3 installation base Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 87 reat Actions 8 1 5 Checking the fan unit tacho cable WARNING Avoid damage do not push the measuring pin of the volt ohm multimeter too deeply into the socket Remove the casing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Dismantle the tacho cable plug 81 pole connector Pin 1 iihi argh aa iraran Pin 16 16 pole connector Loosen the fastening screw of the UBA 3 see fig 9 pos 1 Remove the UBA 3 by pulling it forward as indicated by the arrow see fig 9 pos 2 Test the tacho cable to make sure that there is no short circuit in it and that it is not broken see fig 11 Pin 81 Assemble the tacho cable plug fig 11 UBA3 installation base Re assemble the UBA 3 in reverse order of disassembly Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main swi
2. Pos Description Product No Pos Description Product No 1 Casing 24 30 kW 7099988 34 Air inlet pipe 24 30 kW 7099024 Casing 45 60 kW 7099901 Air inlet pipe 45 60 kW 7099023 2 Casing latches left 2 pc 7099039 35 Seal 050 mm 5 pc 7099058 3 Casing latches right 2 pc 7099038 Venturi 24 30 kW 7099020 4 Casing seal 24 30 kW 7098752 36 Venturi 45 kW 7099925 Casing seal 45 60 kW 7098798 Venturi 60 kW 7099931 5 Wall mounting bracket 7098364 37 Seal set 4 pc 7099021 6 Back panel 24 30 kW 7099001 38 Fan 78184 Back panel 45 60 kW 7099903 39 Gas control valve 7099025 7 Cap air vent 7100250 40 Gas supply pipe GB142 USA 76685 8 Exhaust adapter 3 3 28268 41 Spring 5 pc 7100549 9 Seal ring 3 77470s 42 Seal 2x16x22 5 pc 7098778 10 Seal ring 80 mm 7096475 Orifice 4 45 24 30 kW 7099016 11 Flue gas collector 7098857 43 Orifice 5 40 45 kW 76690 12 Oval seal 7098858 Orifice 7 50 60 kW 76686 Heat exchanger 24 30 kW 7746900159 44 Condensate trap 75978 13 Heat exchanger 45 kW 7746900160 45 Seal condensate trap 5 pc 7100742 Heat exchanger 60 kW 7746900161 14 Heat exchanger baffle 24 30 kW 7098828 47 Supply pipe CH 24 30 45 kW 75990 Seal condensate collector 24 30 kW 7098834 Supply pipe CH 60 kW 75991 15 Seal condensate collector 45 kW 7098838 48 Return pipe 24 30 45 kW 709965 Seal condensate collector 60 kW 67900522
3. sweep and Service buttons for more than t 2 seconds m g q psi i Current heating system pressure See page 20 1 Current boiler load See page 20 Service mode activated You can now temporarily lower the boiler load Press the Service button to partial load to check and if relevant set the gas air ratio or the ionization current A Operating code See page 46 Press and hold the Reset button until the y display shows L30 Press the Service button 4 m LAL y Current boiler load See page 20 1 m The boiler will reduce its load to 30 within a E couple of seconds The maximum boiler water Current supply temperature 0 199 F temperature as set on the BC10 basic controller 18 93 C See page 20 applies Check the gas air ratio see page 108 or the ionization current see page 95 and adjust the gas air ratio if necessary ry Have 30 min passed or was the power interrupted Press the Service button no Y Deactivate om g service mode Ly a Current supply temperature 0 199 F 18 93 C See page 20 Deactivate service mode Press and hold the Chimney sweep button for more than 2 seconds until the decimal point has disappeared Press the Service button
4. Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 11 aa Operation 4 2 3 Manual Operation menu MANUAL OPERATION MENU ig Current supply temperature 0 199 F 18 93 C See page 20 Activate manual operation To activate manual operation Press and hold the Chimney sweep button for more than 5 seconds i As soon as a flashing dot is shown in the right hand bottom corner of the display manual operation is active The means that the boiler is permanently in heating mode The maximum boiler water temperature as set on the BC10 basic controller now applies The Heat request LED is lit gt y Press the Service button Current heating system pressure See page 20 y Press the Service button Operating code See page 20 During manual operation the Adjustments menu on page 12 can be used to temporarily change the required boiler load in case of an emergency Power interrupted Press the Service button y JS Deactivate manual operation Current supply temperature 0 199 F 18 93 C See page 20 Deactivate manual operation Press and hold the Chimney sweep button for more than 2 seconds until the flashing deci
5. the boiler at least 14 5 psi 1 bar Is at least one thermostatic valve open Open a thermostatic valve i Check the supply and safety sensors page 89 Replace the supply and or safety sensors page 91 Are the supply and safety sensors okay Check the primary circulation pump Is the primary circulation pump okay Yes Replace the primary circulation pump page 31 page 83 Buderus 52 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications dU S 2 4 The temperature difference between the supply and return sensors is more than 90 F 50 K Operating code y Wait approx 30 seconds until the boiler automatically becomes operational again No fault message g Yes Are all servicing cocks Open the servicing cocks open Is at least one thermostatic valve open Open a thermostatic valve Yes Check the supply and return sensors page 89 Replace the supply and return sensors page 91 Are the supply and return sensors okay Check the primary circulation pump Replace the primary circulation pump Is the primary circulation pump okay page 83 page 31 Buderus
6. Is the contact okay Restore the contact between the UBA 3 and the UBA 3 mounting base See page 125 fig 109 Yes y Try to remedy the fault by replacing the entire cable loom Yes as the malfunction been repaired No page 83 page 31 The system pressure is too low cE read Locking boiler fault code Is the pressure in the heating system at least 14 5 psi 1 bar No Fill and bleed the heating system Replace the pressure sensor to test whether the fault can be traced back to the sensor See page 116 Is the blocking boiler fault code Yes cleared from the display page 83 Buderus page 31 48 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications oF Iid h OII No temperature increase after burner start or the temperature difference between the supply Operating code and safety sensors is more than 27 F 15 K oF Ild The temperature difference between the supply and safety sensors is more than 27 F 15 K Locking boiler fault code Wait approx 60 seconds until the boiler automatically becomes operational again i fault message d F No Are all servicing cocks open O
7. fig 5 Checking the fuses 8 1 2 External connection board fuse Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Remove the cover from the connection box fig 6 Dismantle the fuse holder fig 7 pos 10 Remove the fuse from the fuse holder Check the circuit continuity through the fuse using the volt ohm multimeter If broken replace it with a new ceramic fuse 5 amps 250V fast blow F5AH 250V Re install the cover on the connection box Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 6 Removing the cover from the connection box seek nS PK PS PZ Grid a pojedoleoofoco OORT oo 12 3 4 5 6 7 8 9 10 fig 7 External connection board pos 1 RC Room thermostat connection color orange pos 2 Outdoor temperature sensor connection color blue pos 3 Potential free On Off thermostat connection color green pos 4 DHW temperature sensor connection color grey pos 5 External switching contact potential free for floor heating safety etc connection color red pos 6 DO NOT USE pos 7 Primary loop pump 120V 60Hz connection color green pos 8 DHW tank pump 120V 60Hz connection color grey pos 9 DHW recirculating pump 120V 60Hz connectio
8. F y tt The return sensor contact is interrupted Locking boiler fault code Press the Reset button i New fault message No 44 or CU Yes Check the wire to the supply or return sensor for the proper contact page 92 Is the wire okay Replace the cable loom or the affected part thereof Yes y Check the supply and return sensor page 89 Are the supply and return sensors okay Replace the supply and return sensor page 91 page 83 Buderus page 31 64 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications TBR f G eet No ionization after four startup attempts Locking boiler fault code 27 page 71 Press the Reset button New fault message BH Yes Is th Contact the gas utility company to ensure that z saad Yes no nitrogen remains in the gas tank or gas heating system propane supply pipes c gas fired i No Measure the static inlet gas pressure See page 107 Is the inlet gas pressure page 68 okay Yes Bleed the gas supply pipe See page 106 Has the gas supply pipe been bled of air Bleed the gas supply pipe See page 106 Check the hot surface ignitor is activated during the operat
9. Check the wiring between the pressure sensor and the UBA 3 mounting base by measuring the resistance fracture See page 126 fig 110 Is the wiring okay Replace the cable loom or the affected part thereof Try to remedy the fault by integrating another provisional pressure sensor See page 116 as the malfunction been repaired Yes gt No page 83 page 31 Buderus 82 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Check the contacts between the UBA 3 and the UBA 3 mounting base between the BC10 and the base plate and all other plug and socket connections See from page 92 y Remedy contact faults See from page 92 y Press the Reset button and hold it for 2 seconds See page 9 a Replace the UBA 3 See page 125 Yes Has the UBA 3 already been replaced Call the Buderus customer service department See on the back side of this document Remedy the fault using the structure diagram from this document that corresponds with the fault code Is the same fault message displayed Has a new fault occurred page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 83 rea Actions 8 Actions 8 8 Buderus 84 Logamax plus GB142 2
10. Press the service button i Peg Current heating system pressure See page 20 Press the service button Operating code See page 21 Press the service button Y q3 L Current supply temperature 0 199 F 18 93 C See page 20 Have 30 min passed or was the power interrupted no Deactivate flue gas test yes Deactivate flue gas test Press and hold the chimney sweep button for more than 2 seconds until the decimal point has disappeared Buderus 10 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Operation KE 4 2 2 Service Mode menu C SERVICE MODE MENU D f dc Current supply temperature 0 199 F 18 93 C See page 20 Activate service mode no Boiler load in line wi Activate service mode 1st step A Press and hold the Chimney sweep button for 2 to 5 seconds i ic As soon as a non flashing dot is shown in the right hand bottom corner of the display the boiler will run in heating mode at 100 load for 30 minutes The maximum boiler water temperature set on the BC10 basic controller applies me Activate service mode 2nd step Simultaneously press and hold the Chimney ith Settings menu
11. Close the gas shut off valve when no more air escapes Remove the hose and tighten the screw plug again fig 55 Bleeding the gas supply pipe Carefully open the gas shut off valve see fig 56 pos 2 Check the testing nipple for leaks Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Buderus 106 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 8 1 25 Measuring the inlet gas pressure flow pressure Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Open at least one thermostatic radiator valve Close the gas shut off valve see fig 56 pos 1 Open the screw plug on the testing nipple for the inlet gas pres sure see fig 57 pos 1 by two turns Set the pressure gauge to zero Connect the measuring hose of the pressure gauge to the testing nipple see fig 57 pos 2 Carefully open the gas shut off valve see fig 56 pos 2 Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Put the heating boiler into operation see Flue gas test menu on page 10 Measure the inlet gas pressure when the Burner On Off LED on the BC10 basic controller lights The inlet gas pressure must be
12. Connect the conduits correctly Close the shut off valve in the cold water inlet and open a hot water tap at random to see if water comes out of it The cause is then a defective mixer tap a thermostat controlled mixer valve or a short circuit between the hot and cold water c conduit circuits Yes Is this the case No y Check to see if any other external part of the heating circuit is a possible cause Are such items detected Place the affected components out of service page 31 page 83 Buderus 34 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 33 22 Y Check the hot water temperature sensor See page 89 Is the hot water temperature sensor okay No Replace the hot water temperature sensor See page 91 Check the wire of the hot water temperature sensor between the terminal strip and the UBA 3 mounting base using a continuity checking device See page 92 Is the wire okay Replace the cable loom or the affected part thereof Yes page 83 page 31 page 33 Check that the burner in the boiler activates as specified in the structural diagram page 17 Remedy the fault using the structure diagram that corresponds with the fault code Does the burner in the bo
13. Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 109 EA Actions Loosen the 2 external connection board fastening screws see fig 64 pos 1 fig 64 Loosening the fastening screws Remove the external connection board see fig 65 Remove the transformer shield see fig 66 fig 66 Removing the transformer shield Buderus 110 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Pull both plugs on the rear of the transformer see fig 67 Check to see if you measure any resistance on the two cable plugs If you do then the transformer is not the problem If you don t measure any resistance then replace the transformer as described in the following steps Remove the transformer by pulling it in the direction indicated by the arrow see fig 68 Install the new transformer Re assemble all parts and plugs in reverse order of disas sembly Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 29 Automatic air purging system replacing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Close the maintenance shut off valves and dr
14. Loosening with one turn the nut between the supply connection and three way valve connection AB see fig 102 pos 2 Pull the supply pipe out of the heat exchanger see fig 102 pos 1 WARNING Water will be released fig 102 Removing the supply pipe Buderus 122 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Loosen the fastening screws of the internal condensate water overflow valve see fig 103 pos 1 i fig 103 Loosening the fastening screws of the internal condensate water overflow valve Pull the combustion air supply see fig 104 pos 2 and flue gas exhaust see fig 104 pos 1 connections on top of the 1 boiler upwards to remove them h fig 104 Loosening the combustion air supply and flue gas exhaust connections Loosen the 6 fastening screws of the flue gas adapter see fig 105 pos 1 fig 105 Loosening the fastening screws Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 123 rea Actions Remove the flue gas adapter see fig 105 pos 1 from the top of the boiler Remove the heat exchanger by grabbing its bottom end and pulling forward and then pushing it upwards see fig 107 pos 1 Assemble the new heat exchan
15. Press the Reset button No New fault message HP Yes y Check the wire to the safety sensor for the correct contact page 92 Is the wire okay Yes y Check the safety sensor page 89 Replace the cable loom or the affected part thereof Is the safety sensor okay Replace the safety sensor page 91 c Yes page 83 page 31 Buderus 62 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications m F f amp Beat The supply sensor contact is shorted Locking boiler fault code The return sensor contact is shorted Locking boiler fault code H Fat E Press the Reset button New fault message No 4U or CU Yes y Check the wire to the supply or return sensor for signs of short circuiting page 92 Is the wire okay Replace the cable loom or the affected part thereof Yes Check the supply and return sensor page 89 Replace the supply and return sensor Are the supply and return sensors okay page 91 page 31 page 83 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 63 Pr The supply sensor contact is interrupted Locking boiler fault code
16. Pull out the sensor and replace it by a new one Restore the plug and socket connection Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 17 Replacing the safety sensor Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 91 rest Actions 8 1 10 Checking the supply return safety sensors cable WARNING Avoid damage do not push the measuring pin of the volt ohm multimeter too deeply into the socket Check all plug and socket connections of the sensors and the UBA 3 A plug that has not been inserted correctly may be the cause for a fault message Then start the boiler by pressing Reset Go Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to O Off Remove the casing Loosen the fastening screw of the UBA 3 see fig 18 pos 1 Remove the UBA 3 by pulling it forward as indicated by the arrow see fig 18 pos 2 Disconnect the plug and socket connection of the cable for the sensor Check the cable between the plug and socket connection and the 81 pole plug in the UBA 3 installation base see fig 19 using a circuit continuity testing device See the electric circuit diagram fig 110 on page 126 Test this in a straight li
17. tions is not followed exactly a fire or explo sion may result causing property damage personal injury or death Do not store or use gasoline or other flam mable vapors and liquids in the vicinity of this or any other boiler What to do if you smell gas Do not try to light any boiler Donottouch 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 lf you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier 1 4 Observe these instructions for heating system water Thoroughly flush the system prior to filling Only use untreated main water to fill and top off the system Do not use salt bedding exchangers to soften the water Do not use inhibitors or other additives No Toxic chemicals such as used for boiler treatment shall be introduced into the heating water used for space heating The maximum permissible flow rate of the GB142 24 30 this is 11 GPM gal min for the GB142 45 is 15 GPM and for the GB142 60 is 20 GPM When using oxygen permeable pipes e g for floor heating systems you must separate the system using heat exchang ers Unsuitable heating system water promotes the formation of sludge and corrosion This may damage the heat exchanger or affect its o
18. 0 Off Reconnect the plug to the fan unit Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 8 Checking for 120V AC voltage Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 8 1 4 Checking the fan unit supply cord 120V AC WARNING Avoid damage do not push the measuring pin of the volt ohm multimeter too deeply into the socket Remove the casing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Disconnect the 120V AC plug of the fan unit Loosen the fastening screw of the UBA 3 see fig 9 pos 1 Remove the UBA 3 by pulling it forward as indicated by the arrow see fig 9 pos 2 Set the volt ohm multimeter to Resistance testing Test the fan unit supply cord to make sure that there is no short circuit in it and that it is not broken anywhere see fig 10 and fig 110 on page 126 Reconnect the plug to the fan unit Re assemble the UBA 3 in reverse order of disassembly Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Fit the casing fig 9 Dismantling the UBA 3
19. 53 External connection board an a 2 z3 9 10 277 RC Room thermostat connection color orange Outdoor temperature sensor connection color blue Potential free On Off thermostat connection color green DHW temperature sensor connection color grey External switching contact potential free for floor heating safety etc connection color red DO NOT USE Primary loop pump 120V 60Hz connection color green DHW tank pump 120V 60Hz connection color grey DHW recirculating pump 120V 60Hz connection color lilac Main connection 120V 60Hz connection color white Fuse holder Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 105 reat Actions Fit the cover on the external connection box see fig 54 Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 24 Bleed the gas supply pipe Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Close the gas shut off valve see fig 56 pos 1 Open the screw plug on the testing nipple for the inlet gas pres sure and for purging fig 55 by two turns and install a hose Open slowly the gas shut off valve Run the gas that flows out through a water bath
20. 56 pos 1 Remove the hose and tighten the screw plug on the testing nipple again Open the gas shut off valve see fig 56 pos 2 Check the testing nipple for leaks fig 60 Adjusting the gas air ratio Fit the casing Set the main switch on the BC10 to 1 On Buderus 108 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 8 1 27 Measuring the carbon monoxide content CO Measure the carbon monoxide content on the flue gas sampling point see fig 61 The CO values in an air free condition must be below 400 ppm or 0 04 vol Values of 400 ppm and up indicate that the burner adjustment may be wrong the gas burner fitting or the heat exchanger are dirty or that there may be burner faults You must establish and resolve the cause The boiler must be operational when you do this 8 1 28 Transformer replacing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Dismantle the cover of the external connection board see fig 62 Pull the 4 plugs from the external connection board see fig 63 pos 1 2 3 and 4 fig 61 Flue gas sampling point fig 62 Removing the cover from the connection box N o fig 63 Pulling the external connection board plug Buderus
21. Is the supply cord okay Replace the supply cord cc Y page 83 page 31 Buderus 50 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 50 22 y Check the primary circulation pump for soiling Is the primary circulation pump soiled Is the expansion tank correctly connected to the supply conduit Clean the circulation pump inside Connect the expansion tank to the return conduit Check whether the pressure sensor is soiled See page 116 l Is the pressure sensor soiled No Y Clean the pressure sensor Replace the pressure sensor See page 116 Has the malfunction been repaired page 83 page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 51 Operating code cP amp 2 1 g Temperature increase of supply sensor or safety sensor is more than 7 5 F sec 5 K sec y Wait approx 30 seconds until the boiler automatically becomes operational again fault message PP Yes No Are all servicing cocks open Open the servicing cocks s the pressure in the heating system measured on Fill and bleed the heating system
22. Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 53 JH IZ 6 4 The air fan has failed during the operating phase Locking boiler fault code Check that both the plug and socket connections of the blower are correctly fitted See page 88 fig 12 re the plug and socke connections fitted correctly Reconnect the plug and socket connection of the blower See page 88 fig 12 Yes Y Check blower activation 120V AC See page 86 Is the activation okay Yes page 55 y Check the tacho wire of the blower See page 88 Tacho wire okay Replace the tacho wire page 88 Check whether you can remedy the fault by temporarily fitting a new blower See page 88 paragraph 8 1 6 Yes Has the malfunction been repaired gt No Check that the mains voltage is 120V AC Sufficient mains voltage Have the electrical system tested __ page 83 page 31 Buderus 54 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 54 2 y Check the supply cord of the blower 120V AC See page 87 Is the supply cord okay Replace the supply cord page 31 page 83 JF 2 14 The blower
23. Open the screw plug on the testing nipple for the burner pres sure fig 58 pos 1 by two turns Set the pressure gauge to zero Use a hose to connect the connection of the pressure gauge to the burner pressure measuring nipple fig 58 pos 2 Open the gas shut off valve see fig 56 pos 2 Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 58 Checking the gas air ratio Put the heating boiler into operation see Service Mode menu incorrect correct incorrect on page 11 a a Read out the gas air ratio from the pressure gauge when the boiler is in part load operation The boiler is running in part load operation when in the Service mode menu 40 has been set The differential pressure PGas Pair Must be 0 02 inch W C 5 Pa 0 02 inch W C 5 Pa read out on pressure gauge 0 04 0 inch W C 10 Pa 0 Pa See fig 59 0 06 0 04 0 02 o 0 02 inch W C turn counterclockwise turn clockwise lt gt fig 59 Differential pressure gas air ratio part load Ifthe gas air ratio is incorrect it can be adjusted on the set screw fig 60 pos 1 NOTE The set screw is located behind the screw on cover This must be removed first Set the main switch on the BC10 to O Off Close the gas shut off valve see fig
24. Remove the hot surface ignitor fig 24 pos 4 Install the new hot surface ignitor with a new gasket and attach the mounting plate with fastening screws see fig 24 pos 1 Restore the plug and socket connection of the hot surface ignitor Fit the casing Pin 1 28 55 16 pole connector OOo 81 pole connector fl ol ol oO Oo ol im oO Oo ol ol ol ol Oo ol ol ol ol ol oO Oo ol ol ol ol ol POOOOOOOOOOOOOUOOOOOOOOooo OOo Pin 1 ee ee aGa GRP Gaa GS Pin 16 Pin 81 fig 22 UBA 3 installation base Bre a fig 23 Testing the supply cord of the hot surface ignitor fig 24 Replacing the hot surface ignitor Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 15 Testing the ionization current WARNING Avoid damage do not push the measuring pin of the volt ohm multimeter too deeply into the socket Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Disconnect the plug and socket connection o
25. for natural gas min 3 5 to 10 5 inch W C 8 7 to 26 1 mbar nominal supply pressure 7 0 inch W C 17 4 mbar for LPG min 8 0 to 13 0 inch W C 19 9 to 32 3 mbar nominal supply pressure 11 0 inch W C 27 4 mbar Set the main switch on the BC10 to 0 Off Close the gas shut off valve see fig 56 pos 1 Remove the hose and tighten the screw plug on the testing nipple again Open again the gas shut off valve see fig 56 pos 2 Check the testing nipple for leaks Fit the casing Set the main switch on the BC10 to 1 On NOTE If the required inlet gas pressure is not available you should consult your gas utility company If the inlet gas pressure is too high a gas pressure regu lator is to be integrated upstream of the gas valve fig 56 Gas shut off valve closed 1 gas shut off valve open 2 fig 57 Measure the inlet gas pressure Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 107 rea Actions 8 1 26 Measure and adjust the gas air ratio Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to O Off Remove the casing Close the gas shut off valve see fig 56 pos 1 Open at least one thermostatic radiator valve
26. 26 page 108 1 7 Disposal Dispose of the boiler packaging in an environmentally sound manner Dispose of components of the heating system e g boiler or control device that must be replaced by handing them in to an authorized recycling facility Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 5 a Safety and general instructions 1 8 Abbreviations AM10 Outdoor reset module AS System fault code AV Air Vent BC Operating code BC10 Control panel on the boiler BCT Boulter Buderus cylinder thermostat BDV Boulter Buderus diverter valve BKS Blocking boiler fault code CB Connection Block CH Central Heating CHF Central Heating Supply CHR Central Heating Return CM10 Cascade module CT Cylinder Thermostat CWDO Condensate water drainage outlet CM10 Cascade module DHW Domestic Hot Water DV Diverter Valve E Earth EM10 External control module EMS Energy management system FA Outdoor sensor HK1 or HK2 Central Heating line KIM Boiler identification module L Live Line LED Light Emitting Diode LSV Lock Shield Valve MCW Mains Cold Water MM10 Controler for HK2 second Central Heating line module N Neutal PE Ground PL Permanent hot line Prog Programmer RT or
27. Check that the capacitor of the DHW circulation pump is okay i Is the capacitor of the DHW circulation pump okay Replace the capacitor y Yes Replace the DHW circulation pump page 31 Buderus 44 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Check that the cable plug from the pressure sensor is connected See page 8 fig 1 pos 17 No digital system water pressure indication on the display of the BC10 basic controller Is the plug and socket connection okay Reconnect the plug and socket connection of the pressure sensor See page 8 fig 1 pos 17 Check the wires between the pressure sensor plug and the UBA 3 mounting base by using a proper measuring device See page 126 fig 110 Is the wiring okay Replace the cable loom or the affected part thereof Replace the pressure sensor to test whether the fault can be traced back to the sensor See page 116 paragraph 8 1 33 Can a pressure Yes indication be read out on the display page 83 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 45 Diagnosis 7 2 Faults with a fault code The following structural diagrams can be used for the systematic troubl
28. External connection board fuse 85 8 1 3 Checking the fan unit 120 VAC control 86 8 1 4 Checking the fan unit supply cord 120V AC 87 8 1 5 Checking the fan unit tacho cable 88 8 1 6 Replacing the fan unit 88 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 3 ee Safety and general instructions 1 Safety and general instructions Please observe these instructions in the interest of your own safety 1 1 Designated use The boiler was designed for heating water for a space heating system and generating hot water e g for domestic purposes The boiler is delivered with a BC10 basic controller and the Universal Automatic Burner Control Unit 3 UBA 3 pre installed The boiler can be fitted with a modulating outdoor reset control AM10 scope of delivery and an On Off thermostat or relay panel end switch 24 V accessories 1 2 Hazard definitions The following defined terms are used throughout the documen tation to bring attention to the presence of hazards of various risk levels Notices give important information concerning the life of the product DANGER Indicates the presence of hazards that can cause severe personal injury death or substan tial property damage WARNING Indicates the presence of hazards that can cause severe personal injury death or substan tial property damage CAUTION Indicates presence of hazards that can cause min
29. GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Symptoms 6 Symptoms Display code Typeof Reset Diagnosis Remed J J 3 Other g y as M ae a Key to display code display required cae amp isplay E isplay code code code iC 20 Flue gas sensor is activated BKS no Flue gas sensor not available has measured a flue gas tempe rature higher than 221 F 105 C IL 211 The UBA 3 does not register any BKS no No heating page 48 page 48 connections to the unused contacts 78 operation and no and 50 hot water J am The system pressure is too low BKS no No heating page 48 page 48 operation and no hot water JF No temperature increase after burner BC page 49 page 49 start or the temperature difference 1 between the supply and safety sensors is more than 27 F 15 K e temperature difference between the no page 49 page 49 JF 7 Th diff b h BKS supply and safety sensors is more than 27 F 15 K oe es ee A r P EJ 766 The primary circulation pump does not VKS yes No heating page 50 page 50 265 f tct generate a pressure difference
30. breaker Set the main switch on the BC10 to 0 Off Remove the casing Check that the plug of the gas control valve has been installed correctly see fig 32 pos 1 Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 19 Checking the gas control valve Control Buderus 98 NOTICE You can drive the burner the gas valve using the relay test in combination with the RC control device See installation and maintenance instruc tions of the RC control device WARNING Avoid damage do not push the measuring pin of the volt ohm multimeter too deeply into the socket Remove the casing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Start up the boiler in accordance with the Flue gas test menu See page 10 Flue gas test menu Use a volt ohm multimeter to check that while operating code OL is displayed there is a voltage on the plug of the gas control valve The test must indicate a voltage of 20 24 VDC both when testing on the central and left contacts and when testing on the central and right contacts see fig 33 Fit the casing fig 32 Checking the cable connections to the gas control valve e g HONEYWELL gas control valve TO Poe fig 33 Voltage testing on the
31. called up by button Two display codes see table 2 level 3 and level 4 are shown After the first display code level 3 is displayed the second one level 4 can be called up by pushing the Service 2 button On the BC10 basic controller level 4 can only be called up in the event of a fault code Under normal operating conditions it is only possible to call up level 4 using the RC control device or a service tool Buderus If the display code is a fault code this fault code either flashes locked fault code in the display or it is shown permanently blocking fault code A boiler reset is only necessary with a locking fault code flashing see 8 fig 2 The cause of the fault must be remedied first The cause has to be remedied and the boiler resumes regular operation In the event of a locking boiler fault code both the display value and the display code flash If there are more than once display codes at the same time the display codes will be shown in turn And if one of these display codes is a locking display code the blocking display codes shown will also flash 20 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications The following display values can be shown on the display of the BC10 basic controller Abbreviations used in table 2 Type of displ
32. gas control valve Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 8 1 20 Checking the gas control valve cable connection between gas control valve and UBA 3 installation base WARNING Avoid damage do not push the measuring pin of the volt ohm multimeter too deeply into the socket Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Remove the plug of the gas control valve see fig 34 fig 34 Removing the gas control valve plug Loosen the fastening screw of the UBA 3 see fig 35 pos 1 Pull the UBA 3 forward in the direction indicated by the arrow see fig 35 pos 2 fig 35 Dismantling the UBA 3 Test the resistance of the cable between the plug of the gas control valve and the UBA 3 installation base see fig 36 fig 37 and circuit diagram fig 110 on page 126 Reconnect the plug to the gas control valve see fig 34 Re install the UBA 3 see fig 35 Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 36 Testing the cable between the gas control valve and the UBA 3 installation base Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifi
33. incorrectly sensor wire Sensor wire Check the sensor broken or installation on the shorted hot water tank The sensor is Compare the defective resistance value to the sensor graph m al S Hot water remains cold AS The system Permanent Remedy the leak if AD BID A A constantly tries to tapping or leak relevant heat the hot water tank to the hot Sensor Check the sensor water targetvalue connected or connection and the setting fitted incorrectly sensor wire The hot water Sensor wire Check the sensor priority is broken or installation on the cancelled when shorted hot water tank the fault message appears The sensor is Compare the defective resistance value to the sensor graph Fill pump Test the fill pump connected operation e g incorrectly or using a relay test defective m Thermal disinfection AS Thermal Tap flow ratetoo Choose the time for A uit B tt tat P PE 5 disinfection was great during thermal disinfection interrupted disinfection so that no period additional heat request occurs at Boiler load too this time low for simultaneous heat use by other connected loads e g 2nd heating circuit Sensor Check the sensor connected or connection and the fitted incorrectly sensor wire Sensor wire Check the sensor broken or installation on the shorted hot water tank The sensor is Compare the defective resistance value to the sensor graph Fill pump Test the fill pump defective
34. modifications 95 rea Actions Test the ionization cable between the plug and socket connec tion and the UBA 3 installation base to make sure that it has no short circuit to earth see fig 27 and fig 110 on page 126 and that it is not broken anywhere see fig 28 Assemble the plug and socket connection of the ionization elec trode Re assemble the UBA 3 in reverse order of disassembly Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 27 Testing the earth connection circuit of the ionization electrode 1 _ UBA3 a He Sas ma L HEE A eed E NEE EO ees 2 Io g e sie iag OBE E E SII 00e L Tr AIE fig 28 Testing the earth connection circuit of the ionization electrode 2 Buderus 96 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 8 1 17 Checking the ionization electrode replace if necessary Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Disconnect the plug and socket connection of the cable Set the volt ohm multimeter to Resistance testing Test the earth connection circuit of the ionization electrode see f
35. of the volt ohm multimeter too deeply into the socket fig 14 Checking the supply return sensors Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 89 rea Actions Disconnect the plug and socket connection of the cable for the sensor concerned Test the resistance of the sensor concerned Supply sensor see fig 14 pos 1 Return sensor see fig 14 pos 2 Safety sensor see fig 15 pos 1 Measure the temperature near the sensor using a seconds thermometer Compare the values measured to the values in table 4 on the next page If the values differ the sensor is broken Reconnect the plug and socket connection if the sensor is OK Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 15 Checking the safety sensor Temperature in Resistance in F C Q 32 0 29 490 41 5 23 462 50 10 18 787 59 15 15 136 68 20 12 268 77 25 10 000 86 30 8 197 95 35 6 754 104 40 5 594 113 45 4 656 122 50 3 893 131 55 3 271 140 60 2 7
36. okay Bleed the gas supply pipe See page 106 Has the gas supply pipe been bled of air Yes y Measure the dynamic inlet gas pressure See page 107 Is the dynamic inlet gas pressure okay Yes y Measure the gas air ratio during the startup phase See page 108 No Is the gas air ratio correctly adjusted page 74 Ensure that no nitrogen remains in the gas tank or gas supply pipes in close consultation with the gas utility company page 75 Bleed the gas supply pipe See page 106 page 76 Adjust the gas air ratio See page 108 page 77 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 73 Check that the correct gas orifice was fitted See page 127 table 5 Was the correct gas orifice fitted Fit the correct gas orifice See page 127 table 5 Check the following elements for soiling damage and correct assembly the combustion air inlet conduit the air suction tube the seal between the Venturi and the blower the gas orifice see page 101 and page 127 table 5 the blower see page 86 the connection between the blower and the burner the burner the heat exchanger see page 117 the flue gas conduit Are the above mentioned components clean and
37. on and off Switching on the heating system Set the main switch on the BC10 basic controller to position 1 a On 0 1 Switching off the heating system Set the main switch on the BC10 basic controller to position 0 Off 0 1 4 2 Menu structure of the BC10 basic controller The menu structure of the boiler can_ke viewed on the BC10 using the Reset Chimney swoop and Service see fig 2 pos 9 10 and 11 buttons and the display indication see fig 2 pos 4 The menu structure consists of 4 menus schematically represented on the following pages using structure diagrams Flue gas test menu page 10 Service Mode menu page 11 Manual Operation menu page 12 Settings menu page 12 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 9 ca Operation 4 2 1 Flue gas test menu FLUE GAS TEST MENU 4 Current supply temperature 0 199 F 18 93 C See page 20 Activate flue gas test Activate flue gas test Press and hold the chimney sweep button 2 to 5 seconds ic The flue gas testis activated as soon as a dotis visible in the lower right hand corner of the display This means that the boiler runs in heating mode at 100 for 30 minutes The maximum boiler water temperature as set on the BC10 basic controller applies here
38. operation and no hot water 3p S Temperature increase of supply sensor BC page 52 page 52 or safety sensor is more than 9 F sec 1 5 K sec EJT The temperature difference between the BC page 53 page 53 supply and return sensors is more than 1 90 F 50 K JA Jy The air flow by the blower has failed BKS no page 54 page 54 during the operating phase JF S 714 The blower is switched off during the BKS no page 55 page 55 safety test ie S Ta 4 The blower is switched off during the VKS yes No heating page 56 page 56 445 Pa safety test operation and no hot water 3 p ya 5 The blower is running too slowly VKS yes No heating page 57 page 57 operation and no hot water 3 J ya 5 The blower is running too fast VKS yes No heating page 58 page 58 operation and no hot water Ty A Ta if S The supply sensor has measured a VKS yes No heating page 59 page 59 temperature higher than 221 F 105 C operation and no hot water Ty T yaaq The UBA 3 does not register the short cut VKS yes No heating page 60 page 60 van bestween the unused contacts 22 and operation and 24 no hot water E S ya 18 The sensor test has failed VKS yes No heating page 60 page 60 operation and no hot water Ty L ya eo The safety sensor is shorted or VKS yes No heating page 61 page 61 Pi measures temperatures higher than 266 operation and F 130 C no hot water Ty p ya J Th
39. operation e g using a relay test table2 Display indications on the BC10 basic controller 1 only visible using the service tool is being carried out Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 25 6 Symptoms Symptoms Display code a Typeof Reset Diagnosis Remedy Main Sub Key to display code display required Dor display display code 2 symptoms code code Ag S BIB No communication with EMS AS The boiler no EMS bus system Reset by switching longer gets heat is overloaded the heating system requests the ERwin on and off i s does NE i no ea l Inform the onger heats BUDERUS customer service department if necessary AD Hea Water pressure sensor AS The digital water Replace the digital pressure sensor water pressure is defective sensor Age EHIE No communication with BC10 AS BC10 settingsare Contactproblem Check the BC10 no longer taken atBC10orBC10 connection over by RCxx is defective Replace the BC10 devices if necessary YF F y3 Ha S The UBA 3 has no connection to the VKS yes No heat
40. the heating system 14 5 psi 1 bar Is at least one thermostatic valve open Yes y Check the primary circulation pump Open a thermostatic valve Is the primary circulation Replace the primary return sensors okay Hl pump okay circulation pump Yes y Check the supply or return sensor page 89 Are the supply and Replace the supply and return sensor page 91 page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 59 e pet The UBA 3 does not register the short cut ay fact bestween the unused contacts 22 and 24 Logig baleit coce Check the contact between the UBA 3 and the UBA 3 mounting base See page 126 fig 110 Restore the contact between the UBA 3 and the UBA 3 mounting base See page 125 fig 109 Is the contact okay Yes y Try to remedy the fault by replacing the entire cable loom Has the malfunction been repaired Yes gt page 83 page 31 ME cs rom The sensor test has failed Locking boiler fault code Measure the voltage to check for a possible short circuit in the supply or safety sensor wiring See page 126 Replace the cable loom or the affected part Is th
41. the supply cord okay Replace the supply cord page 31 i E p f G PTE The blower is running too slowly Locking boiler fault code Check to see if the blower is soiled or wet l Is the blower dry and clean No Yes Check that the mains voltage is 120V AC Sufficient mains voltage Ne Yes Try to remedy the fault by integrating another provisional blower See page 88 Clean or replace the blower See page 88 Have the electrical system tested i Ye Has the malfunction been repaired z page 83 page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 57 RER amp Bist The blower is running too fast Locking boiler fault code t Check the plug and socket connection of the tacho wire to the blower This is the thin plug See page 88 fig 12 Is the plug and socket Ng connection okay Yes Restore the plug and socket connection Check the tacho wire by measuring the resistance is the wire broken See page 88 Y No Tacho wire okay Replace the tacho wire e Yes y Check that the mains voltage is 120V AC y Sufficient mains voltage Have the electrical syst
42. to make any changes due to technical modifications Exploded view Logamax plus GB142 45 60 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 131 Bosch Thermotechnology Corp 50 Wentworth Avenue Londonderry NH 03053 Tel 603 552 1100 Fax 603 584 1681 www buderus net U S A Products manufactured by Bosch Thermotechnik GmbH Sophienstrasse 30 32 D 35576 Wetzlar www buderus com Bosch Thermotechnology Corp reserves the right to make changes without notice due to continuing engineering and technological advances 721 494A 0003 Buderus
43. 142 boiler with capacities 24 30 45 and 60 kW These Servicing Instructions are intended for specialist install ers who have the necessary training and experience for working on heating and gas systems Subject to technical changes Slight changes may be made to the illustrations process steps and technical data as a result of our policy of continuous improvement Updating of documentation Please contact us if you have any suggestions for improvements or corrections Buderus 2 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Contents 8 1 7 Checking the supply return safety hot water 1 Safety and general instructions 4 temperature sensors 89 1 1 Designated use 4 8 1 9 Checking the hot water temperature sensor 91 1 2 Hazard definitions 4 8 1 10 Checking the supply return safety sensors cable 92 1 3 The following instructions must be observed 4 8 1 11 Checking the hot surface ignitor control me 14 Observe these instructions for heating 8 1 12 Checking the hot surface ignitor resistance 93 system water 5 8 1 13 Checking the hot surface ignitor supply cord 93 1 5 Tools materials and additional equipment 5 8115 Testing the ionization current 3 gt io 8 1 16 Checking the ionization electrode cable 95 16 Inspection 2 8 1 17 Checking the ionization electrode 1 7 Disposal 5 replace if necessary 96 1 8 Abbreviations 6 8 1 18 Checking the gas control valve cable connect
44. 2 24 30 45 60 We reserve the right to make any changes due to technical modifications page 66 Check the following elements for soiling damage and correct assembly the combustion air inlet conduit the air suction tube the seal between the Venturi and the blower the gas orifice see page 101 and page 127 table 5 the blower see page 86 the connection between the blower and the burner the burner the heat exchanger see page 117 the flue gas conduit Are the above mentioned components clean and free from damage Clean and or replace the corresponding components Measure the ionization current See page 95 Is the ionization current page 71 okay Yes page 71 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 67 Check whether the gas stop tap is open See page 101 No p tap open Is the gas sto Open the gas stop tap See page 101 Yes y Check to see if there is a blockage in the conduit between the gas stop tap and gas valve Did you find a blockage Deal with blockage No Check for blockages in the remaining section of the gas supply pipe Did you find a blockage Yes Deal with blockage No y If the required inlet gas pressure is not available yo
45. 4 30 45 60 We reserve the right to make any changes due to technical modifications 1 Testing measuring adjusting and replacing various components 1 1 Checking the UBA 3 fuse replace if necessary Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Loosen the fastening screw of the UBA 3 by turning it counter clockwise see fig 4 pos 1 WARNING Do not pull or move side to side the UBA 3 during loosening or tightening of UBA 3 fastening screw Remove the UBA 3 once the fastening screw is fully loosened by pulling it forward carefully as indicated by the arrow see fig 4 pos 2 Dismantle the fuse holder by loosening the bayonet connector see fig 5 pos 1 Remove the fuse from the fuse holder Check the circuit continuity through the fuse using the volt ohm multimeter If broken replace it by a new spare ceramic fuse 5 amps 250V fast blow F5AH 250V fig 5 pos 2 Re assemble the UBA 3 in reverse order of disassembly Fasten the UBA 3 by only turning the fastening screw clock wise WARNING Do not push or force the UBA 3 in place by hand Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 4 Dismantling the UBA 3 1 eee HETIL O
46. 45 60 We reserve the right to make any changes due to technical modifications 77 TBP S 4 The hot surface ignitor activates too long Locking boiler fault code Press the Reset button No KIM defective contact the Buderus customer Has the malfunction been repaired service department See on the back side of this document Yes page 31 S att a al aay imgrrupted Locking boiler fault code Press the Reset button Has a new fault code No occurred Remedy the fault using the structure diagram that corresponds with the fault code a page 31 Buderus 78 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications The UBA 3 is defective Locking boiler fault code a The UBA 3 is defective Locking boiler fault code page 83 BY 2 4e2 The external switch contact is activated Locking boiler fault code Check that the switch contact is connected to the boiler See page 106 fig 54 pos 5 EV j Is an external switch contact connected Check to see if an external switch contact is open by measuring its resistance using a volt ohm multimeter Is the external switch contact open External switch con
47. 60 149 65 2 339 158 70 1 990 167 75 1 700 176 80 1 458 185 85 1 255 194 90 1 084 203 95 940 212 100 817 table4 Sensor resistance values target values Buderus 90 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 8 1 8 Replacing the supply return safety sensors Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Close the maintenance shut off valves Drain the Logamax plus GB142 Disconnect the plug and socket connection Unscrew the sensor concerned and replace it by a new one Supply sensor see fig 16 pos 1 Return sensor see fig 16 pos 2 Safety sensor see fig 17 pos 1 Restore the plug and socket connection Open the maintenance shut off valves Purge air from the boiler Fit the casing NOTICE Fill and purge the Logamax plus GB142 as required See installation and maintenance instruc tions Logamax plus GB142 24 30 45 60 Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 9 Checking the hot water temperature sensor Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Disconnect the plug and socket connection of the cable for the hot water temperature sensor
48. 7214 9400 02 2010 US CA Servicing instructions Condensing gas boiler Logamax plus GB142 24 30 45 60 WARNING Improper installation adjustment alteration service or maintenance can cause injury loss of life or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier NOTICE In the Commonwealth of Massachusetts this boiler must be installed by a licensed Plumber or Gas Fitter Warning If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other boiler What to do if you smell gas Do not try to light any boiler Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department installation and service must be performed by a qualified installer service agency or the gas supplier Notice This manual must be retained for future reference For installers Please read thoroughly before servicing Buderus Eo Preface About these instructions These Servicing Instructions contain important information to diagnose and resolve issues concerning the GB
49. For direct vent boilers mechanical vent heating boilers or domestic hot water equipment where the bottom of the vent terminal and the intake is installed four feet or above grade the following requirements must be satisfied If there is not one already present a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms The carbon monoxide detector and alarm shall comply with NFPA 720 2005 Edition A carbon monoxide detector shall a Be located inn the area where the boiler or equipment is located b Have battery back up power c Beaminimum comply with NFPA 720 2005 Edition A product approved vent terminal must be used and if applicable a product approved air intake must be used Installation shall be in strict compliance with the manufacturer s instructions A copy of the installation instructions shall remain with the boiler or equipment at the completion of the installation Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 7 EA Product description 3 Product description fig 1 Logamax plus GB142 24 30 left and GB142 45 60 right pos 1 Drawer with control unit pos 9 Latches of which two have locks pos 2 Universal Burner Automat UBA 3 pos 10 Sighting glass pos 3 Control unit BC10 pos 11 Heat exchanger pos 4 Gas valve pos 12 Back cover pos 5 Cover pos 13 Air i
50. ME Se ee E lO O als PP ggg g slo gt g a a 1 i Il o 4 ao que woos gdh tb pas t4 fie 4 b 44 11 O0OOO 1Q00 0000 aBuuojsues in S69 yun ueg 1 1 I a 1 I 1 l l im ae i D wane 1 OVA 1 1 i l i i Zain i ti aad n 94 uid LOQ _____ GOO a beac Qs 8 sg g RIR R 00 OOO OOO 000 ow OES GeO soe az niz a24 OWA 021 Return sensor e 33 ajg 25 S Supply sensor Safety temperature sensor 10 2 uu0 jod L8g oo EEEBEEEEEEpSppeppop EmA mO ua REGDSShebOOOEGGS 40J uUON j0d 9 o e VEN xoq uonosuuog A ozi pue pz OL 0 OV 4O N9UON ajOd 1 g 10 2 uu09 ajod g fig 110 Electric circuit diagram Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 126 Type of gas supply Factory setting of gas burner fitting Appendix ea Natural gas H LPG P Delivered factory set to Wobbe index 14 1 kWh m based on 59 F 15 C 14 7 psi 1 013 mbar suitable for Wobke index range 11 3 15 2 kWh m Information on gas type instruction plate Set to gas category G 20 2E Previous indications set to Wobbe index 15 0 kWh m based on 32 F 0 C 14 7 psi 1 013 mbar suitable for Wobbe index range 12 0 15 7 kWh m Suitable for propane af
51. RC Room Thermostat SC Service code T Timer TRV Thermostatic Radiator Valve UC Other display codes UBA 3 Universal automatic burner control unit 3 VKS Locking boiler fault code WC Wiring Centre WM10 Controler for HK1 first Central Heating line ZV Two Port Zone Valve Buderus 6 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 2 The installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the latest edition of the National Fuel Gas Code ANSI 2223 1 In Regulations and guidelines Canada installation must be in accordance with the require ments of CAN CSA B149 1 Natural Gas and Propane Installa tion Code Where required by the authority having jurisdiction the installa tion must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Install CO detectors per local regulations The boiler requires yearly maintenance see maintenance section see chapter 8 1 27 Measuring the carbon monoxide content CO on page 109 Operating Limits of the boiler Max boiler temperature Max operating pressure The hot water distribution system must comply with all applicable codes and regulations When replacing an existing boiler it is important to check the condition of the entire hot water distribution system to ens
52. Return pipe 60 kW 709945 Condensate collector sealing 24 30 kW 7098840 49 Pressure sensor 8718600019 16 Condensate collector sealing 45 kW 7098844 50 Bottom plate 7099049 Condensate collector sealing 60 kW 67900521 51 Transformer 120V 78191 17 Clamp 7098848 52 Grommet 7099050 18 Sensor NTC 7100136 53 External connection board 7099042 19 Revision set air vent 7098822 54 External connection board cover 7099046 20 Sight glass 7098575 55 Fuse 5 AF slow blow 73904s Burner box 24 30 kW 7099057 56 UBA cover 7099047 21 Burner box 45 kW 7098875 57 UBA3 120V 7099707 Burner box 60 kW 67900525 58 Drawer 7099043 22 Safety sensor 78194 59 Drawer front 7099037 Seal burner 24 30 kW 7098916 60 Controller connection plate 78186 23 Seal burner 45 kW 7098920 61 On off switch 7099041 Seal burner 60 kW 67900526 62 Controller cover 73698 Gas air distribution plate 24 30 kW 7100922 Boiler ident module 24 kW 78223 24 Gas air distribution plate 45 kW 7098926 63 Boiler ident module 30 kW 78224 Gas air distribution plate 60 kW 67900527 Boiler ident module 45 kW 78225 25 Orifice plate 24 30 kW 7100920 Boiler ident module 60 kW 78226 Orifice plate 60 kW 7746900120 64 Cable harness low voltage 78193 Burner 24 30 kW 7099003 65 Cable harness high voltage 7099957 26 Burner 45 kW 7098932 66 O ring 10 pc 38434s Burner 60 kW 67900528 67 Sealing bush set 7099002 27 Gas air inlet 7099004 68 Cable harness of on of
53. UBA 3 has been installed the LED will flash at a high frequency for max 10 sec while data is being exchanged serene ____ HAH A display check is carried out for max 1 second o __ Flashes twice for 2 seconds until communication between the UBA 3 and the BC10 has been established l ig m Current supply temperature 0 199 F Liu 18 93 C See page 20 Operating code The heating boiler is started Start of air side pre flushing phase Pe The blower runs for lt 20 seconds at Press the Service button approx 60 of the maximum speed Pog Is the Current heating system pressure irp raina phase See page 20 purging p okay Press the Service button Unit will show an error code Fault must be fixed before proceeding See chapter 6 7 and 7 2 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 15 page 15 mM OH Operating code The boiler is in ready mode there is no heat request Start of pump post purge time via the heating system Pump post purge time in line with Settings menu See page 12 and page 20 Factory default setting 5 minutes l there a heat request from the room or outdoor t
54. ain the Logamax plus GB142 see fig 69 fig 69 Draining the Logamax plus GB142 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 111 rea Actions Remove the plastic cover from the top of the boiler see fig 70 VA fig 70 Removing the plastic cover of the automatic air purging system 5 ee eo Remove the float cap see fig 71 yr fig 71 Removing the float cap Dismantle the valve case by pulling it upwards through the opening in the housing see fig 72 Assemble the new valve case and all other parts in reverse order of disassembly NOTICE Fill and purge the Logamax plus GB142 as required See installation and maintenance instructions Logamax plus GB142 24 30 45 60 Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 72 Dismantling the valve case for the automatic air purging system Buderus 112 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 8 1 30 Burner replacing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Close the gas shut off valve see fig 73 pos 1 Remove the cable pl
55. air intake and outlet systems and the chimney connection the regulations for the power supply connection the technical rules laid down by the gas utility company con cerning the connection of the gas burner fitting to the local gas main the instructions and standards concerning the safety equip ment for the water space heating system the Installation Instructions for building heating systems The boiler must be located in an area where leakage of the tank or connections will not result in damage to the area adja cent to the boiler or to lower floors of the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the boiler The pan must not restrict combustion air flow The boiler must be installed such that the gas ignition system components are protected from water dripping spraying rain etc during boiler operation and service The boiler must not be installed on carpeting Do not restrict or seal any air intake or outlet openings Ifyou find any defects you must inform the owner of the sys tem of the defect and the associated hazard in writing 4 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications DANGER AN if flammable gas explodes Beware if you smell gas there may be an explosion hazard Warning If the information in these instruc
56. an the The primary circulation pump stops target value t The blower stops page 16 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 19 6 Symptoms 6 Symptoms 6 1 Display indication on the BC10 basic controller 6 1 1 General A display value or code is shown on the display of the BC 10 basic controller see page 8 fig 2 6 1 2 Display values on the display of the BC10 basic controller The display value is shown automatically or can be called up by pressing the Chimney sweep or Service button see page 10 and 12 The following display values can be shown on the display of the BC10 basic controller Deni Factory errs Y Type of display value Unit Range default setting 12 Current supply temperature F o L949 1 C z J3 Peg Current heating system pressure psi JP oo Ped gg Configured target load L4a L99 L kss FG Configured target pump post purge time min FOO FRO Fld FS table 1 Display values on the BC10 basic controller 6 1 3 Display codes on the display of the BC10 basic controller A display code shows the current status of the Logamax plus GB142 The display value is sh pressing the Service n automatically or can be
57. as switched off Start the BC pump over run time via the tank for at 1 least 30 seconds and maximum 1 minute table2 Display indications on the BC10 basic controller 1 only visible using the service tool 2 is being carried out Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 21 6 Symptoms Symptoms Display code Typeof Reset Diagnosis Remedy i Other Key to display code display required code Main Sub amp display display code code x Sh x Sh symptoms Operating phase BC Possibly no The switch optimization program is heating operation 1 activated GA This program is activated if there is more than one burner firing requests from an RC or ON OFF regulator within 10 minutes This means that the boiler cannot be restarted until at least ten minutes have elapsed since initial startup of the burner i BC JE The burner is started Readiness for operation BC The boiler is in ready mode 1 The time proportional program is activated HE The time proportional program is activated as soon the load requested by the modulating room controller is lower than the lower limit of the boiler load During the time proportional program the burner is switched on and off repeatedly The period in which the burn
58. at request On devices with external hot water tanks i Turn the operating switch on the BC10 to position 0 OFF and turn the operating switch to 1 ON y Open hot water tap y Check that the hot water outlet conduit immediately under the hot water tank becomes hot and that the settings on the RC device are correct Does this conduit warm up to approx 140 F 60 C Check thatthe hot water supply has been registered with the control device See the Operating instructions of the BC10 and the RC control device that the hot water target value setting is high enough 140 F 60 C See page 8 fig 2 thatthe hot water supply is not switched off by the timer program of the RC control device See the Operating Instructions of the RC control device Y Are the settings okay Yes Check that the Hot water mode LED on the BC10 is lit See page 8 fig 2 No Adjust the settings page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 33 page 33 The cause of the fault is to be found outside the device and the hot water tank o Se Check that the cold water inlet and hot water outlet conduit connections on the hot water tank are not reversed Are the water side conduits connected properly Yes
59. ating page 81 page 81 gt gt valve is defective operation and no hot water Yat yz 36 The UBA 3 is defective VKS yes y KIM or UBA 3 is defective VKS yes No heating page 80 page 80 gP 2344 va gt operation and no hot water yo f 1i KIM or UBA 3 is defective VKS yes No heating page 80 page 80 J JE 44 operation and no hot water table 2 Display indications on the BC10 basic controller 1 only visible using the service tool 2 is being carried out Buderus 24 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Symptoms 6 Symptoms Display code Main gt Sub i HE heset d Other Diagnosis Remedy p i Key to display code isplay require symptoms display amp display code 2 code code AD Hog S Outdoor sensor AS The minimum Sensor Check the sensor outdoor connected or connection and the temperature is fitted incorrectly sensor wire assumed Sensor wire Check the sensor broken or installation shorted The sensor is Compare the defective resistance value to the sensor graph Ag AOA Hot water temperature sensor AS No water is Sensor Check the sensor heated any more connected or connection and the AOI aod Hot water temperature sensor 2 fitted
60. ay code BC Operating code SC Service code BKS Blocking boiler fault code VKS Locking boiler fault code flashing AS System fault code UC Other display codes Symptoms Display code Typeof Reset Diagnosis Remed z J J 3 Other g y Main Sub Key to display code display required symptoms display amp display amp code 2 code code No indication in page 28 page 28 display ee Communication test while starting up UC No heating Att This code flashes 2 x 2 seconds while operation and no starting up to indicate that the hot water communication between the UBA 3 and the BC10 basic controller is being tested If anew UBA 3 or a new KIM was fitted this code will flash for max 10 seconds If this code continues to flash on the display there is a fault in the communication between the UBA 3 and the BC10 basic controller See page 46 This fault code will also appear when connecting a thermostat to the RC terminals A The boiler is in the flue gas test mode or BC page 10 or page 10 or page 11 in service mode page 11 or any other 1 indication witha permanent dot in the bottom right hand corner H S The boiler is in heating mode BC 1 The boiler is in manual operation mode BC The room page 12 page 12 sa temperature is too any other 1 high indication witha flashing dot in the bottom right hand corner H The boiler is in hot water mode BC 1 TA The boiler h
61. cations 99 8 1 21 Ohming out the gas control valve Buderus 100 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Remove the plug of the gas control valve see fig 38 Set the volt ohm multimeter to Resistance testing Use a scale of 200 Q or greater Test the resistance of both coils of the gas control valve using the volt ohm multimeter The resistance measured between the left and central contacts see fig 39 must be approx 75 Q and between the right and central contacts see fig 40 this must be approx 185 Q 10 Q If this is not the case the gas control valve will probably be defective It must then be replaced Attach the plug to the gas control valve Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 81 pole connector Pin 1 papap paar ar hhh Pin 16 16 pole connector fig 388 Removing the gas control valve plug fig 39 Testing the resistance on the gas burne
62. control device settings are correct See the Operating Instructions of the RC control device Increase the temperature setting on the RC control device See the Operating Instructions of the RC control device Are the RC control device settings correct Check that the Heating request LED on the BC10 is lit See fig 2 page 8 S the Heating request LED lit Check the control device See page 104 Check that the boiler water temperature setting on the BC10 see page 9 or the RC control device is high enough Increase the boiler water temperature setting on the BC10 see page 9 or on the RC control device Is the boiler water temperature set ting high enough Check that the boiler load setting is correct See Adjustments menu on page 12 Increase the boiler load setting Is the boiler load setting high See Adjustments menu on page 12 enough Isa hot water tank connected Isa tank pump fitted page 83 page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 41 Check that the DHW circulation pump is running as described for the primary circulation pump DHW circulation pump running Check that during heating mode there is a 120V AC voltage on the DHW circ
63. e 16 page 18 The Heat request LED is lit mr UL The blower is started up The hot surface ignitor is activated for seven seconds The circulation pump is started up i mM UL Ignition phase The gas valve is opened ED The GB142 enters heating mode The Burner LED is lit Is the temperature in the hot water at least 9 F 5 K lower than the temperature set on the BC10 or RC no page 17 Is the supply temperature 11 F 6 K higher than the target value The target value is calculated by the outdoor temperature dependent regulator or is set in the event of room temperature dependent regulation on the BC10 room or outdoor temperature dependent regulator in the request position The Heat request LED goes off mM m F oy The gas valve is closed the burner is shut down The gas valve is closed the burner is shut down The Burner LED goes off i Start of pump post purge time via the heating system Pump post purge time in line with Settings menu See page 12 and page 20 Factory default setting 5 minutes The Burner LED goes off The blower stops Is Air side after purging by blower for the supply 30 seconds no temperature 11 F 6 K ak 7 lower th
64. e gas supply pipe Did you find a blockage No Deal with blockage c Deal with blockage Check whether the overall gas conduit network is of sufficient capacity Is the overall gas conduit network of sufficient capacity Reinforce the gas conduit network Consult the gas utility company page 77 Buderus 76 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 74 Check the plug and socket connection between the ionization electrode and cable loom See page 95 Is the plug and socket connection okay Yes Measure the resistance in the wires between the ionization electrode plug and the UBA 3 mounting base See page 99 Is the wiring okay Yes Y Replace the ionization electrode Correctly insert the plug into its socket Replace the cable loom or the affected part thereof See page 96 page 77 page 73 page 77 Press the Reset button Has a new fault code No occurred Has a new locking boiler fault code KL occurred Did you go through all structure diagrams thru 14 page 83 Remedy the fault using the structure diagram that corresponds with the fault code page 31 Buderus Logamax plus GB142 24 30
65. e pump impeller wheel Is the tank filling pump soiled or is the pump No impeller wheel defective Y i es Replace or clean the tank filling The external hot water tank is furred up pump Decalcify the tank page 31 page 36 Check that the pump impeller wheel of the tank filling pump is not blocked Is the No pump impeller wheel of the tank filling pump blocked ii Yes As described for the primary circulation pump the tank filling pump must be turned in the direction of rotation of the pump using a screwdriver page 31 page 37 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 37 Check that the capacitor of the tank filling pump is okay Is the No capacitor of the tank filling pump okay Yes Replace the tank filling pump Replace the capacitor page 31 Buderus 38 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 34 Check the primary circulation pump for corrosion or scale Is there corrosion or scale inside the primary circulation pump No Check the following elements for soiling and or damage the combustion air inlet conduit the air suction tube the gas orifice see page 101 the blower see page 86 the connecti
66. e safety sensor contact VKS yes No heating page 62 page 62 is interrupted operation and no hot water E Y Th is shorted VKS yes No heati 63 63 uy Zee e supply sensor is shorted o heating page page Pa operation and no hot water table2 Display indications on the BC10 basic controller 1 only visible using the service tool 2 is being carried out Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 23 6 Symptoms Symptoms Display code Typeof Reset Diagnosis Remedy 5 i pve Sub Key to display code display required cael 9 display display code 2 Sympioms code code yg 4 y3 24 The supply sensor contact is interrupted VKS yes No heating page 64 page 64 Ast on a n operation and no hot water No ionization after ignition BKS no page 65 page 65 BA ec After four startup attempts a locking boiler fault follows 15 A f Se yo ee i A No ionization after four startup attempts VKS yes No heating page 65 page 65 JE A gt JE g operation and no hot water Vo aa So aa TEE F An ionization current was measured VKS yes No heating page 72 page 72 JE JE ed before the burner start opera
67. e wiring E f thereof okay page 83 page 31 Buderus 60 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications i e Pr The safety sensor is shorted or measures temperatures higher than 266 F 130 C Locking boiler fault code Press the Reset button No New fault message HL Yes Are all servicing cocks open Open the servicing cocks Is the pressure in the heating system at least 14 5 psi 1 bar Fill and bleed the heating system Is at least one thermostatic valve Open a thermostatic valve open Yes Check the primary circulation pump 5 the primary circulation pump okay Replace the primary circulation pump Yes y Check the wire to the safety sensor for signs of short circuiting page 92 Is the wire okay Replace the cable loom or the affected part thereof Yes page 62 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 61 page 61 y Check the safety sensor page 89 Replace the safety sensor page 91 page 83 page 31 a D f cS ett The safety sensor contact is interrupted Locking boiler fault code
68. em tested L Check that there is no blockage in the blower or the heat exchanger and that the flue gas system is connected Deal with blockage _ y No Check to see if there is a second blower in the flue gas outlet conduit or air inlet system Is a secon blower fitted Yes Take the second blower out of service gt No y Check to see if the blower wheel has come loose at the motor spindle Replace the blower See page 88 par 8 1 6 Y Blower wheel loose Ye No y Attempt to rectify the fault by temporarily fitting another blower See page 88 Yes as the malfunction been repaired 4 44 page 83 page 31 Buderus 58 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications N H R e DT The supply sensor has measured a temperature higher than 221 F 105 C Locking boiler fault code ITA 4 PEE The return sensor has measured a 7 temperature higher than 221 F 105 C Locking boiler fault code Y Press the Reset button New fault message CA HA Are all servicing cocks Open the servicing cocks open system pressure measured on the boiler in the heating system at least Fill and bleed
69. emperature dependent regulator Has the pump post purge time expired temperature set on the BC10 or RC The primary circulation pump stops page 19 Has the primary circulation pump been off for more than 24 hours yes The primary circulation pump is run for 10 seconds to prevent it from seizing up tank at least 9 F 5 K lower than the temperature set on the BC10 or RC room or outdoor temperature dependent regulator page 17 page 19 Is there a heat request from the room or outdoor temperature dependent regulator Have ten seconds passed or was the power supply interrupted tank at least no 9 F 5 K lower than the temperature se on the BC10 or RC page 17 page 19 Buderus 16 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 16 Function Ea The Hot water mode LED on the BC10 is lit i mr UL The blower is started up The tank filling pump is activated The hot surface ignitor is activated for seven seconds The primary circulation pump is started mM UL Ignition phase The gas valve is opened H GB142 is in the hot water mode The Burner LED is lit Is the temperature in the ho
70. er is switched on depends on the difference between the load required by the modulating room controller and the lower limit of the boiler load As soon as the burner is switched on the device is operating at minimum load As soon as the burner i itched off the display code DE os is indicated in the display of the BC10 The time proportional program is deactivated automatically as soon as the load required by the modulating room controller is higher than the lower limit of the boiler load The boiler is in ready mode there is no BC heat request OH The gas valve is opened BC Power Up BC Boiler is starting up after a reset or after 1 the main power is switched on This display code will be displayed for 4 minutes maximum E3 E O 0 Q The boiler switches off the temperature BC is higher than the target temperature OY 245 The supply sensor has measured BKS no a temperature higher than 203 F 95 C OQ 0 0 0 0 aq The safety sensor has measured BKS no a temperature higher than 203 F 95 C OY BKS no gy4 705 The return sensor has measured a temperature higher than 203 F 95 C table2 Display indications on the BC10 basic controller 1 only visible using the service tool is being carried out Buderus 22 Logamax plus
71. eshooting of faults with fault codes While trying to establishes the fault causes you should always also check the contacts of all electrical plug and socket connections and the connection plugs in the UBA 3 WARNING Danger to life due to electric shock Switch off the Logamax plus GB142 when testing the connections Whenever a fault has been remedied you must press the Reset button for at least 5 seconds to reset the UBA 3 to its setting status release NOTE Resetting is not possible by switching off the operating switch If a fault is displayed again you should follow the relevant structural diagram to carry out further troubleshooting Certain trouble shooting activities have to be carried out in the heating mode of the Logamax plus GB142 The flue gas test or the service mode must be activated then see chapter 4 Operation on page 9 Flue gas test menu on page 10 and Service Mode menu on page 11 ey pe comnainigaice between UBA 3 and Other display code Press the Reset button New fault message page 83 page 31 No Buderus 46 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications ay Iid 1B The supply sensor has measured a A Hapa temperature higher than 203 F 95 C Locking belles laullicoss OY 9 2 1 1 The safety sensor ha
72. ew locking boiler fault code BH occurred Did you go through all structure diagrams thru 35 page 83 page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 71 K An ionization current was measured before A Locking boiler fault code the burner start Press the Reset button Y No New fault message KC Yes Check the ionization electrode for soiling Damage see page 95 Replace the ionization electrode See page 96 Is the ionization electrode okay page 72 page 31 m An ionization current was measured after the z EC ra Oy nee aiei Locking boiler fault code Check that the burner is still under pressure after the heat request has ended See page 108 par 8 1 26 l Replace the gas valve See page 101 Is the burner still under pressure page 77 page 31 Buderus 72 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications BL ced lonization fails during the operating phase Locking boiler fault code Is the heating system propane gas fired No Yes Measure the static inlet gas pressure See page 107 Is the static inlet gas pres sure
73. ew of the UBA 3 see fig 109 pos 1 Pull the UBA 3 forward in the direction indicated by the arrow see fig 109 pos 2 Install the new UBA 3 Tighten the fastening screw again Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 109 Dismantling the UBA 3 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 125 9 Appendix Appendix 9 WARNING Label all wires prior to disconnection when servicing Wiring errors can cause improper and dangerous operation ajnpow uoyoun4 sng 10 uu02 049g 1 10 U09 w001 ugenpoN High Voltage JOSU S aunyesaduua s00pinO 994J el Ua 0d 01jU09 aunyesadua HO UO Josuas MHA Bulyeay J00 10 Bra aauj eNUa og 108 U09 YOIIMS eux anen em g jeuiaxg VA OSZ Xew OVA OZ L Joyeynoulo 18 10g VA OSZ Xew OVA OZ L JoyeinosI9 MMHG VA OSZ Xew OWA OZ L dund unen ZH 09 OVA OZ L Ajddns suie blue orange AEI 2 4 green grey grey 25 24 lilac 14 13 gosh t Tes white N 3 youms Bupeiodo jnpow uop un4 OVA O21 yes Stag 8 amp SBE Ol itt i Er ia a t 16 is einpow uonoun4 OVA 02 a oo amun ea RS SS bN B85 0 9 00900 ooo 0O 0000 000 Se ee a aay UE eA ee Ce ree e I Ake ol
74. f switch 7099072 28 Seal fan 7099023 69 Cable harness BX holder 7099070 29 lonization electrode 78195 70 Fuse holder 38345 30 Hot surface ignitor 7099006 71 Seal 60 mm 5 pc 7098878 31 Shield hot surface ignitor 7100229 72 O ring set orifice 7099018 32 Mounting plate 7098852 73 Seal 5 pc 7099059 33 Seal mounting plate 5 pc 7098850 74 Set screw M5x20 5 pc 7099065 not shown in exploded views Buderus 128 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Pos Description Product No 75 Cap 24 30 kW 79105 76 Double nipple THR x COMPR 75977 77 Cabel saddle 10 pc 7098810 78 Bolt M6x16 2 pc 7099078 79 Clip pressure sensor 7101370 80 Drainplug 7099364 81 Cap connection piece 38498 82 Clip 5 pc 73651s 83 Centering ring 5 pc 73480s 84 Coupling nut pump 73481s 85 Seal pump 10 pc 15022s 86 Coupling nut pump 15020 87 Conversion set pump 73149 Conversion kit propane 24 30 kW 76687 Conversion kit propane 45 kW 76688 Conversion kit propane 60 kW 7746900156 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 129 10 Spare parts Exploded view Logamax plus GB142 24 30 Buderus 130 Logamax plus GB142 24 30 45 60 We reserve the right
75. f the monitoring cable Connect the measuring device in series see fig 25 Set the multi meter to DC pA Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker Set the main switch on the BC10 to 1 On Start up the boiler in accordance with the Service Mode menu See page 11 Service Mode menu Test the ionization current at partial load The boiler is in part load operation as soon as in the Service Mode menu L 40 is selected The ionization current must be gt 1 4 DC pA Remove the measuring device Reconnect the plug and socket connection of the monitoring cable if the ionization current is OK Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 16 Checking the ionization electrode cable Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Dismantle the plug and socket connection of the ionization electrode Loosen the fastening screw of the UBA 3 see fig 26 pos 1 Remove the UBA 3 by pulling it forward as indicated by the arrow see fig 26 pos 2 a fig 25 Testing the ionization current fig 26 Dismantling the UBA 3 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical
76. free from damage Clean and or replace the corresponding components Measure the ionization current See page 95 Is the ionization current okay page 77 Yes Y page 77 Buderus 74 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 73 Check whether the gas stop tap is open See page 101 Is the gas stop tap open Open the gas stop tap See page 101 Check to see if there is a blockage in the gas conduit section between the gas stop tap and gas valve Did you find a blockage Deal with blockage Check for blockages in the remaining section of the gas supply pipe Did you find a blockage Deal with blockage c If the required inlet gas pressure is not available you should consult the relevant gt gas utility company page 77 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 75 Check whether the gas stop tap is fully open See page 101 Is the gas stop tap fully open Open the gas stop tap See page 101 Check to see if there is a blockage in the gas conduit section between the gas stop tap and gas valve Did you find a blockage yn Check for blockages in the remaining section of th
77. ger and all other parts in reverse order of disassembly NOTICE Fill and purge the Logamax plus GB142 as required See installation and maintenance instruc tions Logamax plus GB142 24 30 45 60 Remove the flue gas collector from the old heat exchanger including the oval seal Put silicon kit on both sides of the oval seal the flue gas collector and the heat exchanger Reassemble the flue gas collector with the oval seal to the heat exchanger Check if the oval seal is placed correctly by opening the condensate collector see page 122 fig 100 Open the gas shut off valve see fig 108 pos 2 Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Also check all joints and gaskets affected by the replacement activities while carrying out the tightness test in operating conditions Set the gas air ratio again See paragraph 8 1 26 page 108 Buderus j oN fig 106 Removing the flue gas adapter fig 108 Gas shut off valve closed 1 gas shut off valve open 2 124 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 8 1 35 UBA 3 replacing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Loosen the fastening scr
78. he BC10 to position 0 OFF See page 9 par 4 2 Make the heating system ready for operation y Turn the operating switch on the BC10 to position 1 ON See page 9 par 4 2 A Logamax plus GB142 15 24 30 45 60 okay Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 31 page 30 Use a volt ohm multimeter to check the supply wires of the primary circulation pump the blower and the hot surface ignitor for signs of short circuiting See page 87 and page 93 Replace the cable loom or the affected part thereof and the fuse again See page 84 Are the wi res okay Yes y Use a volt ohm multimeter to measure contacts L and N of the transformer for resistance s the resistance approx 50 Ohms Yes Replace the transformer see page 109 And replace the fuse again gt See page 84 Measure the supply cord of the transformer to make sure it is not broken or shorted Is the supply cord okay Replace the supply cord of the transformer and replace the fuse again See page 84 page 31 Buderus 32 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications No hot water but heating is operational possibly radiators become hot without there being a he
79. he UBA 3 Buderus During a fault in the UBA 3 or if the KIM is not recognized 26 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 7 Diagnosis 7 1 Faults without a fault code Hot water request Although the UBA 3 indicates that the system is ready for operation it is possible that in the event of a hot water request no hot water is made available or it is only made available for a short time Structure diagram for troubleshooting see page 33 Heating mode Although the UBA 3 shows that the system is ready for operation and the room temperature has not reached the preset value the Logamax plus GB142 does not enter the heating mode Structure diagram for troubleshooting page 44 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 27 No indication in disp Do the other functions of the device work normally No page 29 Check that the mains power switch is ON Is the mains power switch ON yes Switch on the mains power switch Check that the operating switch is in position 1 ON See page 9 Is the operating switch on the BC 10 in position 1 ON Turn the operating switch on the BC 10 to position 1 ON See page 9 fig 2 Check that there is a 120V AC power suppl
80. ht to make any changes due to technical modifications Install the new burner see fig 79 WARNING Fit the burner so that the scale mark is located on the left hand side see fig 79 Re assemble all other parts in reverse order of disassembly i Ml fig 79 Installing the burner Open the gas shut off valve see fig 80 pos 2 Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Also check all joints and gaskets affected by the replacement activities while carrying out the tightness test in operating conditions Set the gas air ratio again See paragraph 8 1 26 fig 80 Gas shut off valve closed 1 gas shut off valve open 2 8 1 31 Sight glass replacing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Loosen both screws of the sight glass see fig 81 pos 1 Remove the sight glass mounting plate Disassemble the sight glass inclusive of both gaskets Assemble the new sight glass and all further parts in reverse order of disassembly remember to fit new gaskets Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 81 Loosening the screws of the
81. ig 27 The height of the resistance value must be infinite Loosen the fastening screws see fig 29 pos 1 Remove the earth cable see fig 29 pos 2 Remove the mounting plate see fig 29 pos 3 Dismantle the ionization electrode see fig 29 pos 4 Set the volt ohm multimeter to Resistance measurement Test the resistance of the ionization electrode see fig 30 The resistance must be 0 Q Check the ionization electrode for contamination wear or damage see fig 31 Replace the ionization electrode if required Install a new ionization electrode with a new gasket and secure the mounting plate with the fastening screws Fit the earth cable see fig 29 pos 2 Restore the plug and socket connection Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 29 Replacing the ionization electrode fig 30 Testing the resistance of the ionization electrode X X _ ___ h A fig 31 Checking the ionization electrode Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Buderus 97 reat Actions 8 1 18 Checking the gas control valve cable connections Switch off the power supply of the heating system on the circuit
82. iler activate Is a tank filling pump fitted page 39 page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 35 page 34 Check that the tank filling pump is running Is the tank filling pump running No Check that during hot water mode there is a 120V AC voltage on the tank filling pump Is the tank filling pump being activated No Check the connection board to make sure that there is 120V AC on both contacts L and N of connection PS gray during hot water mode page 37 the connection board Replace the supply have on both contacts L and N of cord of the tank filling connection PS 120V AC during hot pump water operation yoo Check the fuse on the connection board Value 5A See page 84 Replace the fuse on the connection board Is the fuse on the connection board gt okay See page 84 Check the cable loom of the device Is the cable loom okay Replace the cable gt loom Replace the circuit board Is the tank filling pump running No 44 page 83 page 31 Buderus 36 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 36 Check the tank filling pump for soiling or for a defectiv
83. iler does not react to a heat request open 2 Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to O Off Remove the casing Remove the cover from the connection box see fig 50 Use a jumper wire to create a bridging circuit between the two WA contacts see fig 53 pos 3 Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker Set the main switch on the BC10 to 1 On Ifthe boiler switches to heating mode operating code H after some time the cause of the fault must be outside the boiler Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off See page 9 Menu structure of the BC10 basic controller Remove the bridge between the two WA contacts see fig 53 pos 3 Connect the On Off thermostat directly to the two WA contacts of the boiler using a short cable see fig 53 pos 3 Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Set the On Off thermostat to the request position If the boiler switches to heating operation operating code H after some time the fault is caused by the cable between the On Off thermostat and the boiler fig 51 Installing the cover
84. ing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Pull the plug of the hot surface ignitor Loosen the fastening screw of the UBA 3 see fig 21 pos 1 Remove the UBA 3 by pulling it forward as indicated by the arrow see fig 21 pos 2 Set the volt ohm multimeter to Resistance testing N2 DNS L lt fig 21 Dismantling the UBA 3 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 93 rea Actions Test the supply cord of the hot surface ignitor to make sure that there is no short circuit in it and that it is not broken fig 23 fig 22 and fig 110 on page 126 Fit the plug to the hot surface ignitor Re assemble the UBA 3 in reverse order of disassembly Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Fit the casing 8 1 14 Replacing the hot surface ignitor Buderus 94 Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Disconnect the plug and socket connection of the cable of the hot surface ignitor Loosen the fastening screws fig 24 pos 1 Remove the earth cable fig 24 pos 2 Remove the mounting plate fig 24 pos 3
85. ing code HC See page 92 Is the hot surface ignitor activated during the operating code HC page 68 if Yes Check the resistance of the hot surface ignitor See page 93 s the resistance of the Replace the hot surface ignitor hot surface ignit gt 9 okay ae ot See page 94 Yes page 66 page 71 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 65 page 65 Check the hot surface ignitor glows during the operating code C See page 92 i Replace the hot surface ignitor See page 94 hot surface ignitor activated glow during the operating code C j es Check the gas valve is opened during the operating code _ See page 98 Is the gas valve age 69 open pag Yes AA Measure the dynamic inlet gas pressure See page 107 Is the dynamic inlet gas pressure page 70 okay Measure the gas air ratio during the startup phase See page 108 s the gas air ratio correctly Adjust the gas air ratio adjusted See page 108 Check that the correct gas orifice was fitted See page 127 table 5 Was the a Fit the correct gas orifice H correct gas orifice fitted See page 127 table 5 page 67 page 71 Buderus 66 Logamax plus GB14
86. ing page 82 page 82 de val pressure sensor or there is a short circuit operation and no hot water YF F y3 Ag S Short circuit in connection to pressure J i sensor Yr A y3 HE S The return sensor has measured a VKS yes Be vas temperature higher than 221 F 105 C Yr y3 un The return sensor is shorted VKS yes Ju Jeti yp J y3 4i The return sensor contact is interrupted VKS yes e fa E 240 The UBA 3 is defective BKS no No heating page 80 page 80 operation and any digit no hot water or letter y yaqa S KIM or UBA 3 is defective VKS yes No heating page 80 page 80 operation and any digit to no hot water or letter re cB yi 7 The heating system pressure is too low SC page 78 page 80 A H The heating system pressure is too low SC page 78 page 80 rE Reset is carried out After pressing the UC 2 Reset button this code is displayed for 5 seconds table 2 Display indications on the BC10 basic controller 1 only visible using the service tool 2 is being carried out 6 2 LED on the UBA 3 In addition to the display indication on the BC10 basic controller there is a red LED on the UBA 3 The meaning of this LED is explained in see table 3 LED Meaning Off Flashing slowly 1 Hz Normal operation There is a boiler fault locking fault Flashing fast 10 seconds During startup after replacing the KIM or the UBA 3 On table 3 LED on t
87. ions 98 8 1 20 Checking the gas control valve 2 Regulations and guidelines 7 cable connection between gas control valve and UBA 3 installation base 99 8 1 21 Ohming out the gas control valve 100 3 Product description 8 8 1 22 Replacing the gas control valve 101 8 1 23 Checking the control unit connections to the boiler 104 4 Operation 9 8 1 24 Bleed the gas supply pipe 106 4 1 Operating the BC10 basic controller 9 8 1 25 Haaa E gas pressure mm A anera i 8 1 26 Measure and adjust the gas air ratio 108 2 Menu iructure or the BC10pasic coniroller 3 8 1 27 Measuring the carbon monoxide content CO 109 TA Flue gas test menu 19 8 1 28 Transformer replacing 109 4 2 2 Service Mode menu m 8 1 29 Automatic air purging system replacing 111 4 2 3 Manual Operation menu 12 8 1 30 Burner replacing 113 42 4 Adjustments menu lg 8 1 31 Sight glass replacing 115 8 1 32 Condensate trap replacing 116 8 1 33 Pressure sensor replacing 116 5 Function 14 8 1 34 Heat exchanger replacing 117 5 1 General 14 8 1 35 UBA 3 replacing 125 5 2 Structure diagram Function 15 9 Appendix 126 6 Symptoms 20 6 1 1 General 20 6 1 3 Display codes on the display of the BC10 10 Spare parts 128 basic controller 20 6 2 LED on the UBA 3 26 7 Diagnosis 27 7 1 Faults without a fault code 27 7 2 Faults with a fault code 46 8 Actions 84 8 1 Testing measuring adjusting and replacing various components 84 8 1 1 Checking the UBA 3 fuse replace if necessary 84 8 1 2
88. is switched off during the safety test Fully switch off the heat request and check that the blower is still operational after 1 minute Is the blower No still operational Locking boiler fault code Yes page 83 page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 55 i 4 amp 1 The blower is switched off during the safety Locking boiler fault code test Check that both the plug and socket connections of the blower are correctly fitted See page 88 fig 12 Are the plug and socket connections fitted correctly No Reconnect the plug and socket connection of the blower See page 88 fig 12 Yes y Check blower activation 120V AC See page 86 Is the activation okay Yes page 57 y Check the tacho wire of the blower See page 88 Tacho wire okay Replace the tacho wire See page 88 e Attempt to rectify the fault by temporarily replacing the blower See page 88 Yes Has the malfunction been repaired gt page 31 page 83 Buderus 56 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 56 Check the supply cord of the blower 120V AC See page 87 Is
89. mal point has disappeared 4 2 4 Adjustments menu Buderus 12 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications ADJUSTMENTS MENU q3 EN Current supply temperature 0 199 F 18 93 C See page 20 Open the Adjustments menu yes Operation KE Open programming mode Simultaneously Boiler load and pump post purge time settings confirmed press and hold the Chimney sweep and Service buttons for more than 2 seconds Vaa L As soon as the display shows L the programming mode is open The first parameter shown on the display is used to set the boiler load for heating operation Adjust boiler load no yes lower yes higher Adjust the boiler load with the Reset button Adjust the boiler load with the Chimney sweep button ee E Les L__ is the maximum heating load setting of 100 Factory default setting L 100 T A The setting L30 means that the heating load is lowered to 30 S Press the Service button o As soon as the display shows F the second parameter can be set This parameter indicates the pump post purge time yes lower Adjust pump pos yes higher purge ti
90. me O Adjust the pump post purge time with Adjust the pump post purge time with the the Reset button Chimney sweep button i i F id FOO is the minimum pump post purge time setting in minutes F60 is the maximum pump post purge time setting in minutes F1d is the maximum pump post purge time setting for one day Factory default setting F 5 5 minutes Have at min passed without a button being pressed or was the power suppl interrupted yes Press the Service button Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Buderus 13 cea Function 5 Function 5 1 General To clarify the operation of the Logamax plus GB142 24 30 45 60 thermal power gas boilers under normal operating conditions the work steps are schematically represented in the structure diagrams on the following pages of this chapter Buderus 14 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Function ea 5 2 Structure diagram Function C aa up y Connect the heating system to the power grid by turning the circuit breaker ON y Turn the main switch on the BC10 to position 1 ON see page 8 fig 2 y The LED of the UBA 3 lights for 1 second This means that the UBA 3 is reading the KIM If a new KIM or
91. n color lilac pos 10 main connection 120V 60Hz connection color white pos 11 Fuse holder Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 85 rea Actions 8 1 3 Buderus 86 Checking the fan unit 120 VAC control NOTE The fan unit can be controlled using the RC control device relay test function Further instructions for the RC control device are in the Installation and Maintenance Instructions WARNING Avoid damage do not push the measuring pin of the volt ohm multimeter too deeply into the socket Remove the casing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Disconnect the 120V AC plug of the fan unit Test the voltage with the volt ohm multimeter set it to VAC Minimum value 250V AC Connect the volt ohm multimeter to the outer two plug contacts blue and brown see fig 8 Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Start up the boiler in accordance with the Flue gas test menu See page 10 Flue gas test menu Check that while the operating code OL_ is displayed 120V AC is available on the outer two contacts blue and brown of the plug see fig 8 Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to
92. ne twice and test it diagonally twice Restore the plug and socket connection if the cables are OK Install the UBA 3 Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 11 Checking the hot surface ignitor control Buderus 92 NOTICE The hot surface ignitor can be controlled using the RC control device relay test function Further instructions for the RC control device are in the installation and maintenance instructions Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Disconnect the plug and socket connection of the hot surface ignitor Set the measuring device to 120V AC Connect the measuring device to the plug on the cable harness Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker fig 18 Dismantling the UBA 3 81 pole connector pamm G Bo Pin 1 rip inh inhi hihihi Pin 16 16 pole connector Pin 81 fig 19 UBA 3 installation base Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Set the main s
93. ntake for the fan pos 6 Flue measuring points pos 14 Fan pos 7 Parallel flue pos 15 Condensate trap pos 8 Burner pos 16 External Connection Board under the cover pos 17 Pressure sensor 90 i a 6 RARE x JZ ON NN l 1 1211 10 9 8 7 fig 2 Basic Controller Logamatic BC10 pos 1 Main switch pos 7 Under the cover a RC system controller can be installed pos 2 DHW temperature knob pos 8 LED Burner Operation pos 3 LED DHW status pos 9 Service Tool connector pos 4 Display pos 10 Service button pos 5 Space heating water temperature knob pos 11 Chimney sweep button pos 6 LED Heating system status pos 12 Reset button 1 ECO mode means that the temperature inside the hot water tank is 140 F 60 C with a hysteresis AT of 18 F instead of 9 F Buderus 8 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Operation KE 4 Operation 4 1 Operating the BC10 basic controller 4 1 1 General The boiler is equipped with an control unit the basic controller BC10 The BC10 allows you to operate the boiler Briefly press on the control panel cover to open it see fig 3 The basic controller BC10 see fig 2 is located on the left side in the drawer On the right side of the drawer there s space for a RC control unit fig 3 Opening the control panel 4 1 2 Switching the heating system
94. ode plugs Loosen the fastening screws see fig 96 pos 1 Pull the earth cable from the hot surface ignitor see fig 96 KO pos 2 Xx 7 Dismantle the mounting plate see fig 96 pos 3 fig 96 Replacing the hot surface ignitor Buderus 120 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Remove both the hot surface ignitor and the ionization elec trode by pulling them loose see fig 97 pos 1 fig 97 Removing the hot surface ignitor and the ionization electrode Dismantle the condensate trap connection to the condensate collector see fig 98 pos 1 fig 98 Dismantling the condensate trap connection to the condensate collector Open the four latches of the condensate collector see fig 99 pos 1 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 121 rea Actions Remove the condensate collector see fig 100 pos 1 Loosening the backflow connection between the primary pump and heat exchanger see fig 101 pos 1 Dismantle the tension spring between the supply pipe and the heat exchanger see fig 101 pos 2 fig 101 Loosening the backflow connection and dismantling the tension spring
95. of the connection box Buderus 104 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Ifthe boiler does not switch to heating mode after some time the fault is caused by the On Off thermostat Correct the cause of the fault Fit the cover on the connection box see fig 51 Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On If a modulating control unit is used and the boiler does not react to a heat request Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Remove the cover from the connection box see fig 52 Connect the modulating control directly to the two RCxx contacts of the boiler using a short cable see fig 53 pos 1 Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker Set the main switch on the BC10 to 1 On Set the modulating control to the request position If the boiler switches to heating mode operating code H_ after some time the fault is caused by the cable between the modulating control and the boiler Ifthe boiler does not switch to heating mode after some time the fault is caused by the modulating control Correct the cause of the fault 3 4 5 6 fig
96. on between the blower and the burner the burner the heat exchanger see page 117 the flue gas conduit Are the above mentioned components clean and free from damage Measure the inlet gas pressure flow pressure See page 107 Is the inlet gas pressure okay page 40 Ye Clean the primary circulation pump inside Clean and or replace the corresponding components If the required inlet gas pressure is not available you should consult the relevant gas utility company Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 39 Check the gas air ratio See page 108 No Adjust the gas air ratio See page 108 Is the gas air ratio okay Check the hot water tank for scale build up Is the hot water tank scaled up Decalcify the tank c Check to see if any other external part of the heating circuit is a possible cause of the fault Are such items detected Yes Place the affected components out of service page 83 page 31 Buderus 40 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications hot water available no heating operation On devices with external hot water tanks Check that the RC
97. or personal injury or property damage CAUTION Risk of electric shock Indicates presence of hazards due to electric shock NOTICE Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage L gt gt gt Buderus 1 3 The following instructions must be observed The boiler must only be used for its designated purpose observing the Installation Instructions Only use the boiler in the combinations and with the accesso ries and spares listed Other combinations accessories and consumables must only be used if they are specifically designed for the intended application and do not affect the system performance and the safety requirements Maintenance and repairs must only be carried out by autho rized professionals You must report the installation of a condensing gas boiler to the relevant gas utility company and have it approved You are only allowed to operate the condensing gas boiler with the combustion air flue gas system that has been specif ically designed and approved for this type of boiler Please note that local permission for the flue system and the condensate water connection to the public sewer system may be required You must also observe the local building regulations stipulating the installation rules the local building regulations concerning the
98. pen the servicing cocks e Is the System pressure measured on the boiler No Fill and bleed the heating system in the heating system at least 14 5 psi 1 bar Is at least one thermostatic valve open Open a thermostatic valve f Check the supply and safety sensors page 89 Replace the supply and or safety sensors Are the supply and safety page 91 sensors okay Yes y Check the primary circulation pump Is the primary circulation Replace the primary pump okay circulation pump g Yes page 83 page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 49 er es Z EE The primary circulation pump does not Lakin balaren eia generate a pressure difference Check the primary circulation pump for mechanical jamming Try to undo the jam or replace the primary S the primary circulation pump circulation pump jammed No Does the primary circulation ump run during L ea No page 51 Check the primary circulation pump activation Is the activation okay Replace the primary circulation pump K gt Check the primary circulation pump check that the supply cord is not broken
99. peration 1 5 Tools materials and additional equipment For the installation and maintenance of the boiler you will need the standard tools for central heating gas and water fitting In addition a handtruck with a fastening belt is very useful Safety and general instructions fa 1 6 Inspection We advise you to offer your customer an annual inspection and maintenance contract If inspection reveals that maintenance work is necessary you can carry this out as required in the Instal lation instruction of the boiler Installation CAUTION Check and clean the heating system at least once a year Carry out a maintenance overhaul if neces sary Immediately repair defects to avoid damage to the heating system Periodically examine the venting systems and cleaning of the screens in the vent terminal Also periodically inspect the low water cutoffs including flushing of float types And periodically inspect the burner flames See page 8 fig 1 pos 10 Check the neutralization unit if present Check to see if there are no obstructions to the flow combus tion and ventilation air For direct vent boilers proper reassembly and resealing of the vent air intake system is required Maintenance Cleaning the heat exchanger the burner and the condensate trap see installation instructions Maintenance Checking the ionization signal par 8 1 15 page 95 Checking and adjusting the gas air ratio par 8 1
100. power supply the blower see page 86 the primary circulation pump see page 126 Check the fuse on the rear of the UBA 3 again using a volt ohm multimeter See page 84 Replace the fuse again See page 84 Is the fuse okay Turn the operating switch on the BC10 to position 1 ON See page 9 par 4 2 Is there any indication on the BC10 display Yes page 32 V Turn the operating switch to 0 OFF y Connect the external primary circulation pump y Turn the operating switch on the BC 10 to position 1 ON See page 9 par 4 2 Replace the external primary circulation pump Replace the fuse again See page 84 Is there any indication on the BC10 display page 31 Buderus 30 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 30 20 y Turn the operating switch on the BC10 to position 0 OFF See page 9 par 4 2 y Connect the blower See page 86 y Turn the operating switch on the BC10 to position 1 ON See page 9 par 4 2 Replace the blower See page 88 i Replace the fuse again See page 84 Is there any indication on the BC10 display page 31 Q Fit the casing y Turn the operating switch on t
101. r ass y 1 8 1 22 Replacing the gas control valve DANGER Work on gas pipes and fittings must only be carried out by a registered service provider Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Close the gas shut off valve see fig 41 pos 1 Remove the cable plug from the gas control valve see fig 42 pos 1 fig 40 Testing the resistance on the gas burner ass y 2 fig 41 Gas shut off valve closed 1 gas shut off valve open 2 fig 42 Removing the gas control valve plug Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 101 rea Actions Remove both cable plugs from the fan unit see fig 43 pos 1 Loosen the union nut of the gas control valve see fig 44 pos 1 Loosen both sets of retaining clips fig 44 pos 2 and fig 45 pos 1 of the burner cover and remove the burner cover with the fan unit and the gas burner fitting Buderus fig 44 Loosening the union nut fig 45 Loosening the retaining clips 102 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Loosen th
102. ree screws on the gas control valve see fig 46 pos 1 Remove the gas control valve see fig 47 Remove the gas orifice from the gas control valve see fig 48 pos 1 Install the gas orifice in the new gas control valve Mount the new gas control valve on the fan unit Assemble the burner cover with the fan unit and the gas control valve Close both retaining clips Tighten the union nut of the gas pipe on the gas control valve Make sure that you have inserted the gasket Connect both cable plugs to the fan unit Connect the cable plug to the gas control valve Open the gas shut off valve see fig 49 pos 2 Switch on the power supply of the heating system on the circuit breaker fig 48 Dismantling the gas orifice Set the main switch on the BC10 to 1 On Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 103 reat Actions NOTICE Carry out all start up activities according to the Installation and Servicing Instructions and complete the start up report You must also check all gaskets and seals affected by the replace ment activities during the tightness test carried out in operating conditions Fit the casing 8 1 23 Checking the control unit connections to the boiler If an On Off thermostat is used and the bo
103. s in the remaining section of the gas supply pipe Did you find a blockage No Check for blockages in the remaining section of the gas supply pipe Did you find a blockage No Deal with blockage gt Deal with blockage Check whether the overall gas conduit network is of sufficient capacity Is the overall gas conduit network of sufficient capacity Reinforce the gas conduit network m Consult the utility company page 71 Buderus 70 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 67 Check the plug and socket connection between the ionization electrode and cable loom See page 95 Is the plug and socket connection okay Yes Correctly insert the plug into its socket Measure the resistance in the wires between the ionization electrode plug and the UBA 3 mounting base See page 95 Replace the cable loom or the affected part iri Is the wiring okay thereof Yes y Check the ionization electrode and replace it l if necessary See page 96 Y page 71 pages 65 to 71 Press the Reset button Has a new fault code occurred Remedy the fault using the structure diagram that corresponds with the fault code c Has a n
104. s measured a r MaE temperature higher than 203 F 95 C Locking boiler faulticods OY Iid H4 The return sensor has measured a 5 Ayo temperature higher than 203 F 95 C Leding WEL chee coe y Wait approx 60 seconds until the boiler automatically becomes operational again y No fault message 4 Yes Are all servicing cocks open Open the servicing cocks Is the System pressure measured on the boiler in the heating system at least No Fill and bleed the heating system 14 5 psi 1 bar Is at least one thermostatic valve open Open a thermostatic valve Check the supply safety and return sensors page 89 Are the supply and safety sensors okay Replace the supply safety and or return sensors page 91 Yes y Check the primary circulation pump Is the primary circulation pump okay Replace the primary circulation pump Yes page 83 page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 47 iL ell to the unused contacts 78 and 50 The UBA 3 does not register any connections Locking boiler fault code Check the contact between the UBA 3 and the UBA 3 mounting base See page 125 fig 109
105. sight glass Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 115 rea Actions 8 1 32 Condensate trap replacing Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Pull the condensate trap from the condensate plate see fig 82 Remove the condensate trap Fill the new condensate trap with water before re installing it Re assemble the new condensate trap in reverse order of disassembly Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 33 Pressure sensor replacing Buderus 116 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Close the maintenance shut off valves and drain the Logamax plus GB142 Remove the cable plug from the pressure sensor Loosen the pressure sensor by removing the securing clip see fig 84 Assemble the new pressure sensor and the plug in reverse order of disassembly NOTICE Fill and purge the Logamax plus GB142 as required See installation and maintenance instructions Logamax plus GB142 24 30 45 60 Fit the casing Switch on the power
106. supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On fig 84 Loosening the pressure sensor 8 1 34 Heat exchanger replacing Remove both cable plugs from the fan unit see fig 87 pos 1 Switch off the power supply of the heating system on the circuit breaker Close the maintenance shut off valves and drain the Logamax plus GB142 see 116 fig 83 Set the main switch on the BC10 to 0 Off Remove the casing Close the gas shut off valve see fig 85 pos 1 Remove the cable plug from the gas control valve see fig 86 pos 1 fig 85 Gas shut off valve closed 1 gas shut off valve open 2 fig 86 Replacing the gas control valve e g HONEYWELL gas control valve fig 87 Disconnecting the cable plug from the fan unit Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 117 rea Actions Loosen the union nut of the gas control valve see fig 88 pos 1 Pull both retaining clips see fig 89 pos 1 on the burner cover to open them and remove the burner cover with the fan unit and the gas control valve Remove the burner gasket see fig 90 pos 1 Remove the gas air distributor plate see fig 90 pos 2 Remove the orifice plate only applies to Logamax pl
107. t water tank higher than the hot water temperature setting in the BC10 or RC control device The Hot water mode LED goes off page 18 no 7 page 19 Is the supply temperature 82 8 K higher than the hot water temperature setting or higher than 200 F 93 C mn HY The gas valve is closed the burner is shut down t The Burner LED goes off i The blower stops Is the supply temperature lower than the preset yes hot water temperature plus 63 F 35 K Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 17 page 18 4 y mM OA Y The gas valve is closed the burner is shut down y The Burner LED goes off Yy Start the pump over run time through the hot water tank at least 30 seconds max 1 minute if there is a heat request Air side after purging by blower for 30 seconds y The blower stops Y OH Y The primary circulation pump stops The tank filling pump is stopped Is there a heat request from the room or outdoor temperature dependent regulator page 19 Buderus 18 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Function A pag
108. tact has energized Measure the cable loom between the UBA 3 and the terminal strip See page 126 fig 110 Is the cable loom okay Yes Replace the cable loom or the affected part thereof y Check the contact between the UBA 3 and the UBA 3 mounting base Is the contact okay Yes page 83 Restore the contact page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 79 page 79 Check to see if a bridge wire is present See page 106 fig 54 pos 5 EV Is there a bridge wire Yes Measure the cable loom between the UBA 3 and the terminal strip See page 126 fig 110 Is the cable loom okay Yes Check the contact between the UBA 3 and the UBA 3 mounting base No Is the contact okay Yes page 83 Restore the bridge on the terminal strip again see page 106 fig 54 Replace the cable loom or the affected part thereof Restore the contact Y page 31 Press the Reset button fault message YH or GH or GP or GU or E page 83 Buderus page 31 80 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications PALF S IET The gas
109. tch on the BC10 to 1 On 8 1 6 Replacing the fan unit NOTE Follow the installation instructions for 120V fan units Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to O Off Remove the casing Remove both cable plugs from the fan unit see fig 12 pos 1 fig 12 Disconnect the cable plug from the fan unit Buderus 88 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 8 1 7 Remove the air suction tube see fig 13 pos 1 Remove the fan unit fastening screw see fig 13 pos 2 Remove the fan unit by swinging it to the right see fig 13 pos 3 Install the new fan unit Install the fastening screw air suction tube and both plugs Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On Checking the supply return safety hot water temper ature sensors Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing NOTICE The current temperature measured by the supply return and safety sensors can be read out from the RC control device For further instructions see installation and main tenance instructions of the RC control device WARNING Avoid damage do not push the measuring pin
110. ter conversion also see the chapter Conversion to another type of gas supply Information on gas type instruction plate Set to gas category G 31 3P Table 6 Factory setting of gas burner fitting Boiler Type of gas Gas orifice Venturi capacity supply diameter in article inch mm number 24 kW _ Natural gas H 0 174 4 45 423 072A LPG P 0 131 3 35 423 072A 30 kW Natural gas H 0 174 4 45 423 072A LPG P 0 131 3 35 423 072A 45 kW _ Natural gas H 0 213 5 40 423 170A LPG P 0 158 4 05 423 170A 60 kW _ Natural gas H 0 293 7 50 423 173A LPG P 0 213 5 40 423 173A Table 5 Gas orifice diameter The diameter of the gas orifice islocated on the gas orifice The article number of the Venturi is located on both clamps of the Venturi see fig 111 pos 1 and 2 sa ly 2 fig 111 Venturi article number Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Buderus 127 10 Spare parts 10 Spare parts Below is a list of the spare parts for this boiler Look up the position number in the exploded view drawing on the next two pages for the illustration Spare parts may be ordered from Buderus
111. tion and no hot water TE F S T3 JE S An ionization current was measured after VKS yes No heating page 72 page 72 J the burner switch off operation and no hot water izati i i i BKS no BL 229 Het fails during the operating page 73 page 73 yo Se Bic j The hot surface ignitor activates too long VKS yes No heating page 78 page 78 JE P JE 4 operation and no hot water y F y3 Ji The power supply was interrupted and VKS yes No heating page 78 page 78 a Fo oa switched on again after a fault message operation and no hot water Sette on ES z a A i r The UBA 3 is defective VKS yes No heating page 78 page 78 a cbt operation and no hot water yi yi n VKS es JA sao S The UBA 3 is defective y AY The external switch contact is activated BC page 79 page 79 1 AAA Display test while starting up This code Uc oe is displayed for a maximum of 1 second y y3 35 KIM or UBA 3 is defective VKS yes No heating page 80 page 80 operation and no hot water KIM or UBA 3 is defective VKS yes No heating page 80 page 80 operation and no hot water The UBA 3 is defective VKS yes No heating operation and no hot water The UBA 3 is defective VKS yes No heating operation and no hot water DQ 0 0 0 DQ 0 0 0 0 gL y The gas valve coil or the wiring to the gas VKS yes No he
112. u should consult your gas utility company page 71 page 65 Measure the resistance in the wires between the switch of the hot surface ignitor and the UBA 3 See page 99 Is the wiring okay Replace the cable loom or the affected part thereof page 83 Buderus page 71 68 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 66 Check the plug and socket connection of the gas valve See page 99 Is the plug and socket connection okay Yes Reconnect the plug and socket connection at the gas valve See page 99 Check the gas valve during the operating code to make sure it receives power then See page 98 Yes Replace the gas valve i 9 Does the gas valve receive power See page 101 No y Measure the resistance in the wires between the gas valve plug and the UBA 3 mounting base Is the wiring okay Replace the cable loom or the affected part thereof Yes y page 83 page 71 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 69 Check whether the gas stop tap is open See page 101 No Is the gas stop tap open Yes Open the gas stop tap See page 101 Check for blockage
113. ug from the gas control valve see fig 74 pos 1 Remove both cable plugs from the fan unit see fig 75 pos 1 fig 73 Gas shut off valve closed 1 gas shut off valve open 2 fig 74 Replacing the gas control valve e g HONEYWELL gas control valve fig 75 Disconnecting the cable plug from the fan unit Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 113 rea Actions Loosen the union nut of the gas control valve see fig 76 pos 1 Loosen both sets of retaining clips fig 76 pos 2 and fig 77 pos 1 of the burner cover and remove the burner cover with the fan unit and the gas burner fitting Remove the burner gasket see fig 78 pos 1 Remove the gas air distributor plate see fig 78 pos 2 Remove the orifice plate only applies to Logamax plus GB142 24 30 and GB142 60 see fig 78 pos 3 Note that the orifice plate of the GB142 60 has a different shape Remove the burner see fig 78 pos 4 Buderus ey E Siafi AY E AN lt l fig 76 Loosening the gas control valve eee fig 77 Loosening the retaining clips mh fig 78 Removing the burner 114 Logamax plus GB142 24 30 45 60 We reserve the rig
114. ulation pump Is there a voltage Check the connection board to make sure that there is 120V AC on both contacts L and N of connection PS green during heating mode Replace the supply cord of the tank filling pump Is Yes there a voltage Check the cable loom of the device l Is the cable loom okay Replace the cable loom gt l Yes Replace the connection board Is the DHW circulation Yes pump running No page 83 page 31 Buderus 42 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 36 Check the DHW circulation pump for soiling or for a defective pump impeller wheel Is the DHW circulation pump soiled or is the pump impeller wheel defective Clean or replace or the DHW circulation pump The fault is caused by the system and not by the boiler page 31 page 36 Check that the pump impeller wheel is not blocked Is the pump impeller wheel blocked As described for the primary circulation pump the DHW circulation pump must be turned in the direction of rotation of the pump using a screwdriver page 31 page 43 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 43 page 36
115. ure safe operation Massachusetts Installations Only For direct vent boilers mechanical vent heating boilers or domestic hot water equipment where the bottom of the vent terminal and the intake is installed below four feet above grade the following requirements must be satisfied 1 If there is not one already present a carbon monoxide detector and alarm shall be placed in a living area outside the bedrooms The carbon monoxide detector and alarm shall comply with NFPA 720 2005 Edition A carbon Monoxide detector and alarm shall be located in the room that houses the boiler or equipment and shall a Be powered by in series on the same electrical circuit as the boiler or equipment b Have battery back up power c Meet ANSI UL 2034 Standards and comply with NFPA 720 2005 Edition d Have been approved and listed by a Nationally Recognized Testing Lab A product approved vent terminal must be used and if applicable a Product approved air intake must be used Installation shall be in strict compliance with the manufacturer s instructions A copy of the installation 220 F 105 C 44 psi 3 bar Regulations and guidelines 2 A metal or plastic identification plate shall be mounted at the exterior of the building four feet directly above the location of vent terminal The plate shall be of sufficient size to be easily read from a distance of eight feet away and read Gas Vent Directly Below b
116. us GB142 24 30 and GB142 60 see fig 90 pos 3 Note that the orifice plate of the GB142 60 has a different shape Remove the burner see fig 90 pos 4 Buderus fig 88 Loosening the gas control valve fig 89 Loosening the retaining clips _h fig 90 Removing the burner 118 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Disconnect the plug and socket connections of the supply return and safety sensors see fig 91 92 and 93 Actions a K NS C Za KR p fig 91 Loosening the plug and socket connections of the supply sensor fig 92 Disconnect the plug and socket connection of the return sensor L J O o id 4 a No ON A I ot z e SN fig 93 Disconnect the plug and socket connection of the safety sensor Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 119 rea Actions Disassemble the supply and return sensors see fig 94 pos 1 and 2 WARNING To prevent mix ups the supply sensor is marked by a red sleeve on the side of the cable harness e Dismantle the safety sensor see fig 95 pos 1 Disconnect the hot surface ignitor and ionization electr
117. valve coil or the wiring othe 925 king boiler fait code tiL fat t amp MEES The UBA 3 is defective Locking boiler fault code Press the Reset button Y No New fault message H Yes y Check the plug and socket connection of the gas valve See page 98 par 8 1 18 j S the plug and socket Restore the plug and socket connection connection okay See page 98 par 8 1 18 Yes Measure the wire between the gas valve and the UBA 3 See page 99 fig 8 1 20 Replace the cable loom or the affected part m i Is the wire okay thereof Yes y Measure the resistance of the two gas valve coils See page 101 par 8 1 22 i Replace the gas valve See page 101 page 31 Is the resistance correct Buderus 81 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications Short circuit in connection to pressure sensor Locking boiler fault code ro E PE The UBA 3 has no connection to the pressure O ot 7 H sensor or there is a short circuit Ledning bolariauii cocte ro t jeng Check the plug and socket connection of the pressure sensor See page 8 fig 1 pos 17 Is the plug and socket i NA Restore the plug and socket connection connection okay
118. witch on the BC10 to 1 On Start up the boiler in accordance with the Flue gas test menu See page 10 Flue gas test menu Test that during the ignition phase while the operating code OL is being displayed 120V AC is measured Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the measuring device Assemble the plug and socket connection of the hot surface ignitor Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 12 Checking the hot surface ignitor resistance Switch off the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 0 Off Remove the casing Disconnect the plug and socket connection of the cable of the hot surface ignitor Test the resistance of the hot surface ignitor on the plug A resistance value between 50 300 Q means that the hot surface ignitor is OK see fig 20 Remove the measuring device Reconnect the cable plug if the hot surface ignitor is OK Fit the casing Switch on the power supply of the heating system on the circuit breaker Set the main switch on the BC10 to 1 On 8 1 13 Checking the hot surface ignitor supply cord WARNING Avoid damage do not push the measuring pin of the volt ohm multimeter too deeply into the socket Remove the cas
119. y at the mains power switch Deal with any problem in the electrical system Is there a voltage at the mains power switch y yes Measure the resistance of the 120V AC supply cord no Replace the cable loom or the affected Is the 120V AC cord okay part thereof yes y Check the fuse on the rear of the UBA 3 using a volt ohm multimeter See page 84 Y Is the fuse okay yes no page 83 y Replace the fuse See page 84 Y yes s there any indication on the BC10 display f no Turn the operating switch on the BC10 to 8 position 0 OFF See page 9 par 4 2 page 30 page 31 Buderus 28 Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications page 28 Check that there is between 7 8 and 15 2 VDC on both contacts 1 and 2 of the BC10 See page 126 Is there a voltage No Y Replace the BC10 See the fitting instructions of the BC10 Measure the relevant part of the cable loom See page 126 Is the cable loom okay page 83 Replace the cable loom or the affected part thereof page 31 Buderus Logamax plus GB142 24 30 45 60 We reserve the right to make any changes due to technical modifications 29 page 28 Disconnect the following boiler components from the electrical

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