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Installation instructions - Columbia Pipe & Supply Co.

1. Date Date Date Date Date Date Date Inspection activities see paragraph 1 Check the general condition of the heating system 2 Carry out a visual inspection and function test of the heating system 3 Checking the gas and water bearing system components for Operational tightness 9 9 on page 54 Visible corrosion 11 2 on page 63 Signs of wear Fill the condensate trap 9 3 on page 48 Measure the ionization current 9 12 on page 56 pA pA HA HA pA pA pA Measure the gas inlet pressure 9 7 on page 50 working pressure inch W C inch W C inch W C inch W C inch W C inch W C inch W C 6 Check and adjust the gas air ratio 9 8 on page 52 inch W C inch W C inch W C inch W C inch W C inch W C linch W C 7 Carry out a leakage test in 9 9 on page 54 operating conditions 8 Measure the flue gases CO 9 10 on page 55 ppm ppm ppm ppm ppm ppm ppm emissions 9 Fill the heating system Pre pressure of expansion psi psi psi psi psi psi psi vessel also see installation instructions for expansion vessel Filling pressure 9 2 on page 47 psi psi psi psi psi psi psi 10 Check th
2. Service Mode menu Step 1 20 Shows currently measured space heating water temperature in F Also see paragraph 13 3 Step 2 To activate service mode 1st step Press and hold the button for more than 2 but not longer than 5 seconds Step 3 20 The non flashing dot is shown in the right hand bottom corner of the display shows the boiler is now in Flue gas test mode Step 4 To activate service mode 2nd step Simultaneously press and hold the buttons for more than 2 seconds Step5 j Display shows the maximum capacity setting during heating mode in 96 Also see paragraph 13 4 In this case L _ _ 100 96 Service mode has been activated You can now adjust the boiler performance to partial load i e to check the gas air ratio or the ionization current Step 6 Press and hold the button until the display shows for boilers at sea level 25 with a 80 kW boiler or 20 with a 100 kW boiler for boilers at high altitude L 35 with a 80 kW boiler or L 30 with a 100 kW boiler Step 7 For boilers at sea level 0 4000 ft L25 Display setting with a 80 kW boiler and L 20 with a 100 kW boiler For boilers at high altitude 4000 10 000 ft L 36 Display setting with a 80 kW boiler and L 30 with a 100 kW boiler Minimum capacity setting during heating mode in 96 Also see paragraph 1
3. Start up activities Page Measurement results Remarks 1 Check for gas leaks 46 2 Fill the heating system 47 Pre pressure expansion vessel refer to the installation instructions for the expansion vessel psi Heating system filling pressure psi 3 Fill the condensate trap with water 48 4 Write down the gas characteristics Heat input btu ft3 Heat output _ s tu f8 5 Bleed the gas supply valve 49 6 Check the air flue gas connection 49 m 7 Checking the appliance configuration 50 8 Measure the gas inlet pressure working pressure 50 inch W C 9 Check and adjust the gas air ratio 52 inch W C 10 Carry out a leakage test in operating conditions 54 11 Measure the flue gases CO emissions 55 ppm 12 Carry out a function test 56 Measure the ionization current 56 uA 12 Measure the pH value Fill in the record book 13 Boiler settings 58 14 Final activities 60 Close the boiler door and the control panel Hand over Confirming proper start up Company stamp signature date Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 85 KE Reports 15 2 Inspection report Indicate the inspection activities that have been carried out enter the values measured and enter your signature and the date
4. c eee eee 8 Regulations and guidelines 9 3 1 Massachusetts Installations Only 9 Dimensions and connections 11 4 1 Without pump group 11 4 2 With pump group aa 12 Packaging and transportation 13 5 1 Scope of delivery 13 5 2 Transporting the boiler 13 Installation eee eee 15 6 1 Requirements for the installation room 15 6 2 Installing the boiler 15 6 3 Water and Gas connection 17 6 4 Connecting the condensate drain pipe 21 6 5 Combustion Air and Ventilation Openings 22 6 6 Flue gas adapter 24 6 7 Installation of the Exhaust and Air Intake SVSIGTT ix eate AA AA 24 Electrical connections 30 7 1 External connection board connections 30 7 2 Installing function modules accessories 33 7 3 Electrical wiring diagram 37 Operation ENNA 9 bee Weekes 39 8 1 BC10 basic controller 39 8 2 BC10 operating instructions 41 Buderus 10 11 12 Start up procedure aaa 45 9 1 Check for gas leaks 46 9 2 Fill the heating system 47 9 3 Fill the condensate trap with water 48 9 4 Bleed the gas supply valve 49 9 5 Check the air flue gas connection 49 9 6 Checking the appliance confi
5. Fig 14 Installing the condensate trap Fig 15 Installing the condensate trap hose 20 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 6 4 Connecting the condensate drain pipe NOTICE The condensate must be drained from the boiler in accordance with local state or federal rules and regulations NOTICE Use materials approved by the authority having jurisdiction In the absence of such authority PVC and CPVC pipe must comply with ASTM D1785 F441 or D2665 Cement and primer must comply with ASTM D2564 or F493 For Canada use ULC certified PVC or CPVC pipe fittings and cement Install the condensate drain pipe taking the following into account An air gap of at least 1 2 54 cm must be maintained between the boiler condensate trap hose and the condensate pipework see fig 16 and fig 17 f the condensate outlet of the boiler is lower than the drain a condensate pump must be used The condensate produced by the boiler has a pH value between 3 and 4 Install a neutralization unit if required by the local code 6 4 1 Connecting the expansion vessel in a single boiler system CAUTION Damage to the installation due to faulty pressure relief valve The expansion vessel must be of sufficient capacity Connect the expansion tank to the boiler return If a check valve is available connect the expansion
6. Table 19 BC10 Display codes 1 Only visible on the Service Tool or a specific RC controller Buderus 80 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 14 Technical specifications Technical specifications EIN 14 1 Technical specifications of GB162 boilers at sea level 0 4 000 ft General specifications unit GB162 80 NG GB162 80 LP GB162 100 NG GB162 100 LP Gas category Natural gas Propane Natural gas Propane Rated thermal load btu h 72 000 290 000 62 000 270 000 72 000 333 000 62 000 315 000 Rated heating capacity btu h heating curve 176 140 F 80 60 C 64 100 255 200 55 200 237 600 64 100 293 000 55 200 277 200 Rated heating capacity btu h heating curve 122 86 F 50 30 C 71 300 281 300 61 400 261 900 71 300 326 300 61 400 308 700 Boiler efficiency at max capacity heating curve 176 140 F 80 60 C 88 88 Boiler efficiency at max capacity 96 heating curve 122 86 F 50 30 C 97 98 CSA Output btu h 261 000 243 000 295 000 279 000 De ration altitudes 2 000 4 000 ft 1 000 ft 2 3 2 2 2 1 2 0 AFUE at 80 180 F 27 82 C 93 8 93 9 n a n a BTS 2000 at 80 180 F 27 82 C part load n a n a 96 1 96 1 BTS 2000 at 80 180 F 27 82 C full load n a n a 90 8 90 8 Heating M
7. Checkthe ionization electrode fig 87 and 86 and the glow ignitor for contamination wear or damage DAMAGE TO THE APPLIANCE by damage to the glow ignitor The glow ignitor is made from fragile ceramic material Do not damage the glow ignitor Demand dependent maintenance DAMAGE OF FATAL ACCIDENT from explosive fumes Only carry out work on gas components if you are properly registered DAMAGE TO THE APPLIANCE from leakage Ensure the two nuts securing the sight glas cover plate are tightened with equal torque After completing the above work carry out a tightness test on the gas and flue gas side Replace the ionization electrode and glow ignitor if required fig 88 Insertanew sight glas cover plate gasket when replacing the ionization electrode and or the glow ignitor Buderus Fig 86 Checking the glow ignitor and ionization electrode Fig 87 Checking the ionization electrode Fig 88 Replacing the glow ignitor ionization electrode pos 1 glow ignitor pos 2 ionization electrode pos 3 gasket pos 4 sight glas cover plate pos 5 nut 68 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 12 3 5 Disconnect the condensate trap Disconnect the condensate trap hose fig 89 pos 3 and the rubber sleeve fig 89
8. Fig 72 BC10 basic controller Fig 73 Closing the gas valve Fig 74 Draining the heating system example Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 61 at Inspection 11 Inspection Offer your customer an annual inspection and maintenance contract The activities to be included in an annual inspec tion and maintenance contract can be found in the inspec tion and service reports see pages 86 and 87 CAUTION Insufficient or improper cleaning and mainte nance can cause damage to the installation Inspect and clean the heating system once a year Carry out maintenance as required Immedi ately remedy faults This will avoid further damage to the system WARNING Do not use this boiler if any part has been under water Immediately call a qualified service tech nician to inspect the boiler and to replace any part of the control system and any gas control which has been under water CAUTION Risk of electric shock Before opening the system disconnect the heating system from the power supply using the heating system emergency OFF button or disconnect the relevant circuit breaker of the house from the power grid Secure the heating system against acci dental restarting Periodically examine the venting systems and cleaning of the screens in the vent terminal Also
9. Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 81 EIS Technical specifications General specifications unit GB162 80 NG GB162 80 LP GB162 100 NG GB162 100 LP Electrical data Mains connection voltage VAC Hz 120 60 Electrical protection rating IPX4D Fuses Amp 5 Electrical power consumption Ww full load without a pump group 104 156 Electrical power consumption Ww partial load without a pump group 29 29 Boiler dimensions and weight Height x width x depth with pump group in mm 50 4x20 5x18 3 1280x520x465 Weight without a pump group Ib kg 154 70 Other specifications Pump group pump UP 26 99 Table 20 Technical specifications of GB162 boilers at sea level continued 14 2 Technical specifications of GB162 boilers at high altitude 4 000 10 000 ft General specifications unit GB162 80 NG GB162 100 NG Gas category Natural gas Natural gas Rated thermal load btu h 100 000 290 000 100 000 333 000 Rated heating capacity heating curve 176 140 F 80 60 C btu h 89 000 255 200 89 000 293 000 Rated heating capacity heating curve 122 86 F 50 30 C btu h 99 000 281 300 99 000 326 300 Boiler efficiency at max capacity heating curve 176 140 F Yo 80 60 C 88 88 Boiler efficiency at max capacity heating curve 122 86 F Yo 50 30 C 97
10. See paragraph 9 9 Carry out a leakage test in operating conditions on page 54 11 8 Measure the flue gases CO emissions See paragraph 9 10 Measure the flue gases CO emis sions on page 55 11 9 Fill the heating system To ensure a trouble free operation of your boiler you must to check the pH value every year and correct if necessary See accompanying manual about water quality for more information See paragraph 9 2 Fill the heating system on page 47 11 10 Check the air flue gas connection See paragraph 9 5 Check the air flue gas connection on page 49 Buderus 64 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 12 Maintenance Record the activities in the service report page 87 CAUTION Risk of electric shock Before opening the system disconnect the heating system from the power supply using the heating system emergency OFF button or disconnect the relevant circuit breaker of the house from the power grid Secure the heating system against acci dental restarting CAUTION There is no need to lubricate the combustion motor as it is permanently lubricated 12 1 Prepare the heating system for maintenance Switch OFF the heating system by pressing the main switch of the BC10 INSTRUCTION FOR THE INSTALLER If gas pipes have to be disconnected from the gas burner fitting the burner cover must only be opened by a specialized
11. The contacts for the safety temperature sensor have shorted or the safety temperature sensor has detected a flow temperature of over 266 F 130 C No heating operation and no DHW YYp Ja2 if Blocking fault No heating operation and no DHW a The contacts for the safety temperature sensor have been interrupted g op i Yan X35517 Blocking fault YU eee Eu The contacts for the safety temperature sensor have shorted NG heating operation and e DER Yuu J351 Blocking fault i YY eed TT TTS The contacts for the safety temperature sensor have been interrupted Nonoating operation andino DRN GH 3EH Operating phase Component test phase ER Sam Locking fault The system has detected an insufficient ionization current during the ignition phase YER ya s 71 Blocking fault i TT The system has detected an insufficient ionization current after four No heating operation and no DHW start up attempts Yer 7 N3551 Blocking fault BE ccd xum The system has detected an ionization current before burner start up NG heating epar Io RR RIDE Yer Tangf Blocking fault BE 306 ET E An ionization current has bee
12. 100 kW 0 4 000 4 70 LPG 0 1 220 0 193 7746900499 4 000 10 200 LPG 1 220 3 111 not available Table 23 Gas orifice diameter The gas orifice diameter is marked on the gas orifice in mm Type of gas eng supply Factory pre setting of the gas control valve Natural gas Delivered factory set Natural Gas LP gas Suitable for propane after conversion also see the instruction Conversion to another type of gas supply Information on gas type instruction plate Set to gas category Propane Table 22 Factory setting of the gas control valve Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 83 EIS Technical specifications Hydraulic resistance of the boiler psi mbar 7 25 500 6 53 450 5 80 400 5 08 350 4 35 300 4 3 63 250 2 90 200 Pressure drop 2 18 1504 1 45 100 0 73 50 0 T T T T T 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 L h 2 2 4 4 6 6 8 8 11 0 13 2 15 4 17 6 19 8 22 0 GPM Volume flow Fig 99 Boiler resistance curve Buderus 84 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 15 Reports 15 1 Start up report Enter your signature and the date after completing the start up activities
13. 2 eee eee eee eee 65 12 1 Prepare the heating system for maintenance l l 65 12 2 Remove the boiler door 65 12 3 Clean the heat exchanger burner and condensate trap aaa 66 12 4 Check and adjust the gas air ratio 71 12 5 Functioncheck 0 aaa 71 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 13 14 15 16 17 Display information e 72 13 1 Removing the control panel 72 13 2 Replacing the control panel 73 13 3 BC10 Display readings 73 13 4 BC10 Display settings 73 13 5 BC10 Display codes 74 Technical specifications 81 14 1 Technical specifications of GB162 boilers at sea level 0 4 000ft 81 14 2 Technical specifications of GB162 boilers at high altitude 4 000 10 000 ft 82 Reports 2 c cee tee eee ee 85 15 1 Start up report a aasa anaana aaa 85 15 2 Inspection report aaa 86 15 3 Service report aaa 87 Spare parts 2 22 129 lw KALA 88 INGOX qr E 91 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Buderus 5 a General information 1 General information About these instructions GB162 Natural Gas Propane Gas These Installation Instructions contain i
14. Slide the drawer back into the boiler A Fig 37 Removing the covers Connect the free 120 VAC mains cable fig 37 to the O module fig 38 pos 1 If more modules are used the EN 120 VAC supply for the second module can be taken i fee from the first module using the cable enclosed with the ze N module a ER Se MY EA E e i Fig 38 Interconnecting modules NOTICE 1 The module may have the letters RC or EMS above the connection fig 39 pos 1 Module 1 Module 2 EE B 120 VAC EMS Fig 39 Connecting several modules Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 35 Electrical connections 7 2 2 Buderus 36 Connect the free connector of the EMS bus connecting cable fig 38 to the first module fig 39 If more modules are used the EMS bus connection for the second module may be branched off from the first module using the cable enclosed with the module fig 39 and 41 NOTICE Pay attention to the polarity when using an EMS bus connection cable Connect the wire from terminal 1 to terminal 1 and from terminal 2 to terminal 2 fig 39 and 41 Installing function modules outside the boiler Install the module on the wall according to the installation instructions of the module Make a
15. fig 52 Remove the hose and tighten the screw plug on the testing nipple again NOTICE Testthe tightness of the measuring nipple s used 9 5 Check the air flue gas connection Check the following points s the prescribed flue gas system used see paragraph 6 7 Installation of the Exhaust and Air Intake system page 24 Have the configuration instructions from the relevant flue gas system installation instructions been observed Start up procedure EE Fig 52 Closing the gas valve LI Fig 54 Opening the gas valve Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 49 9 Start up procedure 9 6 Checking the appliance configuration NOTICE The burner must only be put into use with the correct orifice table 12 Consult the relevant gas utility company for the type of gas supply Check that the actual gas supply is in accor dance with the type of gas supply specified on the gas classification label fig 55 Boiler Type of gas Altitude in ft Gas orifice diame supply m ter in inch mm GB162 Natural gas 0 4 000 ft 0 331 TED 80 kW 0 1 220 m 8 40 mm Fig 55 Checking the gas classification label 100kW Naturalgas 4 000 10 200 ft 0 343 1 220 3 111 m 8
16. tion of the PRV must be readily accessible for servicing or replacement and be mounted as close to the boiler as possible To install the PRV a suitable fitting connected to an extension on a T fitting can be sweated to the hot water line Support all piping Maintain an installation clearance from combustible construction of at least 1 25 mm from the hot water piping Installation 8 u 3 O gt 4 a B z Cy I Q Fig 10 pos pos pos pos pos pos pos NOOR WN Aa Pi ump group pressure relief valve supply water valve manual gas shutoff valve circulation pump gas inlet return water valve Pump group cover Ba Fig 11 Low loss header Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 17 EN Installation 6 3 3 Making the gas connection Length of Gas Volume Capacity in ft hr i 27 34 1 n 1 34 1 15 m DANGER 10 3 05 278 520 1 060 1 600 Only carry out work on gas lines if you are a ifi i 20 6 1 190 350 730 1 100 qualified gas fitter The manual gas shutoff valve is part of the pump group NOUS 13 ens 339 sah andis installed in accordance with the pump group instal 40 12 2 130 245 500 760 lation
17. 190 F 88 C Table 15 Setting of the space heating water temperature Buderus Fig 69 BC10 basic controller 58 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 9 14 3 Set the pump run over time Setthe pump run over time according to the Settings menu table 11 page 44 If the heating system is room temperature controlled and not controlled parts of the heating system risk freeze damage e g radiators in the garage setthe pump run over time to 24 hours 9 14 4 Switch DHW mode ON OFF Setthe DHW mode according to the Settings menu table 11 page 44 When DHW mode is switched OFF E the freeze protection for the hot water cylinder if present is switched OFF 9 14 5 Set the DHW temperature Setthe DHW temperature knob fig 70 pos 10 to the required temperature of the hot water in the hot water cylinder see table 16 Start up procedure EE 11 Knob Explanation position 0 DHW mode is OFF only heating mode ECO J Economy mode The DHW will only be reheated to 140 F 60 C if the temperature has signifcantly fallen This reduces the number of burner starts and saves energy As a result the water may be a bit colder initially 86 140 The temperature set on the BC10 is a temperature that cannot be changed using
18. Fig 24 Horizontal venting system room air only Situation 1 i 12 300 mm over maximum snow level or 24 600 mm whichever is greater i Exhaust Intake i El ar pP T m a Fig 26 Vertical venting system sealed combustion Installation 8 N 50mm T J 12 800 mm over maximum snow level or 24 600 mm whichever is greater EXHAUST W BR INTAKE NE Fig 23 Vertical venting system room air only 10 0 MIN 250 mm 0 mm MIN p f b NN VA L 12 300 mm OVER MAXIMUM SNOW LEVEL OR 24 800 mm WHICHEVER IS Im GREATER INTAKE ca EXHAUST KITA C m SI eam gt LA aay Fig 25 Vertical parallel venting system sealed combustion Situation 1 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Buderus 27 EN Installation 10 0 MIN 250 mm 0 mm MIN VA
19. O ang ye I na O i ub 32i H 61 O fueio FE i i i E sz ioejuoo yms EZ Q 3i aym o PT c58 H 222 o ada OVAO 64 O 3 q c 5 9 N H a SEE ova re es O i Aob 55 asa io MO po 8 71 68 AN 4 o cr 2 9 O pa gar Eee N H E H BO UH ERR X i BO j ong E N peceti i HO umoiq x a 3 O a MENU aes N 2 s2 EE assez pi oF 7 1 ze O ey Boao 32 sp B2 2532725 ENTM 235 3 58 H om los SS 55 8 2935855 iPM H s252 5 55 Gag Ot E88 NT 2 i eeQ0 4 pea x 2 oo ob re i 09 O ayym E g S69 3 3 EE BB S S H i g 2222222 E MESTRE S ss5 55 8 i i 3 aemeess i se o Kab a SPA S9 2889 4 QUOI H 8 O H oBueio i tv Q pai O O st g2 KR NILESAT B Sa See 9 Bs e gor 4 38 39 58 o 83 OO Fig 42 Electrical wiring diagram Buderus 37 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Electrical connections Legend of fig 42 pos 1 81 pole connector AC 0 10 24 and 230 V pos 16 pole connector AC 120 V pos Connection for pump in connection kit accessory pos Fan pos Gas valve pos Transformer pos Glow ignitor pos Earth pos lonization pos 10 Pressure sensor pos 11 Return sensor pos 12 Safety temperature sensor pos 13 Supply sensor pos 14 Flue gas sensor pos 15 Fuse 5 amp FAST sand filled pos 16 BUS function modules pos
20. Sealing 10 pc 73969 102 Manometer 73958 41 Air vent revision set 73916 106 Safety valve 4 bar 7746900403 42 Clip 73973 107 Connection pressure gauge 73081 43 Sensor NTC 7746900391 108 Drain pipe 73075 44 Clip 3x2 pc 78156s 109 Valve housing supply combi 7746900406 45 O ring 9 19 x 2 62 10 pc 78175s 110 Adapter parallel 4 7746900384 46 Pressure sensor 73915 111 Adapter insert 4 7746900385 47 O ring 14 x 1 78 10 pc 73679s 112 Open venting insert 7746900386 48 Return Supply pipe 73950 113 Lipring 114 7746800387 49 Connection nipple CH 73080 114 Lipring 103 7746800388 50 Clip 73974 117 Strain relief bracket 7746900398 51 O ring 10 pc 73972 118 Safety valve ASME 7746900405 52 Flue gas sensor 7746700420 119 Low loss header 7746901103A 56 Mounting set with sight glas 8718600172 120 Plug protector 73948 with glow ignitor with ionization electrode BCM 1100 100 kW 0 4 000 ft 7746900394 BCM 1101 80 kW 0 4 000 ft 7746900395 60 Heat exchanger 7746900383 Screw 6 3 x 19 10 pc 73986 Buderus 88 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Exploded view Logamax plus GB162 80 kW 100 kW a E f My M f D Wh jy Fig 100 Buderus 89 Logamax plus GB162 80 kW 100 kW Subjec
21. code code HAH Start up phase The boiler starts up after activation of the mains power supply or comple tion of a system reset This code is displayed for a maximum of 4 minutes yg Blocking fault l JA 235 The UBA 3 or the KIM is defective No heating operation and no DHW Yaw J3 Blocking fault R 9H gii The UBA 3 or the KIM is defective No heating operation and no DHW Yau f Ys3gf Blocking fault 9H chi Arr 1511 The UBA 3 or the KIM is defective Honeatag petation and ne DEI Yao 1 Ys 43 Blocking fault 9H gig The UBA 3 or the KIM is defective No heating operation and no DHW ygt g id Blocking fault No heating operation and no DHW a The contacts for the gas valve have been broken 9 0p i Yar 336 Blocking fault l l i The UBA 3 or the KIM is defective Yao 1 Jsu Blocking fault gp giH The UBA 3 or the KIM is defective No heating operationand no DHW yarn J35 Blocking fault gu gii DHW m The UBA 3 or the KIM is defective Nanang op ration and no Locking fault anag Ani ANO M t t t The contacts to the outdoor temperature sensor have shorted or are inimum outdoor temperature is as sumed interrupted the sensor has been connected incorrectly or is defective RB Aga Locking fault O The contacts to the DHW temperature sensor have shorted or are inter No DHW is heated any more rupted the sensor has been connected incorrectly or is defective RB i Bn Locking
22. B in the safety information above on this label If you don t smell gas go to the next step Open main shut off valve Set the thermostat or other operation control to desired setting Turn on all electric power to the appliance If the appliance will not operate follow the instruction To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Turn off all electric power to the appliance if service is to be performed Set the thermostat or other operating control to lowest setting 3 Close main gas shut off valve m T ou Ndi don 708 375A 2172B Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 45 9 Start up procedure 9 1 Check for gas leaks Prior to the initial start up check that the gas flow pipework is gas tight this must be confirmed in the start up report WARNING The boiler and its manual gas shutoff valve must be isolated from the gas supply piping system during any pressure testing of that system exceeding 0 5 psi 34 5 mbar The maximum test pressure allowed at the manual gas shutoff valve inlet is 0 5 psi 34 5 mbar Cover endangered positions before leak testing Do not spray the leak testing agent onto cables plugs or electrical connection lines Do not allow it to drip onto them either DANGER Leaks may be caused to pipes and screw connections during commissi
23. Loong taut e ee RC20 HK1 communication RC20 addressed incorrectly wired incorrect MN i optimization of the switch times do not ly or defective work R32 BB Heating circuit pump 2 is activated de Locking fault pending on the preset value The power The contacts to the heating circuit flow sensor have shorted or are inter to the mixer is switched off and the mix rupted the sensor has been connected incorrectly or is defective er stays in the state it was last put in can be adjusted manually Heating circuit 2 cannot be operated Hae B ib Locking fault Ed P MM10 not available or no communication The heating circuit addresses on the MM10 and the RC35 do not match up the MM10 or the bus circuit is connected incorrectly or is defective MM10 is not recognized by the RC35 correctly MM10 and the mixer auto matically goes into emergency opera tion Heating circuit pump 2 is activated continuously Monitor data in the RC35 is invalid ES Blocking fault The return temperature sensor has measured a return temperature high er than 221 F 105 C No heating operation and no DHW Table 19 BC10 Display codes 1 Only visible on the Service Tool or a specific RC controller Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 79 13 Display information Display codes Main Sub th ffec
24. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential puposes Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 9 LE Regulations and guidelines c MANUFACTURERS REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM REQUIRED When the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for the installation of the equipment and venting shall include 1 Detailed instructions for the installation of the venting system or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURERS REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM NOT PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for the venting of flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting systems shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system
25. anticipated snow line or roof surface Canada 18 457 mm minimum see fig 21 Vent termination must be at least 7 ft 2 135 mm above a public walkway see fig 22 Vent must be 3 ft 915 mm above any forced air intake within 10 ft 3 050 mm see fig 22 Do not extend exposed vent pipe outside the building beyond recommended distance Condensate could freeze and block vent pipe Vent should terminate at least 3 ft 915 mm away from adja cent walls inside corners and 5 ft 1525 mm below roof overhang see fig 22 It is not recommended to terminate vent above any door or window condensate can freeze causing ice formations Do not use chimney as a raceway if another boiler or fire place is vented into or through chimney All non steel vent pipes must be glued except for the flue gas adapter Installed you can slide the pipe onto the adapter properly supported and the exhaust pipe must be pitched a minimum of a inch 6 35 mm per foot back to the boiler This allows the condensate to drain away All non steel combustion air and vent pipe materials and fittings must comply with the following and must be UL approved venting material Installation 8 12 305 mm t minimum 12 305 mm minimum EXHAUST INTAKE 12 305 mm VO minimum A 12 305 mm 12 305 mm min
26. be observed The boiler must only be used for its designated purpose observing the Installation Instructions Only use the boiler in the combinations and with the accessories and spares listed Maintenance and repairs must only be carried out by trained professionals You are only permitted to operate the condensing gas boiler with the combustion air flue gas system that has been specifically designed and approved for this type of boiler Please note that local approval of the flue system and the condensate connection to the public sewer system may be required If boiler installation is provided as replacement heater DO NOT connect new boiler venting to an existing vent system if it is shared with other appliances You must also observe Thelocal building regulations stipulating the installation rules at the time of installation The local building regulations concerning the air intake and outlet systems and the chimney connection The regulations for the power supply connection The technical rules laid down by the gas utility company concerning the connection of the gas burner fitting to the local gas main The instructions and standards concerning the safety equipment for the water space heating system The Installation Instructions for building heating systems The boiler must be located in an area where leakage of the tank or connections will not result in damage to the area adj
27. front of the boiler of at least 16 5 20 5 37 940 mm Maintain an installation clearance from combustible construction from hot water Fig 3 Dimensions and connections with pump group 1 The pump group is an accessory A LA Flue gas connection F RK Return inside diameter 4 100 mm G1 union nut with female thread B AA Air intake connection G AKO Condensate outlet inside diameter 4 100 mm 32 mm 114 O D C WB Wall Bracket not shown H PF Pump group supply D VK Supply G1 male thread flat seal G1 union nut with female thread l Gas connection to pump group E GAS Gas connection to boiler 1 NPT female thread Rp1 female thread J PR Pump group return G172 male thread flat seal Buderus 12 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Packaging and transportation Ea 5 Packaging and transportation 5 1 Scope of delivery The boiler is delivered factory assembled When receiving the delivery check if the packaging is intact Check that all items are included in the delivery fig 4 Pos Parts Qty Packaging Boiler with casing Wall bracket Condensate trap with hose 1 box Technical documents set or By N NNI Supply and return union nuts with sealing rings Screws and plugs for wall bracket Un
28. glass 28 Glow ignitor 29 Safety temperature sensor 30 Heat exchanger 31 Pressure sensor 32 Return temperature sensor 33 Universal Burner Automatic Version 3 UBA 3 34 Draw with function module integration options 35 Cover shield 36 Condensate trap Pump group scope of delivery 37 Isolating valve blue CH boiler return with pump drain cock check valve and thermometer 38 Manual gas shutoff valve yellow GAS 39 Isolating valve red CH boiler flow with drain cock pressure gauge and thermometer 40 Pressure gauge 41 Isolating valve 42 Thermometer optional accessory 43 Drain valve 44 Safety valve 30 psi 2 bar or 50 psi 3 45 bar optional The pump group also includes an insulation cover see also pump group installation instructions Low loss header scope of delivery single appliance only 45 Low loss header not illustrated Buderus 3 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements EN Contents Contents General information lese 6 Safety and general instructions 7 2 1 Designated use illus 7 22 Hazard definitions 7 2 3 The following instructions must be observed 7 2 4 Heating system water quality 8 25 Pumptest eee eee eee 8 2 6 Freeze protection 000 8 2 7 Tools materials and further equipment 8 28 Disposal
29. instructions 50 15 25 115 215 440 670 Determine proper size gas pipe for the installation using 75 22 88 93 175 360 545 tabl nd table 4 Do not forget the pipe fitting able s and Table 4 Da nar forgat tue Pipe Tiling osses 100 30 5 79 160 305 480 and observe proper size of the fittings 150 47 25 64 120 250 380 Connect the gas supply pipe to the manual gas shutoff valve so that it is free from any strain Table3 Gas Pipe Capacity for different pipe sizes 1 Maximum pipe capacity in P hr based on a specific gravity of 60 42 mbar and a inlet gas pressure of 14 inches W C 35 mbar or less and a pressure drop of 3 inches W C 20 mbar NOTICE Steel pipe Equivalent length for Pipe Fittings in feet m diameter ipe fitti When installing the gas supply connection it in inches E Hype helps Ning must comply with local regulations or if such Gun LANE l Eeee de regulations do not exist with the National Fuel pus kla Gas Code ANSI Z 223 1 NFPA 54 Prancha In Canada the gas supply connection must Equivalent length in feet m comply with local regulations or if such regula 34 19 2 1 0 64 4 1 1 25 0 5 0 15 1 25 0 38 tions do not exist with CAN CSA B149 1 1 25 2 6 0 79 5 2 1 59 6 0 18 1 60 0 49 Natural Gas and Propane Installation Code t B ala Na 1 32 3 5 1 07 6 9 2 11 0 8 0 24 2 15 0 66 sediment trap must be provided upstream of th
30. of burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe e Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common venting system should be resized to appoach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 29 Electrical connections 7 Electrical connections Devices such as pumps outdoor sensor and 3 way valve are all connected to the external connection board The electrical connections to the boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 If installed in Canada electrical connections should conform with CSA C22 1 Code part 1 7 1 External connection board connections WARNING Danger of fatal accident due to electric shock 120 VAC connections may be present on the external connection board when power is supplied to the boiler Open the boiler door Remove the screw to release the cover over the elec trica
31. panel cover Turn the Space heating water temperature knob fig 46 pos 8 and DHW temperature knob fig 46 pos 10 counterclockwise to the O position Turn the vent key a quarter rotation to undo the boiler door lock fig 47 see detailed picture Push the fastener down fig 47 and open the boiler door Remove the insulation cover of the pump group fig 47 A To purge the boiler every radiator in the heating system must have a purge facility In some situations it may even be necessary to provide extra purging facilities at certain loca tions The boiler itself has an automatic air vent Loosen the cap of the automatic air vent fig 48 by turning one rotation counterclockwise 3 jJ Fig 48 Opening the automatic air vent Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 47 9 Start up procedure Open the heating supply and return isolating valves on the pump group fig 49 The open position is parallel to the pipe Fill the heating system to a pressure of about 20 psi 1 5 bar Read the pressure PSI from the pressure gauge on the pump group or on the control panel of the BC10 fig 50 The pressure in the heating system which is measured directly at the boiler must be at least equal to the required pre
32. periodically inspect the low water cutoffs including flushing of float types and clean the condensate collec tions and disposal system 11 1 Prepare the heating system for inspection Switch OFF the heating system by pressing the main switch of the BC10 INSTRUCTION FOR THE INSTALLER If gas pipes have to be disconnected from the gas burner fitting the burner cover must only be opened by a specialized profes Sional Close the gas valve fig 75 pos 1 Fig 75 Closing the valves here in closed position Close the isolating valves fig 75 pos 2 Buderus 62 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Open the boiler door Turnthe vent key through a quarter rotation to undo the boiler door lock fig 76 see detailed picture Push the fastener down fig 76 and open the boiler door NOTICE If the boiler door cannot be opened completely remove it see paragraph 12 2 Remove the boiler door on page 65 11 2 Carry out a visual check for general signs of corrosion Check all gas and water bearing pipes for signs of corrosion and for leaks Replace any pipes that are corroded Carry out a visual inspection of the burner heat exchanger condensate trap automatic air vent and all fittings in the boiler 11 3 Gas valve leakage test Check the internal tightness of the gas fitting on the input sid
33. pressure of the expansion vessel plus 7 psi 0 5 bar This minimum pressure must not be less than 12 psi 0 8 bar if the heating system is cold The maximum pres sure in the heating system measured directly at the boiler must not exceed 30 psi 2 6 bar or 50 psi 3 5 bar when the optional 50 psi 3 5 bar pressure relief valve is used Purge the heating system via the air vents on the heating bodies Start at the lowest floor of the premises and then work your way up from floor to floor 9 3 Fill the condensate trap with water Fill the condensate trap with water fig 51 NOTICE For high temperature and non condensing applications use minral oil Buderus 110 130 Fig 50 Reading the pressure gauge P Fig 51 Filling the condensate trap with water 48 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 9 4 Bleed the gas supply valve Close the gas valve fig 52 Open the screw plug on the testing nipple of the gas supply pressure and for purging fig 53 pos 1 by 2 turns and install a hose Slowly open the gas valve by pushing on the gas valve and turning it counterclockwise through 4 rotation fig 54 The gas valve is open when it is in the vertical position Purge the gas supply into a well ventilated area Close the gas shutoff valve when no more air is present
34. professional Close the gas valve fig 78 pos 1 Close the isolating valves fig 78 pos 2 12 2 Remove the boiler door Unscrew the control panel from the boiler door and hang it on the boiler frame see paragraph 13 1 on page 72 Unscrew the bolt from left hand top hinge of the boiler door and remove it together with the washer e Slightly lift the door and pull it from the hinge Put the door upright in a safe position NOTICE The cover over the electrical connections does not have to be removed from the boiler Fig 79 Removing the boiler door Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 65 E Maintenance 12 3 Clean the heat exchanger burner and condensate trap The boiler heat exchanger has a self cleaning coating CAUTION To avoid a short circuit Do not spray the cleaning agent onto the burner the hot surface ignitor the ionization electrode or other electric components 12 3 1 Remove the gas valve Undo the gas fitting screw connection fig 80 pos 1 and pull the 4 connectors fig 80 pos 2 from the gas valve Soll yet UG Se A LIZ 12 3 2 Remove the burner cover with the fan and the gas valve Pull the mains connector fig 81 pos 1 from the fan Pull the conn
35. ratio on page 52 12 5 Function check Slowly open the gas valve by pushing on the gas valve and turning it 14 rotation in an counterclockwise direction Switch ON the heating system by pressing the main Switch on the BC10 basic controller fig 95 pos 1 Setthe space heating water temperature knob fig 95 pos 8 and the DHW temperature knob fig 95 pos 10 to the maximum temperatures Enter a heat demand via the control unit and check that the boiler starts the heating mode Open a hot water tap and check that the boiler starts the DHW mode Setthe space heating water temperature knob fig 95 pos 8 and the DHW temperature knob fig 95 pos 10 Fig 95 BC10 basic controller to the required temperatures Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Buderus 71 13 Display information 13 Display information 13 1 Removing the control panel To make it easier to use the buttons on the control panel when the boiler door is open and to make it easier to read the values in the display you can disassemble the control panel from the boiler door and hang it from the boiler frame Open the boiler door Loosen the 2 screws of the control panel at the rear side of the boiler door fig 96 pos 1 Loosen the cable tie fig 97 pos 1 Rem
36. shall include a parts list and detailed installation instructions e A copy of all instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or venting design instructions shall remain with the appliance or equipment at the completion of the installation Buderus 10 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Dimensions and connections ES 4 Dimensions and connections 41 Without pump group 16 5 420 mm 18 3 465mm 0 25 6 mm O 20 5 520 mm 0 20 5 520 mm 6 152 mm j A B E 8 T DEMNM 4 1 103 5 mm LL i T24 CEH lt 1 m C qc poc E qe 406 mm m co 8 ble 5 e 5 MEE a Weil 24 8 630 mm TU mm 1 4 35 mm j xm 2 s assmm U mm i 15 1 130 mm t KA 6 4 162 mm i 5 5 140 mm The required permanent clearances closet are in front 1 25 mm right side O left side 0 above 6 152 mm The position selected for installation MUST allow adequate space for servicing in front of the boiler of at least 16 5 20 5 37 940 mm Maintain an installation clearance from combustible construction from hot water p
37. sweep button fig 64 pos 3 approx two seconds until the dot in the right hand bottom corner of the display fig 64 pos 9 appears See also table 8 Flue gas test page 41 After the LED Burner operation fig 64 pos 6 has lit up wait for one minute until the boiler is burning at full load Use a foaming product to check all sealing locations in the total gas circuit of the burner while the burner is active Buderus 54 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements WARNING Leaks may be caused to pipes and screw connections during commissioning and mainte nance activities Carry out a proper leak test Only use approved leak detection agents for leak detection Press the Chimney sweep button fig 64 pos 3 to clear the reading See also table 8 Flue gas test page 41 9 10 Measure the flue gases CO emissions Openatleasttwo thermostatic radiator valves if present Do not switch ON the boiler Push on the control panel to open it Switch OFF the heating system by pressing the main switch of the BC10 basic controller fig 64 pos 1 Remove the cover from the flue gas measuring point fig 65 pos 1 Connect the flue gas analyser to the left hand measuring point fig 65 Switch ON the heating system by pressing the main Switch of the BC10 basic controller Press and hold the Chimn
38. the external hot water cylinder 130 seconds at minimum speed The LED Burner operation is off o A J J Operating phase The room temperature is not possibly reached Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Display information SE Display codes Main Sub th ffect display display Key to display code Other effects code code OA 305 Operating phase 1 The boiler cannot start up temporarily after a DHW request has ended BE 2B3 Pre operative phase The boiler prepares for a burner start up whenever a heat demand or a DHW request arises HE SEE Readiness for operation The boiler is in standby mode There is a current heat demand but too much energy has been supplied OH 203 Readiness for operation 1 The boiler is in standby mode There is no current heat demand oL 284 Ignition phase 1 The gas valve is activated H 71H Start up phase The boiler starts up after activation of the mains power supply or comple tion of a system reset This code is displayed for a maximum of 4 minutes r3 E ny apnd Operating phase The flow temperature sensor has detected that the current flow tempera ture is higher than the flow temperature setting on the BC10 or that itis The room temperature is not possibly higher than the flow temperatur
39. vessel to the CH side of the check valve in the return circuit fig 18 pos 1 Installation 3 B a 1 STA gt 1 2 54 cm Fig 17 Condensate drainage pipe Fig 18 Connecting the expansion vessel in a single boiler system Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 21 EN Installation 6 5 Combustion Air and Ventilation Openings Provisions for combustion and ventilation air must be made in accordance with section 5 3 Air for Combustion and Ventilation of the National Flue Gas Code ANSI Z223 1 NFPA 54 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 Installation Codes or applicable provi sions of the local building codes CAUTION BOILER DAMAGE AND OPERATIONAL FAILURES Due to insufficient or improper openings for combustion air and or ventilation of the boiler room Provisions for combustion air and ventilation are always required regardless whether the combustion air is taken from the outside sealed combustion or inside room air for combustion Insufficient ventilation of the boiler room can lead to high air temperatures This can result in boiler damage Make sure that intake and exhaust openings are sufficiently sized and no reduction or closure of openings takes place When the problem is not resolved do not operate the boiler Please note these restrictions and
40. 3 4 The boiler will reduce its performance to 25 or 20 sea level or 36 or 30 96 high altitude respectively within a couple of seconds The space heating water temperature set on the BC10 basic controller control panel applies now Check the gas air ratio or the ionization current and if necessary set the gas air ratio according to paragraph 9 8 or paragraph 9 12 Step 8 Press the button Step9 F 5 This parameter shows the pump run over time in minutes that starts when the heating mode has ended Also see paragraph 13 4 Step 10 Press the button Step 11 C This parameter indicates the DHW mode status setting Also see paragraph 13 4 Step 12 Press the button Step 13 20 Shows currently measured space heating water temperature in F Also see paragraph 13 3 Step 14 Press the button Step 15 P22 Shows currently measured system pressure in psi Also see paragraph 13 3 Step 16 Press the button Step 17 H Display code Operating phase The boiler is in service mode Also see paragraph 13 5 Step 18 After 30 minutes or after a power interruption the flue gas test ends automatically To end manually press and hold the button for more than 2 seconds until the dot disappears Step 19 The boiler input rating drops to the preset capacity see the Settings menu table 10 Table9 Service mode Buderus 42 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting fro
41. 7 746 800 103 09 2009 US CA Installation instructions Condensing gas boiler Logamax plus CAUTION Before putting the boiler into operation read this manual carefully WARNING Improper installation adjustment alteration service or maintenance can cause injury loss of life or property damage Refer to this manual For assistance or addi tional information consult a qualified installer service agency or the gas supplier CAUTION The operating manual is part of the documentation that is delivered to the installa tion s operator Go through the information in this manual with the owner operator and make sure that he or she is familiar with all the necessary operating instruc tions NOTICE In the Commonwealth of Massachusetts this boiler must be installed by a licensed Plumber or Gas Fitter Warning If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance What to do if you smell gas Donottry to light any boiler e Donot touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Installation and service mus
42. 70 mm LPG 0 4 000 ft 0 193 0 1 220 m 4 70 mm LPG 4 000 10 200 ft not availabl 1 220 3 111 m Table 12 Gas orifice diameter 9 7 Measure the gas inlet pressure working pressure Open at least two thermostatic radiator valves if present Do not switch ON the boiler Push on the control panel to open it Switch OFF the power supply to the heating system Close the gas valve in a clockwise direction fig 56 Turn the vent key through a quarter rotation to undo the boiler door lock fig 47 see detailed picture page 47 Push the fastener down and open the boiler door Fig 56 Closing the gas valve Buderus 50 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Start up procedure Les Openthe screw plug on the testing nipple for the gas inlet pressure by 2 turns fig 57 pos 1 Reset the digital pressure gauge to O NOTICE Throughout the measuring operation keep the digital pressure gauge in the same position horizontal or vertical in which it was reset to O Connect the pressure gauge connection tube to the posi tive port of the testing nipple fig 57 pos 2 Slowly open the gas valve by pushing on the gas valve and turning it 14 rotation in an counterclockwise direction fig 54 page 49 The gas valve is open when it is in the vertical posit
43. 98 CSA Output btu h 261 000 295 000 De ration altitudes 4 000 6 000 ft 1 000 ft 2 3 2 1 De ration altitudes 6 000 8 000 ft 1 000 ft 2 5 2 2 De ration altitudes 8 000 10 000 ft 96 1 000 ft 2 5 2 8 AFUE at 80 180 F 27 82 C 93 8 n a BTS 2000 at 80 180 F 27 82 C part load n a 96 1 BTS 2000 at 80 180 F 27 82 C full load n a 90 8 Heating Maximum flow temperature F C 190 88 Maximum working pressure boiler psi bar 50 3 6 Minimum water circulation volume Gal h l h 0 Flow temperature F C 86 190 30 88 can be set on the BC10 basic controller Resistance at AT 20 K psi mbar 3 26 225 4 57 315 Heating circuit volume of heat exchanger Gal L 1 3 5 0 Pipe connections boiler without pump group Gas connection in Rp1 Heating water connection in G1 union nut with female thread enclosed Condensate connection in mm O 1 32 mm Flue gas values Condensate quantity at 104 86 F 40 30 C Gal h L h 2 4 9 0 2 85 10 8 pH value of condensate pH approx 4 1 Flue gas mass flow rate full load g s 35 3 44 9 Flue gas temperature 176 140 F 80 60 C full load F C 153 67 169 76 Flue gas temperature 176 140 F 80 60 C partial load F C 144 62 144 62 Flue gas temperature 122 86 F 50 30 C full load F C 118 48 124 51 Flue gas temperature 122 86 F 50 30 C partia
44. Connector for BC10 Basic Controller pos 18 Room controller RC and EMS bus pos 19 Outdoor temperature sensor pos 20 Orvoff temperature controller potential free pos 21 DHW sensor pos 22 External switch contact potential free e g floor heating pos 28 External three way valve pos 24 Boiler pump 120 VAC max 100 W pos 25 DHW pump pump 120 VAC max 100 W pos 26 DHW re circulation pump pump 120 VAC max 100 W pos 27 Main power connection 120 V 60 Hz max permissible 5 A pos 28 Mains switch pos 29 120 VAC function module pos 30 Ground BANBAAHN 0 W SSSNYSSRSNNRSSSYSRRSDH Buderus 38 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 8 Operation 8 1 BC10 basic controller The boiler is fitted with a control unit the BC10 basic controller This controller can be used to control the heating system Push on the control panel fig 43 to get access to the BC10 basic controller fig 44 The BC10 basic controller has the following components Main power switch pos 1 The main power switch is used to switch the boiler ON and OFF Reset button pos 2 If a fault has occurred you may have to restart the boiler by pressing the Reset button This is only required in the event of a locking fault Blocking faults are reset automatically as soon as their cause has been corrected The display shows E dur
45. N p WALL TERMINATION lk IN SI Sy INTAKE BEHIND 12 300 mm over maximum snow level or 24 600 mm 71 UT1 qr 4 102 mm J ID whichever is greater Su EXHAUST 53 Intake Exhaust 4 D il Fig 27 Horizontal venting system sealed combustion Situation 2 PVC only Fig 28 Vertical venting system sealed combustion Do not exceed the total equivalent venting length of 100 feet Fittings or Piping Equivalent 30 480 mm maximum requirement each for the intake and feet m exhaust piping 45 degree elbow 4 1 22 NOTICE 90 degree elbow 7 213 Appliance input rates are based on minimum plastic pipe per foot 1 0 30 vent length operation Longer vent lengths parallel vent kit 2 0 61 up to maximum will reduce the input propor tionally concentric roof terminal 20 6 10 4 6 100 150 mm See table 5 for the Friction Loss Equivalent in piping and fittings Table 5 Friction Loss Equivalent in piping and fittings Example When you end up using 3 x 45 elbows and the concentric roof terminal then the total venting length may not exceed 68 feet 20 72 m 3 x 45 elbow 3 x 4 ft 1 22 m 12 ft 3 66 m concentric roof terminal 4 6 20 ft 6 10 m Total f
46. SO 41 5 130 500 49 8 163 200 LEO 50 1 156 600 59 8 195 800 Lu 58 7 182 700 69 7 228 400 LAO 67 3 208 800 79 6 261 000 Lad 75 9 234 900 89 6 293 700 L 84 5 261 000 99 5 326 300 Table 14 Heating capacity as a percentage at high altitude 4 000 10 000 ft 9 14 2 Set the space heating water temperature Setthe upper space heating water temperature limit for heating mode with the space heating water tempera ture knob fig 69 pos 8 see table 15 This limitation does not apply to DHW preparation Display Rated heating capacity 7 596 indication based on natural gas sea level 26 GB162 80 kW GB162 100 kW kW btu h kW btu h Leo 20 0 68 300 L30 24 3 78 300 29 9 97 900 LHO 32 9 104 400 39 9 130 500 LSO 41 5 130 500 49 8 163 200 LEO 50 1 156 600 59 8 195 800 Lu 58 7 182 700 69 7 228 400 LEO 67 3 208 800 79 6 261 000 Lad 75 9 234 900 89 6 293 700 L 84 5 261 000 99 5 326 300 Table 13 Heating capacity as a percentage at sea level 0 4 000 ft Knob position Explanation 0 No supply to heating system e g only DHW mode 86 190 The temperature in F set on the BC10 cannot be changed with a room controller The supply temperature does not rise above this set temperature Aut The temperature is determined automatically on the basis of the heating curve If no room controller is connected the maximum heating temperature is
47. a RC thermostat Aut The temperature is set on the thermostat e g RC35 If no thermostat is connected the maximum DHW temperature is 140 F 60 C Table 16 Setting of the DHW temperature Fig 70 BC10 basic controller Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 59 9 Start up procedure 9 15 Final activities 9 15 1 Close the boiler door and the control panel Close the boiler door fig 71 and lock the fastener by turning the vent screw through 4 rotation in a clockwise direction Push on the control panel to close it 9 15 2 Hand over Hand over all relevant documentation to the end user and explain his her responsibilities under the relevant national and regional regulations Explain and demonstrate the start up and shut down procedures Fig 71 Closing the boiler door Buderus 60 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 10 Shutting down the system CAUTION The heating system may freeze if it is not operational in times of freezing Protect the heating system against freezing if there is a danger of frost affecting the system Drain the heating system water from the lowest point of the heating system The vent screw at the highest point of the heating system must then be open 10 1 Shut down the
48. able 7 Normal operation Flue Gas Test menu Step 1 20 Shows currently measured space heating water temperature in F Also see paragraph 13 3 Step2 To activate the flue gas test Press and hold the button for more than 2 but not longer than 5 seconds Step3 20 The non flashing dot in the right hand bottom corner of the display shows the flue gas test has been activated the boiler is in heating mode at a capacity of 100 for a maximum of 30 minutes Space heating water temperature is as set on the BC10 basic controller DHW mode is not possible Step 4 Press the button Step5 Pgg Shows currently measured system pressure in psi Also see paragraph 13 3 Step6 Press the button Step7 R Display code Operating phase The boiler is in flue gas test mode Also see paragraph 13 5 Step 8 Press the button Step9 20 Shows currently measured space heating water temperature in F Also see paragraph 13 3 Step 10 After 30 minutes or after a power interruption the flue gas test ends automatically To end manually press and hold the button for more than 2 seconds until the dot disappears Table 8 Flue gas test Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 41 EA Operation
49. acent 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 If you find any defects you must inform the owner of the system of the defect and the associated hazard in writing Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 7 EA Safety and general instructions DANGER if flammable gas explodes Beware if you smell gas there may be an explosion hazard Warning If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death 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 Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas suppl
50. ation and no DHW Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 75 13 Display information Display codes Main Sub display display Key to display code code code Other effects 3E 350 Locking fault The flow temperature sensor has not after burner start up detected any temperature increase in the heating system water JF 311 Locking fault The heating water temperature difference measured between the flow temperature sensor and the safety temperature sensor is too high ap EE Locking fault The flow temperature sensor has measured a heating water temperature increase of over 40 F s 5 C s 3y 31g Locking fault The temperature difference measured between the flow temperature sensor and the return temperature sensor is more than 122 F 50 C au J5 Locking fault The pump has stopped or is running without water 24 Jg Locking fault No feedback from the pump JA 3EU Locking fault The tacho signal from the fan has failed during the operating phase 3t YS a Blocking fault s No heatin ration and no DHW rt No current of air after a certain time o heating operation and no JF 313 Operating phase The appliance has been switched off for a couple of seconds because it had been running without any in
51. ault setting is 5 minutes CAUTION Do not set the post purge time to less than 5 minutes Higher Increase the time with the button The maximum setting is F 0 60 minutes or F d 24 hours Step 7 Press the button Step 8 DHW mode status setting Adjust as follows or go to step 9 DHW mode can be switched OFF or ON This setting has priority over other DHW mode settings such as those made on the room thermostat Set the DHW mode with the or buttons E means ON E 0 means OFF NOTE Setting EL n also switches OFF the hot water cylinder frost protection Step 9 After 5 seconds or after a power interruption the settings menu ends automatically To end manually press the button Any adjustments that you have made have been confirmed Table 11 Settings Buderus 44 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Start up procedure EE 9 Start up procedure There are several steps involved in starting up the boiler Complete the commissioning record log book after carrying out all activities described in this chapter paragraph 15 1 Start up report page 85 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the bur
52. aximum flow temperature F C 190 88 Maximum working pressure boiler psi bar 50 3 6 Minimum water circulation volume Gal h l h 0 Flow temperature F C 86 190 30 88 can be set on the BC10 basic controller Resistance at AT 20 K psi mbar 3 26 225 4 57 315 Heating circuit volume of heat exchanger Gal L 1 3 5 0 Pipe connections boiler without pump group Gas connection in Rp1 Heating water connection in G17 union nut with female thread enclosed Condensate connection in mm Q 114 32 mm Flue gas values Condensate quantity at 104 86 F 40 30 C Gal h L h 2 4 9 0 2 85 10 8 pH value of condensate pH approx 4 1 Flue gas mass flow rate full load g s 35 3 44 9 Flue gas temperature 176 140 F F C 153 67 149 65 169 76 165 63 80 60 C full load Flue gas temperature 176 140 F F C 142 61 136 58 142 61 136 58 80 60 C partial load Flue gas temperature 122 86 F F C 118 48 114 46 124 51 120 49 50 30 C full load Flue gas temperature 122 86 F F C 93 34 88 31 93 34 88 31 50 30 C partial load CO content at full load Yo 9 3 9 6 9 4 9 7 Free fan feed pressure Inch w c Pa 0 602 150 0 883 220 Flue gas connection flue gas system room air dependent in mm Q 4 100 mm flue gas system room air independent in mm Q 4 100 mm 4 100 mm parallel Table 20 Technical specifications of GB162 boilers at sea level Buderus
53. d the button for more than 2 seconds until the dot disappears Table 10 Manual operation Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 43 EA Operation Settings menu Step 1 20 Shows currently measured space heating water temperature in F Also see paragraph 13 3 Step 2 To open the Settings menu Press and hold the buttons for more than 2 seconds Step3 This shows the Settings menu is open You can adjust the setting of this parameter Step4 Target output Adjust as follows or go to step 5 Lower Decrease the modulation rate with the button The minimum setting for boilers at sea level is Lg5 25 with an 80 kW boiler and L 20 20 with a 100 kW boiler The minimum setting for boilers at high altitude is L 35 36 with an 80 kW boiler and L 30 30 with a 100 kW boiler Higher Increase the modulation rate with the button The maximum setting is L _ _ 100 This is equal to the factory setting Step 5 Press the button Step 6 F 5 Pump run over time in minutes starts when the heating mode has ended Adjust as follows or or go to step 7 Lower Decrease the time with the button The minimum setting is F 0 minutes The factory def
54. e with the boiler switched OFF at a test pressure of 7 0 inch W C 17 4 mbar for natural gas and 8 0 inch W C 19 9 mbar for LPG Check that the heating system is switched OFF Open the screw plug on the testing nipple for the gas connection by 2 turns Connect the pressure gauge tube to the testing nipple The pressure drop allowed after one minute is max 3 8 inch W C 10 mbar If the pressure drop is higher check all sealing locations of the gas fitting for leaks using a foaming product Repeat the pressure test if no leaks are found Replace the gas fitting if the pressure drop is higher than 3 8 inch W C 10 mbar per minute again see paragraph 12 3 1 Remove the gas valve on page 66 for instructions on how to remove 11 4 Measure the ionization current See paragraph 9 12 Measure the ionization current on page 56 Inspection Eg Fig 76 Opening the boiler door Fig 77 Checking the gas fitting for internal tightness Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 63 at Inspection 11 5 Measure the gas inlet pressure working pressure See paragraph 9 7 Measure the gas inlet pressure working pressure on page 50 11 6 Check and adjust the gas air ratio See paragraph 9 8 Check and adjust the gas air ratio on page 52 11 7 Carry out a leakage test in operating conditions
55. e air flue gas connection 9 5 on page 49 11 Checking the boiler settings of the documents for the control device in accordance with control device requirements 12 Final check of the inspection m activities documenting the measurement and test results 13 Confirming proper inspection Company Company Company Company Company Company Company stamp stamp stamp stamp stamp stamp stamp signature signature signature signature signature signature signature Buderus 86 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 15 3 Service report Indicate the maintenance activities that have been carried out enter the values measured and enter your signature and the date Reports 15 Needs dependant maintenance Page Date Date Date Date Date Date Date activities 1 Clean the heat exchanger burner and 66 L condensate trap 2 Check and adjust the gas air ratio 52 inch W C inch W C inch W C inch W C linch W C inch W C inch W C CO content at full load Yo CO content at part load 3 Function check 71 4 Confirming proper maintenance Company Company Company Company Company Company Company stamp stamp stamp stamp stamp stamp stamp signa
56. e calculated according to the heating reached curve or that it is higher than the flow temperature calculated for the DHW mode gy S TE Locking fault The flow temperature sensor has measured a current flow temperature higher than 203 F 95 C The room temperature is not possibly reached gy I7 Locking fault The safety temperature sensor has measured a current flow temperature higher than 203 F 95 C The room temperature is not possibly reached NG 39G Locking fault The return temperature sensor has measured a current return tempera ture higher than 203 F 95 C The room temperature is not possibly reached Blocking fault n T1 The flue gas sensor temperature is too high cm Lu ut No heating operation and no DHW IL 31 Locking fault There is no connection between contacts 78 and 50 of the UBA 3 instal No heating operation and no DHW lation base Y T3 T3 Blocking fault 2 The flue gas sensor contacts have shorted No heating operation and no DHW Yih ys gf Blocking fault The flue gas sensor contacts are open No heating operation and no DHW SE an Locking fault The system pressure is too low less than 3 psi 0 2 bar Table 19 BC10 Display codes 1 Only visible on the Service Tool or a specific RC controller No heating oper
57. e differential pressure The differential pressure Pas Pair must be 0 02 inch W C 5 Pa x0 02 inch W C 5 Pa read out on pressure gauge 0 04 O inch W C 10 0 Pa fig 61 Enter the result in the commissioning log book see paragraph 15 1 Start up report page 85 If the gas air ratio is incorrect it must be adjusted on the set screw fig 62 pos 1 The set screw is located behind the screw on cover Press the Chimney sweep button fig 59 pos 3 until the dot disappears from the display Switch OFF the heating system by pressing the main Switch of the BC10 basic controller fig 59 pos 1 Close the gas valve fig 56 Remove the measuring devices Tighten the screw in the burner pressure measuring nipple Slowly open the gas valve by pushing on the gas valve and turning it 14 rotation in an counterclockwise direction fig 54 Start up procedure EE wrong correct wrong 15 10 5 0 5 Pa 0 15 0 40 0 05 0 00 0 05 mbar 0 06 0 04 0 02 0 00 0 02 inch W C p turn counterclockwise turn clockwise Fig 61 Air gas difference at part load N E 2 4 UY ime gt Fig 62 Adjusting the gas air ratio Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 53 9 Start up procedure Switch ON the heating system by pressi
58. e manua gas shutoff valve but downstream of the appliance gas 1 38 O22 PAAR qe 2501076 valve Table4 Equivalent length for pipe fittings in feet Buderus 18 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Installation 6 3 4 Installing the heating supply and return pipe NOTICE When using plastic pipes observe the supplier s instructions especially those referring to recommended jointing techniques and the notes relating to the heating system water on page 8 NOTICE To prevent contamination in the heating system we recommend you integrate a dirt filter fig 12 pos 10 in the return pipe near the boiler In an old system it is a requirement to install a dirt filter Also install shutoff valves to enable filter cleaning immediately upstream and down stream of the dirt filter scale cartridge or 51 2 54 cm y strainer Fig 12 Connecting the boiler supply and return Connect the supply pipe with a flat rubber seal installed pos 1 Supply to the Supply connection fig 12 pos 1 making sure it pos 2 Return is not under stress Use a supply pipe with a minimum 3 pos 3 Isolating valves diameter of 175 38 mm pos 4 Drain cock Connect the return pipe with a flat rubber seal installed to pos 5 Gas valve the Return connection fig 12 pos 2 making sure it is pos 6 Pressure relief valve n
59. e switch optimization program is activated This program is activated if there has been a DHW request from an RC regulator more frequently than once every 10 minutes This means that the boiler cannot be restarted until at least ten minutes have elapsed since initial burner start up Table 19 BC10 Display codes 1 Only visible on the Service Tool or a specific RC controller Buderus 74 Main Sub 3 ther effects display display Key to display code O code code yt Operating phase EE Communication test while starting up This display code flashes five times within 5 seconds while starting up to indicate that the communica tion between the UBA 3 and the BC10 basic controller is being tested If a new UBA 3 or a new KIM was fitted this code will flash for max 10 seconds yf Blocking fault aul If this code continues to flash on the display there is a fault in the com No heating operation and no DHW munication between the UBA 3 and the BC10 basic controller A 3n Any display code with a dot in bottom right hand corner 1 Operating phase The boiler is in flue gas test or service mode H 200 Operating phase 1 The boiler is in heating mode Ha ann Any display code with a blinking dot in bottom right hand corner ii 1 Operating phase The room temperature is too high The boiler is in manual operation mode ZH 3g Operating phase 1 The boiler is in DHW mode H a0 1 Operating phase _ 1 Pump run over time via
60. ease see the accompanying Water quality requirements for Logamax plus GB162 80 kW 100 kW manual CAUTION Risk of system damage due to unsuitable heating system water If oxygen permeable pipes are used e g for underfloor heating systems the systems must be separated from one another by plate heat exchangers Unsuitable heating system water promotes sludge and corrosion forma tion This can result in heat exchanger malfunction and damage 2 6 Pump test If the boiler has not been operational for approx 4 weeks the pump will automatically run for 10 seconds every 24 hours This pump test is first carried out 24 hours after the main power has been connected to the boiler 2 7 Freeze protection The boiler has integrated freeze protection that switches the boiler ON at a space heating CH water temperature of 45 F 7 C and switches it OFF at a CH flow tempera ture of 59 F 15 C This feature does not protect the central heating system from freezing If there is a risk of radiators or pipe sections freezing up we recommend setting the pump run over time to 24 hours See paragraph 13 4 on page 73 2 8 Tools materials and further equipment For the installation and maintenance of the boiler you will need the standard tools for space heating gas and water fitting In addition a handtruck with a fastening belt is useful 2 9 Disposal Dispose of the boiler packaging in an environmentally sound man
61. ector of the harness fig 81 pos 2 from the fan while pushing on the connector lock to loosen it Fig 81 Removing the connectors from the fan Buderus 66 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Pull the air suction tube from the fan fig 82 Carefully open the 4 snap retaining clips on the burner cover fig 83 The retaining clips may be under tension Remove the retaining clips Remove the burner cover with the gas air unit fig 84 12 3 3 Remove the burner and the burner seal Remove the burner seal fig 85 pos 1 and replace it if necessary Remove the burner plate fig 85 pos 2 and clean it on all sides using compressed air or a soft brush When re installing the burner plate make sure that the notch is on the right hand side fig 85 see detailed picture zog Fig 85 Removing the burner plate and the burner seal Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 67 EN Maintenance 12 3 4 Checking the glow ignitor and ionization electrode and their replacement if required
62. ey sweep button fig 64 pos 3 approx two seconds until the dot in the right hand bottom corner of the display fig 64 pos 9 appears See also table 8 Flue gas test page 41 After the LED Burner operation fig 64 pos 6 has lit wait for one minute until the boiler is burning at full load Measure the carbon monoxide content at the flue gas measuring point fig 65 The CO values in air free condition must be less than 400 ppm or 0 04 vol 96 Values of 400 ppm or more indicate an incorrect burner adjustment see paragraph 9 8 page 52 a dirty gas burner or heat exchanger or burner faults You must determine and remove the cause see chapter 12 on page 65 Press the Chimney sweep button fig 64 pos 3 to clear the reading See also table 8 Flue gas test page 41 Switch OFF the heating system by pressing the main switch of the BC10 basic controller fig 64 pos 1 Remove the flue gas analyser and fit the cover back onto the flue gas measuring point fig 65 pos 1 Switch ON the heating system by pressing the main Switch of the BC10 basic controller fig 64 pos 1 Press on the control panel to close it Start up procedure EE Fig 65 Measuring the gas supply pressure Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical
63. fault j The contacts to DHW temperature sensor 2 have shorted or are inter No DHW is heated any more rupted the sensor has been connected incorrectly or is defective Ag B10 Locking fault No DHW available but there is heating operation The DHW priority is can The boiler water does not warm up Sensor lead broken or shorted sen i x celled when the fault message appears sor connected incorrectly or defective filling pump connected incorrectly Switch the boiler off and on to reset the or defective permanent tapping or leak boiler HO Bii Locking fault Thermal disinfection has failed Outlet flow during disinfection period too E Thermal disinfection was interrupted high sensor lead broken or shorted sensor connected incorrectly or defective filling pump defective RB HIE Locking fault The boiler no longer receives a heat de No connection to EMS EMS bus system is overloaded UBA 3 MC10 is mand The heating system does not defective heat any longer Table 19 BC10 Display codes 1 Only visible on the Service Tool or a specific RC controller Buderus 78 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Display information KE Display codes Main Sub Other effects display display Key
64. for a longer period Use this mode when the control system has not been installed yet or is out of order See table 10 Manual operation page 43 Service button pos 4 The Service button is used to display the current space heating water temperature the current system pressure etc Service Tool connection pos 5 For further information please contact Buderus LED Burner operation pos 6 The LED Burner operation lights when the burner of the boiler is active and is extinguished when the burner is switched OFF The LED Burner operation indicates the burner status LED Status Explanation ON Burner operational Boiler water is being heated OFF Burner off The space heating water temperature has reached the target value and there is no heat demand Table 6 Meanings of LED Burner operation indications LED Central heat demand pos 7 The LED Central heat demand lights when there is a heat demand and is extinguished when the heat demand is no longer present Space heating water temperature knob pos 8 The Space heating water temperature knob is used to set the upper space heating water temperature limit The unit is F Display pos 9 The heating system display values display settings and display codes can be read out from the display If a fault occurs the display will immediately show the accompanying fault code The fault code flashes if a locking fault has occur
65. guration 50 9 7 Measure the gas inlet pressure working pressure 50 9 8 Check and adjust the gas air ratio 52 9 9 Carry out a leakage test in operating conditions llle eee ees 54 9 10 Measure the flue gases CO emissions 55 9 11 Carry out a function test 56 9 12 Measure the ionization current 56 9 13 Test the Ignition Safety shut off device 57 9 14 Boiler settings 58 9 15 Final activities 60 Shutting down the system 61 10 1 Shut down the heating system using the basic controller 61 10 2 Shutting down the heating system if there is a risk of freezing interruption of use 61 10 3 Shutting down the heating system in the event of an emergency 61 Inspection 2 ol I ninss 62 11 1 Prepare the heating system for inspection 62 11 2 Carry out a visual check for general signs of corrosion llus 63 11 3 Gas valve leakage test 63 11 4 Measure the ionization current 63 11 5 Measure the gas inlet pressure working pressure 64 11 6 Check and adjust the gas air ratio 64 11 7 Carry out a leakage test in operating conditions llle 64 11 8 Measure the flue gases CO emissions 64 11 9 Fillthe heating system 64 11 10 Check the air flue gas connection 64 Maintenance
66. heating system using the basic controller Shut down your heating system by means of the Logamatic BC10 basic controller When the system is shut down the burner is automatically switched off Further information about the use of the BC10 basic controller is provided in chapter 8 Operation on page 39 Push on the control panel to open it Switch OFF the heating system by pressing the main switch of the BC10 fig 72 pos 1 Close the main gas supply or the gas valve fig 73 10 2 Shutting down the heating system if there is a risk of freezing interruption of use If conditions are such that the heating system has to be shut down for a long period while there is a risk of freezing the water must be drained from the heating system Push on the control panel to open it Switch off OFF heating system by pressing the main switch of the BC10 fig 72 pos 1 Close the main gas supply or the gas valve fig 73 Drain the heating water at the lowest point of the heating System using the drain cock orthe heating body fig 74 The automatic air vent at the highest point of the heating system radiator must be open 10 3 Shutting down the heating system in the event of an emergency You must immediately close the main shutoff valve or gas shutoff valve and disconnect the power from the heating system Close the main shutoff valve Shutting down the system EIN
67. his subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 72 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspections the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CRM 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CRM 5 08 2 a 4 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most currect edition of NFPA 54 as adopted by the board and 2
68. ier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING Danger of fatal accident from explosive fumes p Only carry out work on gas pipes and fittings if you are properly registered WARNING Dangerous flue gas can escape if the air supply is insufficient Make sure that air vents are not reduced in size or obstructed The boiler may only be operated after the defect has been remedied Warn the user of the system of the defect verbally and in writing 2 4 Heating system requirements Installing a dirt trap like a y strainer and a desludging device is required This must be installed in the heating system in the immediate vicinity of the boiler in an easily accessible position between the boiler and the lowest point in the return of the system Clean the dirt trap at every annual service Never use salt bedding type exchangers ion exchangers to soften the water Buderus The low loss header and boiler connection set must be installed supplied with the boiler When using oxygen permeable pipes plastic e g for floor heating systems you must separate the system using secondary heat exchangers 2 5 Heating system water quality The quality of the system water is very important Poor water quality can damage heating systems due to scale formation and corrosion For further details pl
69. improvements 55 9 Start up procedure 9 11 Carry out a function test During initial start up and annual inspection and or needs oriented servicing make sure that all control regulating and safety devices are in full working order and if applicable check them for correct adjustment The gas and water circuits must be tested for leaks see paragraph 9 1 page 46 and paragraph 9 9 page 54 9 12 Measure the ionization current Buderus 56 Press on the control panel to open it Open atleast two thermostatic radiator valves if present Do not switch ON the boiler Switch OFF the heating system by pressing the main switch of the BC10 basic controller fig 66 pos 1 Turn the vent key through a quarter turn to undo the boiler door lock fig 47 Push the fastener down fig 47 and open the boiler door Undo the plug and socket connection of the monitoring cable fig 67 10 9 8 Fig 66 BC10 basic controller Fig 67 Removing the ionization electrode plug and socket connection Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Connect the multimeter in series fig 68 Select the uA DC range on the multimeter The multim eter must have a resolution of at least 1 pA Switch ON the heating system by pressing the main Switch of the BC10 basic controller fig 66 pos 1 Activa
70. imum minimum Fig 21 Vent and air pipe position 1 of a sealed combustion system Item Material United states Canada 4 100 jer PVC schedule 40 80 ANSI ASTM D1785 pipe bidon iil ie sci ANSI ASTM D2665 BH Gas venting CPVC schedule 40 80 ANSI ASTM F441 systems Pipe PVC ANSI ASTM D2564 ULC S636 cement primer CPVC ANSI ASTM F493 Components of the certified vent systems must not be interchanged with o ther vent systems or unlisted pipe fittings Plastic components and specified primers and glues of the certified vent system must be from a single system manufacturer and not intermixed with other system manufacturer s vent system parts Approved flue material are from Roof terminals Flue System trade name Supplier 4 6 100 150 mm concentric PVC IPEX 4 100 mm parallel stainless steel Flex L Wall terminals Flue System trade name Supplier 4 100 mm parallel stainless steel Flex L 90 elbow with inlet screen PVC stainless steel Z Flex Heat Fab NOTICE DO NOT use cellular core pipe DO NOT use PVC when using anti freeze in the primary circuit of the boiler Use CPVC or stainless steel only Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 25 EN Installation NOTICE A minimum clearance of 4 ft 1 220 mm horizontally from and in no case above and belo
71. ing the reset operation Chimney sweep button pos 3 The Chimney sweep button is used to put the boiler into flue gas test service or manual operation mode The BC10 maximum heating water temperature setting applies CAUTION Limit the space heating water temperature to the maximum flow temperature of the floor heating circuit CAUTION A power interruption discontinues manual operation Frost damage may occur The flue gas test enables the boiler to be run in full load operation manually for a short period See table 8 Flue gas test page 41 The service mode enables the boiler to be run in part load operation manually for a short period Measurements and settings can be carried out on the boiler See table 9 Service mode page 42 Operation KE Fig 43 Opening the control panel Fig 44 BC10 basic controller pos pos pos pos pos pos pos pos pos pos pos oouooAtoN aw 0 Main power switch Reset button Chimney sweep button Service button Service Tool Connector LED Burner operation LED Central heat demand Space heating water temperature knob Display DHW temperature knob LED DHW demand Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 39 EA Operation The manual operation mode enables the boiler to be operated manually
72. ion Fig 57 Measuring the gas supply pressure Switch ON the heating system by pressing the main 10 9 8 switch of the BC10 basic controller fig 58 pos 1 Press and hold the Chimney sweep button fig 58 pos 3 approx two seconds until the dot in the right hand bottom corner of the display fig 58 pos 9 appears See also table 8 Flue gas test page 41 After the LED Burner operation fig 58 pos 6 has lit up wait for one minute until the boiler is burning at full load Measure the gas supply pressure and enter it in the start up report page 85 The gas supply pressure must be for natural gas min 7 inch W C 17 4 mbar max 10 5 inch W C 26 1 mbar nominal supply pres Fig 58 BC10 basic controller sure 8 inch W C 19 9 mbar pos 1 Main switch for LPG min 8 inch W C 19 9 mbar pos 2 Reset button max 13 inch W C 32 3 mbar nominal supply pres pos 3 Chimney sweep button sure 11 inch W C 27 4 mbar pos 4 Service button Press the Service button fig 58 pos 4 repeatedly pos 5 Connection possibility for the diagnosis connector until the temperature reading is shown in the display pos 6 LED Burner operation Press the Chimney sweep button fig 58 pos 3 to pos 7 LED Central heat demand clear the reading Also see table 8 Flue gas test pos 8 Space heating water temperature knob page 41 pos 9 D
73. ion nut for gas connection DHW sensor Pump group 10 Low loss header single installation only o N O 1 box 1 box ma N Table2 Items supplied with GB162 80 kW 100 kW Fig 4 Items supplied with unit 5 2 Transporting the boiler CAUTION The boiler may be damaged when it is improp erly secured Only transport the boiler using the right transportation equipment such as a handtruck with a fastening belt or special equipment for manuevering steps During transportation the boiler must be secured on the transportation equipment to prevent it from falling off Protect all parts against impacts if they are to be transported Observe the transportation markings on the packaging CAUTION The unpacked boiler may be damaged when not protected against contamination Leave the protective covers on the connec tions Coverthe flue gas connections at the top of the boiler with plastic film Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 13 KE Packaging and transportation Always lift and carry the boiler with two people as shown in fig 5 or use a handtruck or special equipment Fig 5 Lift and carry the boiler correctly CAUTION Damage to the unit by lifting or carrying incor rectly Do not hold the boiler b
74. iping of at least 1 25 mm Fig 2 Dimensions and connections without pump group A LA Flue gas connection E GAS Gas connection to boiler inside diameter 4 100 mm Rp1 female thread B AA Air intake connection F RK Retum inside diameter 4 100 mm G1 union nut with female thread C WB Wall Bracket not shown G AKO Condensate outlet D VK Supply 32 mm 1 O D G1 union nut with female thread Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 11 E Dimensions and connections 4 2 With pump group piping of at least 1 25 mm 16 5 420 mm 18 3 465 mm 0 25 6 mm 0 20 5 520 mm 0 20 5 520 mm 6 152 mm L tit NENNEN 4 1 103 5 mm mmm F q Wy Foy 1 C GZ AA T E 16 406 mm eo ME JE ES aps re DE 28 SiS E x o o 5 D to io A PEE KAG R EA Ed iejo 24 8 630 mm 1 j O 1 4 35mm 1 54 39 mm PG 5 4 138 mm 5 45 459 i G 5 1 130 KA 6 4 062mm 130 mm s80 mm gt 3 a H J ERG uM NN c M T z pti 5 5 140 mm The required permanent clearances closet are j j in front 1 25 mm right side O left side 0 above 6 152 mm The position selected for installation MUST allow adequate space for servicing in
75. isplay pos 10 DHW temperature knob 11 WARNING pos 11 LED DHW demand A leaking testing nipple causes explosive fumes Check the testing nipples used for leaks Only use approved detection products to locate leaks Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 51 9 Start up procedure NOTICE Check the gas supply pipe or contact the rele vant gas utility company if the required supply pressure is not available Ifthe supply pressure is too high a gas pres sure regulator must be integrated upstream of the gas fitting Contact the gas utility company Close the gas valve Remove the gauge connection tube and tighten the screw plug on the testing nipple again Open the gas valve again by pushing on the gas valve and turning it 14 rotation in a counterclockwise direction 9 8 Check and adjust the gas air ratio WARNING 10 9 8 AN Damage to the boiler by incorrect adjustment of the gas air ratio Adjust gas air ratio ONLY with part load Adjust gas air ratio ONLY based on the gas air pressure differential and never based on measured flue gas values such as CO CO4 NOx 110 130 Openatleasttwo thermostatic radiator valves if present Do not switch ON the boiler Push on the control panel to open it Switch OFF the heating system by pressing the main switch of
76. its dangers to the operator of the boiler WARNING BOILER DAMAGE Due to contaminated air Boiler must be clear and free from combustible materials gasoline and other flammable vapors and liquids and corrosive liquids and vapors Never use chlorine and hydrocarbon containing chemicals such as spray chemicals solution and cleaning agents paints glues etc in the vicinity of the boiler Do not store and use these chemicals in the boiler room Avoid excessive dust formation and build up NOTICE When one expects contaminated combustion air near swimming pools chemical cleaning operations and hair salons sealed combustion operation is recommended Buderus 22 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements DANGER Fire danger due to flammable materials or liquids Do not store flammable materials and liquids in the immediate vicinity of the boiler All Air from Inside the Building room air The closet shall be provided with two permanent openings communicating directly with an additional room s The total input of all gas utilization equipment installed in the combined space shall be considered in making this determi nation Each opening shall have a minimum free area of 1 square inch per 1 000 Btu per hour of total input rating of all gas utilization equipment in the confined space but no less than 100 square inches One opening shall com
77. l connections and pull the cover upwards fig 29 7 1 1 Routing the cable through the boiler Route the cable for the low voltage connections through the opening on the left fig 30 pos 1 Routethe cable forthe 120 VAC connections through the opening on the left fig 30 pos 2 Route and attach the cable for the 120 VAC connections using the strain relief clamps fig 30 pos 3 Onlythe 120 V electrical connections require a 14 gauge wire Buderus e a FA WA FW EV cogged m 12 12 4 2h 2 1 24 A h NA Ey NI 2 Af F Fig 30 Routing the cable 30 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 71 2 Low voltage connections WARNING due to electric shock Make sure no power is supplied to the boiler when making connections Connect all components to the relevant terminals RC Terminal Room Controller Connect a Room or Cascade controller to the orange RC terminal fig 31 See also paragraph 7 1 4 FA Terminal Outdoor temperature sensor If outdoor temperature dependant control operation is used an outdoor temperature sensor must be connected Connect the outdoor temperature sensor to the blue FA terminal fig 31 WA Terminal Potential free heat demand With this connection the room temperature based modu lating function of the boiler is n
78. l load F C 96 36 96 36 CO content at full load Yo 9 3 9 4 Table21 Technical specifications of GB162 boilers at high altitude Buderus 82 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Technical specifications EIN General specifications unit GB162 80 NG GB162 100 NG Free fan feed pressure Inch w c Pa 0 602 150 0 883 220 Flue gas connection flue gas system room air dependent in mm Q 4 100 mm flue gas system room air independent in mm 4 100 mm 4 100 mm parallel Electrical data Mains connection voltage VAC Hz 120 60 Electrical protection rating IPX4D Fuses Amp 5 Electrical power consumption full load Ww without a pump group 104 156 Electrical power consumption partial load Ww without a pump group 44 44 Boiler dimensions and weight Height x width x depth with pump group in mm 50 4x20 5x18 3 1280x520x465 Weight without a pump group Ib kg 154 70 Other specifications Pump group pump UP 26 99 Table 21 Technical specifications of GB162 boilers at high altitude continued Thermal Type of Altitude Gas orifice power gas diameter Part number p in ft m P gas boiler supply in mm inch Natural 0 4 000 8 40 gas 0 1 220 0 331 tiated Natural 4 000 10 200 8 70 GB162 gas 1 220 3 111 0 343 7748900399 80 kW
79. m technical improvements Operation KE Manual Operation menu Step 1 20 Shows currently measured space heating water temperature in F Also see paragraph 13 3 Step2 To activate manual operation Press and hold the button for more than 5 seconds Step 3 154 A flashing dot in the right hand bottom corner of the display shows manual operation is active This means that the boiler is permanently in heating mode Space heating water temperature is as set on the BC10 basic controller The LED Heating system status lights DHW mode is possible during manual operation Step 4 Press the button Step 5 Pee Shows currently measured system pressure in psi Also see paragraph 13 3 Step6 Press the button Step7 H Display code Operating phase Also see paragraph 13 5 The boiler is in manual operation mode During manual operation the Settings menu table 11 from step 2 can be used to temporarily change the target boiler performance NOTE If the boiler output has been changed temporarily this must be set again after ending manual operation according to the Settings menu table 11 Step 8 Press the button Step9 20 Shows currently measured space heating water temperature in F Also see paragraph 13 3 Step 10 After a power interruption manual operation ends automatically To end manually press and hol
80. mence within 12 inches 305 mm of the top and one opening shall commence within 12 inches 305 mm of the bottom of the enclosure The minimum dimension of air openings shall be not less than 4 inches 101 6 mm All Air from Outdoor sealed combustion The closet shall be provided with two permanent openings one commencing within 12 inches 305 mm from the top and one commencing within 12 inches 305 mm from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors The minimum dimension of air openings shall be no less than 4 inches 101 6 mm 1 Where directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr of total input rating of all equipment in the enclosure 2 Where communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr of total input rating of all equipment in the enclosure 3 Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 Btu hr of total input rating of all equipment in the enclosure 4 Where ducts are used they shall be of the same cross sectional area as the free area of the opening to which they connect Installation 8 Buderus Logamax plus GB162 80 kW 100 kW S
81. mportant information 80 kW 290 000 btu hr 270 000 btu hr for the safe and professional installation start up and main 100 kW 333 000 btu hr 315 000 btu hr tenance of the boiler with boiler input rating of 80 kW and 100 kW Table 1 max input rate These Installation Instructions are intended for professional installers who have the necessary training and experience for working on heating and gas systems Cascade installation Special cascade units accessories have been developed to enable this boiler to be installed in a cascade system Every cascade unit includes an installation frame horizontal headers connection pipes for the boiler main gas pipe and a vertical low loss header Cascade units are available for installing the boilers inline or back to back These cascade units make installing a cascade system easier and less labor intensive Please contact Buderus for further information about cascade systems Updating of documentation The following technical documentation is available for the Logamax plus GB162 80 kW 100 kW Installation instructions User s manual Service manual Please contact us if you have any suggestions for improve ment or corrections Subject to technical modifications Slight changes may be made without prior notice to the illus trations process steps and technical data as a result of our policy of continuous improvement Buderus 6 Logamax plus GB162 80 kW 100 kW Subject t
82. n EMS bus connection cable using a 2 core cable and the connector enclosed with the module fig 40 Important Use the connector of the same color as the connections on the module NOTICE Pay attention to the polarity when using an EMS bus connection cable Connect the wire from terminal 1 to terminal 1 and from terminal 2 to terminal 2 fig 39 and 41 Connect the EMS bus connection cable to the orange RC connection of the external connection board fig 41 pos 1 To connect other modules see paragraph 7 2 1 Fig 40 EMS bus polarity Fig 41 External connection board Room controller RC and EMS bus connection color orange Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Electrical connections 7 3 Electrical wiring diagram Label all wires prior to disconnection when servicing Wiring errors can cause improper and dangerous operation Verify proper operation after servicing CAUTION Jenueui sy ui sMala papojdxe ay pue uonoes a0 Alas ees sjueuoduioo JenpiAipur jo uoneoo 104 ueiouioeje paijijenb e 3jnsuoo yqnop Aue ur ade NOA JI 094109 pej2euuoo si aduri dde noA ey eaynsu3 aaHigva as LSNW 39NVITddV SIHL ONINHVM YOE A peJo oo JO N J9 9 eui YM paysew euruJe ay 0 pejoeuuoo aq SNU enjq paJoJo9 alim ay pai palojoo JO 7 J9 9 eui yM payJew jeur ay 0 pajpauuoo aq snw uMOJq pa10Joo 8JIM 9u M
83. n measured after the burner shut down Ngang operaio anao RENN raag S5gl Blocking fault a j The system has detected an insufficient ionization current during the operating phase Y T Blocking fault i BP 25g e The glow ignitor was activated for more than 10 minutes Neneating OP EFAN aude BEKE Yul J331 Blocking fault BH e 3 a n The ionization current is too high No heating operation and no DING mE Sir Blocking fault di The power supply was interrupted during a locking fault Ll LI j LI 1 Jut f Jue f Jur l i No heating operation and no DHW ka I KS L 4 I Ka PR J L J4P jiu J44 ysr Jsp Blocking fault HI cbt ju JEBAT The UBA 3 is defect No heating operation and no DHW 1 a i Ya L 1s ag Blocking fault e The UBA 3 is defect BY 237 Operating phase 1 The external switch contact is open Table 19 BC10 Display codes 1 Only visible on the Service Tool or a specific RC controller No heating operation Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Buderus 77 13 Display information Display codes Main Sub ther effects display display Key to display code Omer ciec
84. ndensate collectors 73934 75 Fuse 5AF 10 pc 73904s 16 Mounting flue gas pipe 73907 76 Connection board 73814 17 Exhaust pipe 73935 77 Electronic connection red 73776 20 Condensate collector 73933 78 Electronic connection grey T3774 21 Seal condensate collector 73463 79 Electronic connection green 73773 22 Drain pipe 73932 80 Electronic connection blue 73775 23 Sealing bush white 73449 81 Electronic connection orange 73777 24 Condensate drain pipe 73995 82 Flue gas exhaust connection 73940 25 Fan 7746900382 83 Flue gas adapter 73936 26 Seal Fan 73920 84 Measure niple cap 73937 27 O ring 70 x 3 2 pc 73983 85 Seal 150 mm 73968 28 Venturi 73978 86 Cable harness low voltage 7746900392 29 Seal O 60 mm 2 4 73563 87 Cable harness high voltage 7746900393 30 Gas valve 7746900399 88 Cable harness on off switch 73946 31 Seal 33 x 24 x 3 5 10 pc 73368s 89 Cable harness earth 73947 32 Gas pipe 100 kW 7746900397 90 Mains cable cable harness 7101471 with gas nipple 774601394A 91 Union nut 172 5 pc 73481s 33 Flange Gas valve 73987 92 Sealing 10 pc 15022s 34 O ring 10 pc 73982 93 Nut 1 73675 35 Orifice 100 kW 73980 95 Gas valve 7746900401 36 Screw M5 x 20 10 pc 735728 96 Pump UP26 99U 7746900402 37 Screw M5 x 16 10 pc 73970 97 Air vent 73409 38 Screw M6 x 16 10 pc 73971 100 Casing 73961 39 Air intake for the fan 100 kW 73926 101 Thermometer 7746900404 40
85. ner Dispose of components of the heating system e g boiler or control device that must be replaced in an environmentally responsible manner 8 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 3 Regulations and guidelines 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 Z223 1 NFPA 54 In Canada installation must be in accordance with the requirements of CAN CSA B149 1 Natural Gas and Propane Installation Code Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Install CO detectors per local regulations Boiler requires yearly maintenance see chapter 12 Maintenance page 65 Operating Limits of the boiler Max boiler temperature 230 F 110 C Max operating pressure 30 psi 2 6 bar with optional pressure relief valve 50 psi 3 45 bar The hot water distribution system must comply with all applicable codes and regulations When replacing an existing boiler it is important to check the condition of the entire hot water distribution system to ensure safe opera tion 3 1 Massachusetts Installations Only a For all side wall side horizontally vented gas fueled equipment installed in eve
86. ner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instruction If you cannot reach your gas supplier call the fire department C Useonly your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any parts have been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP read the safety information above on this label Turn off all electric power to the appliance Set the thermostat or other operating control to lowest setting This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Close main gas shut off valve Wait 5 minutes to clear out any gas Then smell for gas Including near the floor If you smell gas STOP Follow
87. ng the main 10 9 8 switch of the BC10 basic controller fig 63 pos 1 Press and hold the Chimney sweep button fig 59 pos 3 approx two seconds until the dot in the right hand bottom corner of the display fig 63 pos 9 appears See also table 8 Flue gas test page 41 After the LED Burner operation fig 63 pos 6 has lit wait for one minute until the boiler is burning at full load WARNING A leaking testing nipple causes explosive fumes Check the testing nipples used for gas tight Fig 63 BC10 basic controller ness Only use approved detection products to locate leaks WARNING DAMAGE TO THE INSTALLATION due to short circuits Cover any hazardous locations prior to locating the leaks Do not spray the leak detection product on cable runs plugs or electrical wiring Do not let it drip onto them either 11 Press the Chimney sweep button fig 64 pos 3 to clear the reading See also table 8 Flue gas test page 41 Check that the boiler performance is still at the required i value See table 11 Settings page 44 Fig 64 BC10 basic controller 9 9 Carry out a leakage test in operating conditions WARNING Pipes and fittings may leak explosive fumes after commissioning activities have been carried out Only use approved detection products to locate leaks Press and hold the Chimney
88. ni toring cable Switch ON the heating system by pressing the main switch of the BC10 basic controller fig 66 pos 1 Press the Chimney Sweep button and hold it for approx two seconds until the display shows the decimal point Check if the boiler does one start up attempt and three restart attampts After each start up attempt the boiler will signal a start up failure A ER code can be seen in the display After the last start up attempt the boiler will lock out The BR code is blinking in the display Connect the plug and socket connection of the moni toring cable Start up procedure Les Fig 68 Measuring the ionization current Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 57 9 Start up procedure Press the reset button Check if the boiler starts up Press the Chimney Sweep button return to normal operating conditions 9 14 Boiler settings 9 14 1 Set the heating capacity Set the required heating capacity on the BC10 according to the Settings menu table 11 page 44 See table 13 and table 14 when making these settings Display Rated heating capacity 596 indication based on natural gas high altitude 7e GB162 80 kW GB162 100 kW kW btu h kW btu h Len Ld 29 9 97 900 LHO 32 9 104 400 39 9 130 500 L
89. o modifications resulting from technical improvements 2 Safety and general instructions Please observe these instructions in the interest of your own safety 21 Designated use The boiler was designed for heating water for a central heating system and generating domestic hot water The boiler is suitable for connection to fully pumped sealed water systems ONLY The boiler can be installed either as a single system or as part of a multiple system cascade system with a maximum of 8 boilers connected together 2 2 The following defined terms are used throughout the docu mentation to bring attention to the presence of hazards of various risk levels Notices give important information concerning the operation of the product Hazard definitions DANGER Indicates the presence of hazards that will cause severe personal injury death or substantial property damage WARNING Indicates the presence of hazards that can cause severe personal injury death or substantial property damage CAUTION Indicates presence of hazards that will or cause minor personal injury or property damage CAUTION Risk of electric shock Indicates presence of hazards due to electric shock NOTICE Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage L gt Safety and general instructions E 2 3 The following instructions must
90. o the lilac PZ terminal fig 32 The maximum allowed connected load of the pump 250 Watts Netz connector Connecting incoming power The boiler must be electrically grounded in accordance with local codes or in absence of local codes with the National Electrical Code ANSI INFPA 70 and or the CSA C22 1 Elec trical Code Install a 120 VAC cable to the boiler mains Netz connection Buderus 32 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 7 1 4 Controller NOTICE t is not possible to connect more than one room controller The following controls can be connected to the boiler Logamatic RC35 room controller Logamatic 4323 controls Control with contact for potential free heat demand Error reporting module EM10 0 10 V input can be used to convert a 0 10 V signal to a modulating signal CM10 two boiler cascade module To install additional modules in the boiler see paragraph 7 2 Installing an RC35 controller as an outdoor reset control in the boiler The RC35 can be installed directly in the boiler with no addi tional connections to the external connection board This configuration is for outdoor reset control only Open the control panel cover Remove the cover fig 33 pos 1 Install the RC35 in the slot fig 33 pos 2 7 2 Installing function modules accessories NOTICE Refer to the installation in
91. oJ o pue ue9JD Jo uaaib paJojod Jo joqui s uuee ay q JO 3 J9 9 eui uim pexreui JOJOBUUOD ay uo BUILUJ9 ay 0 pejoeuuoo eq JSNW Moj o pue Uaaib palojod alim SUL 62 80 kW 100 kW Logamax plus GB 1 brown blue green yellow SMOJ O Se paadold 10j euuoo JNOA ul sjeuiwia ay BurAgmnuepi sBubueui pe1ojoo ay y m puodsalloo Jou Aew eoueljdde eui jo jo pea sureui ay ul SIM BU JO sJojoo ay sy BAI NMOHS TVHLR3N 3018 HLUVA MOTT3A ANY Na33u9 epoo Buimoljo ay ui eouepioooe ui pa10Joo ase pea sureui siy ui SOIM ay ANV 1HOdMWI MojjaA uaa16 Ja zB a d 2 9 O i UMOJq Oc st Q i ena Oc e o L Q i mojafjuses5 Oj a 4 g gg g i a E 22 gt B o oo o o H H SN NN N DO o Q H H nO0ESpgE DEE i 4 85252823535 f F coos5ooS92S i S amp of i iz eo So 82 i 3 168 ORFE EET Hati O HE 520 5a i 3 Gila 5 5 5 1 4 ess oss Eo i 3 3523 535 38 o MER 1888 B55 558 gs o955 2 93 i 9L Q i wog we 8s8 O g 2258585072 1 i joel e N 7 2585559 2 i MO oem bale H H m H L Q mokua SIT s2 m HUE calle 9 2 2 LO c59 He 999 AI dag Hel d Ob paang gp tp Sat SRI i E H N PEN L ir l enterprise d entretien sp cialiste P g 2 5 E pi 2 5 amp g 5 52 ne a5 ead 5 Hel 52S O aburio S i H SS i
92. oning and mainte nance activities Carry out a proper leak test Only use approved leak detection agents for leak detection f 0 5 psi 34 45 mbar or less slowly open the gas valve by pushing on the gas valve and turning it 14 rotation in a counter clockwise direction fig 45 The gas valve is open when it is in the vertical position Shut off the heating system from the power supply Check the new conduit section up to and including its connection i e direct sealing location to the gas fitting for leaks using a foaming product The maximum test pressure allowed at the manual gas shutoff valve inlet is 0 5 mbar 0 2 inch W C Buderus Fig 45 Open the gas valve pos 1 pos 2 pos 3 pos 4 pos 5 pressure relief valve supply water valve pump manual gas shutoff valve return water valve 46 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Start up procedure EE 9 2 Fill the heating system To ensure a trouble free operation of the boiler read the accompanying instructions about water quality before filling the heating system NOTICE At initial start up the boiler will start as soon as the system pressure exceeds 15 psi 1 0 bar If the system pressure falls to below 3 psi 0 2 bar the boiler will stop and generate a fault code Push and open the control
93. orrect handling can damage the boiler Do not use metal brushes or similar hard cleaning tools Handle the glow ignitor with care it is made from fragile ceramic material Cover the boiler interior using a blanket or a cover to prevent dirt entering the boiler Clean the heat exchanger with compressed air or a soft brush fig 94 WARNING Flue gas or condensate may leak if condensate collector is installed incorrectly Buderus Fig 92 Removing the condensate collector Fig 94 Cleaning the heat exchanger 70 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Refit the condensate collector and make sure that the two retaining clips close smoothly If this is not the case the seal between the condensate collector and the flue pipe at the rear side of the heat exchanger may be leaking Connect the flexible condensate drain hose to the condensate collector Re install the condensate trap Rinse the heat exchanger with clean water Reassemble all boiler components in reverse order Bumer with burner seal Burner cover with fan and gas valve Gas valve Glow ignitor and ionization electrode Start up the boiler see chapter 9 Start up procedure page 45 12 4 Check and adjust the gas air ratio See paragraph 9 8 Check and adjust the gas air
94. ot under stress Use a return pipe with a minimum i h i pos 7 Condensate trap diameter of 175 38 mm pos 8 Pump pos 9 Non return valve pos 10 Dirt filter for example scale cartridge or y strainer 6 3 5 Installing the pump Always use the supplied Buderus pump group and the low loss header when installing a single boiler so correct flows are guaranteed It is not necessary to install a low loss header for cascade systems Install the pump fig 12 pos 8 in the return circuit fig 12 pos 2 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 19 EN Installation 6 3 6 Installing the condensate trap WARNING Danger of fatal accident due to poisoning f the condensate trap is not filled with water flue gas can escape and put people s lives at risk High temperature applications Fill the condensate trap supplied with the boiler with water fig 13 Use mineral oil in case of high tempera ture systems and non condensing applications Connect the condensate trap fig 14 pos 1 to the condensate outlet The condensate trap has a bayonet connector insert and turn 1 4 rotation clockwise to click into position Connect the condensate trap hose fig 15 pos 3 and the rubber sleeve fig 15 pos 2 to the condensate trap fig 15 pos 1 Buderus Fig 13 Filling the condensate trap with water
95. ot used This has a negative effect on comfort and energy consumption The boiler will now only modulate up to the preset space heating water temperature Connect the potential free heat demand contact On Off thermostat or relay panel end switch to the green WA terminal fig 31 The maximum allowed resistance of this circuit is 100 ohms NOTICE The RC and WA terminals cannot be used simultaneously FW Terminal DHW temperature sensor Connect the external DHW temperature sensor to the grey FW terminal using the harness enclosed with the DHW temperature sensor NOTICE It is not possible to connect more than one DHW temperature sensor in the boiler Connecta DHW temperature sensor suitable for this particular boiler Electrical connections Net RC T WA EV Bay Ri NE zonan O RES 12345 6 7 8 9 10 Fig 31 External connection board connections no abbr color component 1 RC orange Room controller RC and EMS bus 2 FA blue Outdoor temperature sensor 3 WA green Potential free On off thermostat 4 FW grey DHW temperature sensor 5 EV red External switch contact potential free e g for floor heating safety 6 DWV green Connection for external three way valve 7 PK green External heating pump 120 VAC for use with non Buderus pump group PS grey DHW tank pump 120 VAC PZ lilac DHW recirculation pump 120 VAC 10 Netz white Main power connec
96. ove the control panel fig 97 Fig 97 Removing the control panel Use the two hooks to hang the control panel from the boiler fig 98 Fig 98 Hanging the control panel from the boiler frame Buderus 72 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 13 2 Replacing the control panel Take the control panel from the boiler frame Install the control panel in the boiler door by following the above procedure in reverse order 13 3 BC10 Display readings Display information KE Display readings Display A A s reading Key to display reading Unit Range Remarks 15 Current space heating water temperature E E 90 Pee Current system pressure psi Tp naf BAH yt Table 17 BC10 Display readings 13 4 BC10 Display settings Display settings Displa Factory p y Meaning of display setting Unit Range adjusted setting setting Sea level 0 4 000 ft S i M i configured target load GB162 80 kW s Lea 133 b MR 1002 kaa High altitude 4 000 10 000 ft i WE A amp Tr ET configured target load GB162 80 kW ja L 3b L 33 P eus 1997 E L Sea level 0 4 000 ft P CH R configured target load GB162 100 kW s L 20 L99 Psa 100 Eum High al
97. pos 2 from the conden sate trap fig 89 pos 1 Turn the condensate trap a quarter rotation counter clockwise fig 89 Disconnect the condensate trap from the coupling and remove it fig 90 pos 1 Rinse the condensate trap to clean it Fill the condensate trap with water and reinstall it NOTICE The condensate trap has a bayonet connector After inserting it the condensate trap must be turned rotation clockwise to click into posi tion 12 3 6 Remove the condensate collector Disconnect the flexible condensate drain hose and bend it backwards fig 91 Fig 89 Disconnecting the condensate trap hose pos 1 Condensate trap pos 2 Rubber sleeve pos 3 Condensate trap hose Fig 91 Removing the condensate trap hose Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 69 E Maintenance Open the 2 clamps on the right and left at the bottom of the condensate collector fig 92 pos 1 Pull the condensate collector down fig 92 step 1 and remove it by pulling it towards you fig 92 step 2 Checkthe condensate collector for damage and replace it if required Clean the condensate collector mechanically using compressed air or a soft brush and rinse it with clean water fig 93 12 3 7 Clean the heat exchanger CAUTION Inc
98. red DHW temperature knob pos 10 The DHW temperature knob is used to select the required temperature of the hot water in the hot water cylinder The unit is F See table 16 page 59 LED DHW demand pos 11 The LED DHW status lights when there is a DHW request and is extinguished when the DHW demand is no longer present Buderus 40 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Operation 8 8 2 BC10 operating instructions You can navigate through the menu structure of the boiler on the BC10 using the Reset button the Chimney sweep button the Service button fig 44 pos 2 3 and 4 and the display fig 44 pos 9 The menu structure consists of 5 menus Normal Operation menu see table 7 Flue Gas Test menu see table 8 Service Mode menu see table 9 Manual Operation menu see table 10 Settings menu see table 11 Normal Operation menu Step 1 15 Shows currently measured space heating water temperature in F Also see paragraph 13 3 Step2 Press the button Step3 P27 Shows currently measured system pressure in psi Also see paragraph 13 3 Step 4 Press the button Step5 H Current display code In this case Operating phase Boiler in heating mode Also see paragraph 13 5 Step 6 After 5 seconds the display returns to step 1 or Step7 Press the button T
99. riction loss equivalent 32 ft 9 76 m Total venting length for this example is GB162 80 kW 100 kW 100 ft 30 48 m 32 ft 9 76 m 68 ft 20 72 m each for the intake and exhaust piping Buderus 28 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Installation 8 NOTICE The minimum covering wall thickness is 1 25 mm The maximum covering wall thickness is 16 406 mm For direct venting properly reassemble and reseal the vent and air intake systems CAUTION Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation 8 Seal any unused openings in the common venting system b Visually inspectthe venting system for proper size and horizontal pitch and determine there is no restriction leakage corrosion and other defi ciencies which could cause unsafe condition C Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously d Test for spillage at the draft hood relief opening after 5 minutes
100. ry dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling buiding or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors Regulations and guidelines KEI a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of t
101. s ci na RARE AN NADA HANNA NG 44 73 E Shutting down 20000 cee eee 61 Emergency 6c cece eee 61 Signs Of COMOSION n od eeenardeave rene 63 F Space heating water temperature maximum 40 Fault 5 orc er epee DENEN ec ee A 72 T Flow temperature maximum 81 82 Technical specifications 81 82 Flue gas connection 49 81 83 Transportation uus eia tayo rata o Ed ce gars 13 Flue gas test a 41 Front protection vos aya eo encase Sone DALA bebida ees 8 V FROST ios t iR n RO i OR Dd Luc 15 61 Vent ti sas eec eee ee NEG RR 83 Function modules a 33 Function testing llle 56 W Working pressure a 81 82 G Gas flow pipe c eee eee 49 Gas supply pressure 00 cece eee ee 50 Gas tightness 0 0 0 eee 46 Gas air ratio 2 ee 52 H Heat exchanger 3 66 81 82 Heating system water 200 eae 61 l Inspection log book 0 0 eee eee 86 Installation room 1 2 a 15 Internal leak test 0 0 0 ee 63 lonization current cece eee eee 56 L Leakage test 0 cee eee ees 54 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 91 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 b
102. structions of the rele vant function modules for information about installation and combination possibilities The following function modules accessories can be connected to the boiler Heat demand 0 10V module EM10 Error reporting module EM10 Switch module WM10 Mixing module MM10 The function modules accessories can be installed in two ways in the boiler max 2 see paragraph 7 2 1 outside the boiler see paragraph 7 2 2 Electrical connections Fig 33 Remove the cover and install the room controller in the boiler only for outdoor temperature dependant operation Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 33 Electrical connections 7 2 1 Installing function modules in the boiler Loosen the screw fig 34 step 1 Pull open the drawer fig 34 step 2 Install the wall bracket in the relevant slots in the drawer fig 35 Click the function module s into position in the wall bracket fig 36 Remove the drawer Fig 36 Clicking the function module into position Buderus 34 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Electrical connections Remove the covers of both free connectors on the func tion module connection cables fig 37
103. t display display Key to display code Other effects code code Yr Saga Blocking fault f e The contacts for the pressure sensor have been interrupted or have No heating operation and no DHW shorted Y NG 1 JED J289 Blocking fault No heating operation and no DHW The contacts for the pressure sensor have shorted Xu t Sug Blocking fault u F The contacts for the return temperature sensor have shorted No heating operation and rio DHW i T3 Blocking fault l LH gH E Hr The contacts for the return temperature sensor have been interrupted Mo Doang operaton and ho DHAN EL 290 Locking fault No heating operation and no DHW The UBA 3 or the KIM is defective j 2471 Any display code starting with the letter E except EL thru Blocking fault No heating operation and no DHW 15571 The UBA 3 or the KIM is defective TH Operating phase Possibly no heating operation or no CET The system pressure is too low less than 12 psi 0 8 bar DHW available H3 Operating phase Possibly no heating operation or no The system pressure is too low less than 12 psi 0 8 bar DHW available p Operating phase ENSE The system pressure is too high higher than 58 psi 4 0 bar E Locking fault Reset is carried out This code appears after the Reset button on the display was pressed for 5 seconds
104. t be performed by a qualified installer service agency or the gas supplier Notice e This manual is available in the English and French language e This manual must be retained for future reference For the registered installer GB162 80 kW 100 kW Please read these instructions carefully before starting the operation Buderus EN Product description Product description Fig 1 Logamax plus GB162 with pump group Buderus 2 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements EN Product description 1 BC10 basic controller receptacle 2 Installation option for room controller e g RC35 3 Cover with user manual compartment 4 BC10 basic controller can be expanded e g by the RC35 room controller 5 Connection box low voltage and 120 VAC connections 6 Fan harness and mains lead of the pump Zi Condensate drain outlet 8 Condensate collector 9 Boiler front door 10 Automatic air vent 11 Retaining clips 12 Air intake for the fan 13 Gas pipe 14 Flue gas pipe 15 Door lock 16 Flue gas sensor 17 Flue measuring point 18 Measuring point for air intake 19 Flue gas connection 20 Air intake connection 21 Fan 22 Gas valve 23 Venturi 24 Burner cover 25 Flow temperature sensor 26 lonization electrode 27 Sighting
105. t to modifications resulting from technical improvements Exploded view pump group Logamax plus GB162 80 kW 100 kW Fig 101 Buderus 90 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 17 Index Numerics M 115 VAC connection aa 32 Main connection 0 eee eee eee 31 Main switch eee eee 39 A Manual operation ee eee 43 Appliance configuration 04 50 Menu structure 2 0 0 0 00 cece eee eee 41 B N BC10 basic controller llli 39 Normal operation 0000 ese 41 BUIMNG Em 66 P C Pump run over time llle 8 Carbon monoxide content aa 55 Pump AA AA 8 CO valu6S AA 55 Condensate DSpace X ub ees cade alas d lt 66 R Connections gas flue gas and water 11 12 Resistance hydraulic aa 83 D Room controller 33 DHW circulation pump 32 S DAW pump i sca cece 9 RR D REA 32 Salely orerar aes vex e e RE b SP PES 7 Diagnosis ice esee a pex ape chri 72 Sensor connections aaa 32 33 Dimensions eee eee eens 11 12 Service mode 0 ees 42 Display css ka APA 40 72 Service record log book aaa 87 Display codes 0a 74 Service Tool lees 40 Draining the heating water 61 Setting the heating capacity 58 Setting
106. te the Service mode in accordance with the Service mode menu table 9 page 42 Set the capacity to minimum part load according to the Service mode menu table 9 page 42 After the LED Burner operation fig 66 pos 6 has lit wait for one minute until the boiler is burning at part load Measure the ionization current The ionization current must be gt 5 pA DC at part load operation Enter the result in the start up report see paragraph 15 1 Start up report page 85 If the result is not as it should be check the gas air ratio paragraph 9 8 page 52 or check the ionization elec trode paragraph 12 3 4 page 68 Press and hold the Chimney sweep button fig 66 pos 3 approx two seconds until the dot in the right hand bottom corner of the display fig 66 pos 9 appears See also table 8 Flue gas test page 41 Switch OFF the heating system by pressing the main Switch of the BC10 basic controller fig 66 pos 1 Remove the multimeter and reconnect the monitoring cable Switch ON the heating system by pressing the main switch of the BC10 basic controller fig 66 pos 1 Check that the boiler performance is still at the required value See the Service mode menu table 9 page 42 9 13 Test the Ignition Safety shut off device Switch OFF the heating system by pressing the main Switch of the BC10 basic controller fig 66 pos 1 Disconnect the plug and socket connection of the mo
107. terruption for 24 hours This is a safety check mri a la Blocking fault ER g The tacho signal from the fan is not present during the pre operative or No heating operation and no DHW operating phase T3P yz E Blocking fault The fan is running too slowly No heating operation and no DHW Yay I 5 Blocking fault a i The fan is running too fast No heating operation and no DHW YAY Ya Tat Blocking fault The flow temperature sensor has detected a flow temperature of over No heating operation and no DHW 221 F 105 C Tac L Jag qr Blocking fault There is no bridging cable between contacts 22 and 24 of the No heating operation and no DHW UBA 3 contact strip WE 124g Blocking fault L J The sensor test has tailed No heating operation and no DHW ygor sal Blocking fault The safety temperature sensor has detected a flow temperature of over No heating operation and no DHW 266 F 130 C Table 19 BC10 Display codes 1 Only visible on the Service Tool or a specific RC controller Buderus 76 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Display information KE Display codes Main display code Sub display code Key to display code Other effects Jat ES Blocking fault
108. the BC10 basic controller fig 59 pos 1 Close the gas valve fig 56 Turn the vent key through a quarter rotation to undo the boiler door lock fig 47 see detailed picture Push the fastener down fig 47 and open the boiler door Open the screw plug on the testing nipple for the burner pressure by 2 turns fig 60 pos 1 Set the pressure gauge to 0 NOTICE Throughout the measuring operation keep the digital pressure gauge in the same position horizontal or vertical in which it was reset to O Use a connection tube to connect the positive port of the pressure gauge to the testing nipple for burner pressure fig 60 pos 2 Fig 60 Checking the gas air ratio Buderus 52 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Slowly open the gas valve by pushing on the gas valve and turning it 14 rotation in an counterclockwise direction fig 54 Switch ON the heating system by pressing the main Switch of the BC10 basic controller fig 59 pos 1 Activate the Service mode in accordance with the Service mode menu table 9 page 42 Set the capacity to minimum part load according to the Service mode menu table 9 page 42 After the LED Burner operation fig 59 pos 6 has lit wait for one minute until the boiler is burning at part load Read th
109. the circulation pump and a pressure relief valve NOTICE If you do not use the included pump group you have to install a separate circulation pump under the boiler This pump must be selected so that the volume flow through the boiler is suffi cient to handle the maximum boiler input rating See paragraph 6 3 5 Installing the pump page 19 Install the pump group on the boiler in accordance with the pump group installation instructions A single boiler must be installed with the included low loss header to regulate the flow Install the low loss header fig 11 pos 1 NOTICE Avoid installing the boiler above radiation levels If the boiler is installed above radiation sections a low water cutoff shall be installed and wired to the boiler Follow local code or in case of use of a low water cutoff be aware to use an air vent in order to prevent the boiler from shutting down unnecessarily 6 3 2 Connecting the pressure relief valve PRV The pressure relief valve is a part of the supplied pump group see fig 10 A listed ASME pressure relief valve supplied with the boiler must be installed at the time of instal lation No valve is to be placed between the PRV and the boiler No reducing coupling or other restriction may be installed in the discharge line The discharge line must be a minimum of 4 100 mm above a drain and installed such that it allows complete drainage of both the PRV and the line The loca
110. tion 120 VAC Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 31 Electrical connections EV Terminal External switching contact An external switch contact can be used i e to safeguard a floor heating system so that the heating water temperature will not become too high etc When the external switch contact is opened the boiler will be switched off for heating operation and for domestic hot water operation The pump continues to run for the run over time set on the boiler Remove the cable from the EV terminal fig 31 Connect the external switch contact to the red EV terminal fig 31 DWV Terminal Three way valve Do not use this connection 7 1 3 120 VAC connections NOTICE Use the 120 VAC connections for specific hydraulic configurations and a corresponding controller PK Terminal External pump Netz Connect the external heating or system pump for situa PK PS j 120 VAC tions where the pump of the Buderus pump group is not used to the green PK terminal fig 32 The maximum TETETERT TERI RTT allowed connected load of the pump 250 Watts PS Terminal DHW pump Connectthe DHW pump to the grey PS terminal fig 32 P SE EO VAG Cone none The maximum allowed connected load of the pump 250 Watts PZ Terminal DHW circulation pump Connect the DHW circulation pump t
111. titude 4 000 10 000 ft S Lm 2 f A configured target load GB162 100 kW ie L 30 PEE ae TER Ee Configured target value of the pump run over time nr pa ri IF 5 NOTE Do not set the pump run over HI Fon Feo F td noi F 5 time to less than F 5 5 minutes DHW flow operating condition setting i r i i F1 NOTE If the setting L is displayed 7 rf on 1 On F1 the frost protection of the DHW flow has also been switched off Table 18 BC10 Display settings Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 73 13 Display information 13 5 BC10 Display codes The folllowing table contains all codes that can show on the BC10 display To show the current display code and or subcode press the key repeatedly There are 3 main code groups Operating codes this code gives the status of the boiler No action is necessary Locking faults the boiler resumes normal operation when the fault has cleared Blocking faults the boiler is locked and will only restart after a manual reset The pump will operate continuously for frost protection If a blinking code is displayed together with other codes all displayed codes will blink A locking code will always show on the first screen of the BC10 Display codes 1 Th
112. to display code code code RD H2H Locking fault Water pressure sensor generates a fault code No heating operation and no DHW The digital water pressure sensor is defective Locking fault R 2 B ib BC1 tt tak No communication with BC10 Contact problem at BC10 or BC10 is cee ie M reas en nee i by RCxx devices defective Rie B15 Locking faut EEA an The contacts to the switch sensor have shorted or are interrupted the 9 y y y no longer be provided with the required sensor has been connected incorrectly or is defective heat capacity Ao BE Locking fault WM10 not available or no communication WM10 or bus circuit connect Heating circuit pump 1 is activated con ed incorrectly or defective WM10 is not recognized by the RC thermo tinuously stat A IB 97G Both RC35 and RC20 activate heating circuit 1 and DHW Depending on the Locking fault heating programs set and the required Conflicting addresses Both RC20 and RC35 are registered as Master room temperatures the heating system can no longer work correctly DHW mode does not work well R21 HA Since there is no actual room tempera i ture information room influence and Foching rau optimization of the switch times do not RC20 HK1 temperature sensor The integrated temperature sensor of P p Gi work The EMS works on the basis of the remote control control unit of heating circuit 1 is defective the values last set on the remote con trol AZ EE
113. ture signature signature signature signature signature signature Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 87 E Spare parts 16 Spare parts The following are parts commonly required due to damage or replacements Their failure will affect safety or performance of this appliance For a pictorial representation of the part see the respective position number on the exploded view pictures on page 89 and 90 Description Product No Description Product No 1 Door 7746900396 61 Cover controller BC10 73698 2 Sealing door 73912 62 Burner 73917 3 Door lock 73911 63 Seal Burner 73918 4 Hinge door 73990 64 Clamp 2 pc 73921 5 Wall mounting bracket 73965 65 Burner box 73919 6 Bracket left 73962 66 Front connection board 73910 7 Bracket right 73963 67 Controller connection plate 73692 8 Adjusting foot 73949 68 On Off switch 73660 9 Transport slide L R 73951 69 Knob BC10 38724 10 Drawer modules 73964 70 Draw connection board 73909 11 Screw 4 2 x 8 5 x 10 pc 73988 71 Cover control box 73977 12 Condensate collector 73930 72 Cover connection board 120 VAC 73815 13 Seal condensate collector 73929 73 Transformer 73697 14 Seal O 80 mm 3 2 73931 74 UBA3 18196 15 Upper side co
114. ubject to modifications resulting from technical improvements 23 EN Installation 6 6 Flue gas adapter When installing PVC vent pipes remove the upper lip ring and insert fig 19 pos 1 CAUTION DO NOT use lubricants to avoid degradation of the lip rings n case of open venting use basket fig 19 pos 2 on the air intake Fig 19 Connecting the flue gas adapter parallel 6 7 Installation of the Exhaust and Air Intake system NOTICE Consult local and state codes pertaining to special building code and fire department Ed requirements Adhere to national code require ments NOTICE Observe the listed maximum lengths of vent system which are boiler model dependent The maximum permissible lengths are listed in table 5 page 28 Optional vent kits are horizontal two pipe parallel wall terminal fields The termination shall be at least 4 ft 1 220 mm for the U S and 6 ft 1 330 mm for Canada away from a gas utility meter service regulator or the like for room air applications only Fig 20 Vent pipes The termination shall terminate at least 4 ft 1 220 mm below 4 ft 1 220 mm horizontally from or 1 ft 305 mm above any door window or gravity air inlet into any building Buderus 24 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements Vent must be at least 12 inches 305 mm above grade
115. ve the packaging and dispose of it in an environ mentally manner Measure the installation height see chapter 4 Dimen sions and connections page 11 Installation 8 Buderus Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 15 EN Installation Mark both holes with the wall bracket fig 7 using a spirit level Install the wall bracket with 2 screws fig 7 With two people lift the boiler by holding it by its back and by the transport rail at its bottom and install it on the wall bracket fig 5 page 14 The boiler can be moved sideways to get the correct position Level the boiler with the set screw and a spirit level fig 8 Remove the protective covers from the bottom of the boiler fig 9 NOTICE Some residual water from final testing may leak away Buderus e am Fig 7 Installing the wall bracket Fig 8 Aligning the boiler with the set screw Fig 9 Removing the covers boiler bottom 16 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 6 3 Water and Gas connection 6 3 1 General The water and gas connections to the boiler are made using the pump group see fig 10 scope of delivery This pump group includes
116. w unless a 4 foot 1 220 mm horizontal distance is maintained from electric meters gas meters regulators and relief equipment gn 5 1525 mm a 915 mm pa 4 3 E E 1220 mm 1220 mm 915 mm 7 9 1220 mm Heo wii x Forced Air Inlet C at least 1 ft 305 mm Exhaust terminal must be at least 3 ft 915 mm above grade and snow line above forced air inlet within 10 ft 3 050 mm Gravny AI Inlet Fig 22 Vent and air pipe position 2 of a system with combustion air supply from the room non room sealed Below are approved examples of vertical and horizontal venting installation NOTICE Place pipe supports every 5 feet 1 525 mm of horizontal and vertical run beginning with support near boiler The condensate must be drained in accor dance with the applicable rules See paragraph 6 4 Connecting the condensate drain pipe on page 21 Periodic cleaning of the vent terminal and air intake screens is mandatory Avoid locating vent terminals near equip ment or construction which can be subject to degradation from exhaust gases Buderus 26 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements EXHAUST INTAKE gt v
117. y 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 Buderus 7746800103 0005
118. y the door covering the control panel fig 6 Fig 6 Incorrect way of lifting and carrying the boiler Buderus 14 Logamax plus GB162 80 kW 100 kW Subject to modifications resulting from technical improvements 6 Installation 6 1 Requirements for the installation room DANGER room Install the heating system in a frost free If the boiler is operated dependent on room air the installation room must have the required air vents DO NOT obstruct these vents The air vents must always be free When installed in a room with thin walls or a thin floor resonating noise may occur Install noise reducing parts if required Do not store any flammable materials or liquids in the immediate vicinity of the boiler Never use any chlorinated detergents or halogenated hydrocarbons e g in spray cans solvents and detergents paints adhesives Do not allow too much dust to collect on the boiler 6 2 Installing the boiler Observe the installation distances of the combustion air flue gas system Before starting installation check that the carrying capacity of the wall is sufficient for the boiler weight NOTICE not remove the styrofoam bottom panel To protect the connection orifice you must Do not lift the boiler by the door covering the control panel see paragraph 5 2 page 13 Protect the boiler and the combustion air flue gas orifice against pollution during installation Remo

Installation instructions - Columbia Pipe & Supply Co.

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Installation instructions - Columbia Pipe &amp; Supply Co.

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Installation instructions - Columbia Pipe & Supply Co.