Buderus Buderus Logamax plus GB142-24/30/45/60 INSTALLATION INSTRUCTIONS (7215 0200 – 10/2007 US/CA (en))

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7215 0200 – 10/2007 US/CA (en) For registered installers

Installation instructions

Condensing gas boiler Logamax plus GB142-24/30/45/60

CAUTION!

Before putting the boiler into operation read this manual carefully.

WARNING!

Improper installation, adjustment, alteration, service or maintenance can cause injury, loss of life or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier.

CAUTION!

The operating manual is part of the documentation that is delivered to the installation's operator. Go through the information in this manual with the owner/operator and make sure that he or she is familiar with all the necessary operating instructions.

NOTICE!

In the Commonwealth of Massachusetts this boiler must be installed by a licensed Plumber or Gas Fitter.

Warning: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

– Do not store or use gasoline or other flammable vapors and liquids

in the vicinity of this or any other boiler.

– What to do if you smell gas

• Do not try to light any boiler.

• Do not touch any electrical switch; do not use any phone in your

building.

• Immediately call your gas supplier from a neighbor’s phone.

Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

– Installation and service must be performed by a qualified

installer, service agency or the gas supplier.

Please read thoroughly before installing and servicing

Preface

About these instructions

These Installation Instructions contain important information for the safe and professional installation, start-up and maintenance of the boiler with boiler capacities 24, 30, 45 and 60 kW.

These Installation Instructions are intended for professional installers, who have the necessary training and experience for working on heating and gas systems.

Subject to technical changes!

Slight changes may be made to the illustrations, process steps and technical data as a result of our policy of continuous improvement.

Updating of documentation

Please contact us if you have any suggestions for improvements or corrections.

Buderus • http://www.buderus.net We reserve the right to make any changes due to technical modifications!

2 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Contents

1 Safety and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2 Hazard definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.3 The following instructions must be observed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.4 Observe these instructions for space heating water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.5 Tools, materials and additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2 Regulations and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Dimensions and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Packaging and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5.2 Transporting the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6.1 Requirements for the installation room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

6.2 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

6.3 Making the gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

6.4 Fitting the heating circuit supply and return pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

6.5 Combustion Air and Ventilation Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

6.6 Installation of the flue gas adapter (included in the scope of delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

6.7 Installation of the Exhaust and Air Intake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

7 Connecting the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1 External connection board connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

9 Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

9.1 Testing for gas leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

9.2 Filling the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

9.3 Filling the condensate trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

9.4 Bleeding the gas supply valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

9.5 Checking the combustion air/flue gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

9.6 Checking the orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

9.7 Inlet gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

9.8 Checking and adjusting the gas/air ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

9.9 Carrying out a leak test in operating conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

9.10 Measuring the carbon monoxide content (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

9.11 Function testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

9.12 Measuring the ionization current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

9.13 Testing the Ignition Safety shut off device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

9.14 Installing the casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

9.15 Informing the owner, handing over the technical documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

10 BC10 basic controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

10.1 Operating the BC10 basic controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

10.1.1 Switching the heating system on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

10.1.2 Displaying the operating conditions of the burner and resetting the burner or resetting burner faults . . . . . . 39

10.1.3 Displaying the heating system status and/or faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

10.2 Carrying out additional tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

10.2.1 Carrying out a flue gas test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

10.2.2 Selecting partial load operation (e. g. during flue gas testing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

10.2.3 Switching the heating system to manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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Installation Instructions Logamax plus GB142-24/30/45/60 • version 10/2007 3

Contents

10.3 Configuring the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

10.3.1 Adjusting the heating capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

10.3.2 Setting the DHW temperature value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

10.3.3 Entering the space heating water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

10.3.4 Setting the pump post-purge period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11 Shutting down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

11.1 Shut down the heating system using the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

11.2 Shutting down the heating system in the event of an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

12.1 Preparing the boiler for inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

12.2 Visual inspection for general signs of corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

12.3 Internal leak testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

12.4 Measuring the ionization current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

12.5 Measuring the inlet gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

12.6 Checking and adjusting the gas/air ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

12.7 Carrying out a gas leak test in operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

12.8 Measuring the carbon monoxide content (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

12.9 Carrying out a pressure test of the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

12.10 Checking the functioning and the safety of the air intake and flue gas conduit . . . . . . . . . . . . . . . . . . . . . 48

12.11 Checking venting systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

13.1 Cleaning the heat exchanger, burner and condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

13.2 Checking and adjusting the gas/air-ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

14 Converting the boiler to propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

15 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

15.1 Operating messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

15.2 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

15.3 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

16 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

16.1 Start-up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

16.2 Inspection report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

16.3 Maintenance report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

17 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

18 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Buderus • http://www.buderus.net We reserve the right to make any changes due to technical modifications!

4 Installation Instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Safety and general instructions 1

1 Safety and general instructions

Please observe these instructions in the interest of your own safety.

1.1 Designated use

The boiler was designed for heating water for a central heating system and generating domestic hot water.

The boiler is delivered with a BC10 basic controller and the "Universal Automatic Burner Control Unit 3" (UBA 3) pre-installed.

The boiler can be fitted with a modulating outdoor reset control AM10 (scope of delivery), a room controller RC10 (optional), or an On/Off thermostat or relay panel end switch (accessories).

1.2 Hazard definitions

The following defined terms are used throughout the documentation to bring attention to the presence of hazards of various risk levels. Notices give important information concerning the operation of the product.

DANGER:

Indicates the presence of hazards that will cause severe personal injury, death or substantial property damage.

WARNING:

Indicates the presence of hazards that can cause severe personal injury, death or substantial property damage.

CAUTION:

Indicates presence of hazards that will or cause minor personal injury or property damage.

CAUTION:

Risk of electric shock.

Indicates presence of hazards due to electric shock.

NOTICE:

Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.

1.3 The following instructions must be observed

– The boiler must only be used for its designated

purpose, observing the Installation Instructions.

– Only use the boiler in the combinations and with the

accessories and spares listed.

– Other combinations, accessories and consumables

must only be used if they are specifically designed for the intended application and do not affect the system performance and the safety requirements.

– Maintenance and repairs must only be carried out by

trained professionals.

– You must report the installation of a condensing gas

boiler to the relevant gas utility company and have it approved.

– You are only allowed to operate the condensing gas

boiler with the combustion air/flue gas system that has been specifically designed and approved for this type of boiler.

– Please note that local permission for the flue system

and the condensate water connection to the public sewer system may be required.

You must also observe:

– the local building regulations stipulating the installation

rules.

– the local building regulations concerning the air intake

and outlet systems and the chimney connection. – the regulations for the power supply connection. – the technical rules laid down by the gas utility company

concerning the connection of the gas burner fitting to

the local gas main. – the instructions and standards concerning the safety

equipment for the water/space heating system. – the Installation Instructions for building heating

systems. – The boiler must be located in an area where leakage of

the tank or connections will not result in damage to the

area adjacent to the boiler or to lower floors of the

structure. When such locations cannot be avoided, it is

recommended that a suitable drain pan, adequately

drained, be installed under the boiler. The pan must not

restrict combustion air flow. – The boiler must be installed such that the gas ignition

system components are protected 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.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 5

Safety and general instructions1

– If you find any defects, you must inform the owner of the

system of the defect and the associated hazard in writing.

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.

z 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

z Do not try to light any boiler.

z Do not touch any electrical switch; do not

use any phone in your building.

z Immediately call your gas supplier from

a neighbor’s phone. Follow the gas supplier’s instructions.

z If you cannot reach your gas supplier, call

the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

1.4 Observe these instructions for space heating water

Unsuitable heating system water can promote the formation of scale or sludge, which affects system efficiency. It can also cause corrosion and reduce life of the heat exchanger.

– You must follow Buderus guidelines for boiler water

quality. – Thoroughly flush the system prior to filling. – Use of a Buderus approved boiler cleaner is

recommended. – Never use salt bedding exchangers to soften the water. – Do not use inhibitors or other additives unless approved

by Buderus for that purpose! – When frost protection of the heating system is desired,

only use Buderus-approved Aluminum-safe antifreeze.

– When using oxygen-permeable pipes, e. g. for floor

heating systems, you must separate the system using

heat exchangers. – The maximum permissible flow rate of the

GB142-24/30 this is 11 GPM (gal./min.)(= 42 l/min.), for

the GB142-45 is 15 GPM (= 57 l/min.) and for the

GB142-60 is 20 GPM (= 76 l/min.).

1.5 Tools, materials and additional

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.

1.6 Disposal

– Dispose of the boiler packaging in an environmentally

sound manner. – Dispose of components of the heating system (e. g.

boiler or control device), that must be replaced in an

environmentally responsible manner.

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6 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

2 Regulations and guidelines

Regulations and guidelines 2

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code, ANSI Z223.1. 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 maintenance section see chapter 13 "Maintenance", page 49.

Operating Limits of the boiler:

Max. boiler temperature: 230 °F (110 °C) Max. operating pressure: 44

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 operation.

Massachusetts Installations Only:

For direct- vent boilers, mechanical-vent heating boilers or domestic hot water equipment, where the bottom of the vent terminal and the intake is installed below four feet above grade the following requirements must be satisfied:

1) If there is not one already present, a carbon monoxide detector and alarm shall be placed in a living area outside the bedrooms. The carbon monoxide detector and alarm shall comply with NFPA 720 (2005 Edition).

2) A carbon Monoxide detector and alarm shall be located in the room that houses the boiler or equipment and shall:

a) Be powered by in series on the same electrical

circuit as the boiler or equipment: b) Have battery back-up power: c) Meet ANSI/UL 2034 Standards and comply with

NFPA 720 (2005 Edition): d) Have been approved and listed by a Nationally

Recognized Testing Lab:

3) A product-approved vent terminal must be used, and if applicable, a Product approved air intake must be used. Installation shall be in strict compliance with the manufacturer's instructions. A copy of the installation.

psi (3 bar)

4) A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the location of vent terminal. The plate shall be of sufficient size to be easily read from a distance of eight feet away, and read "Gas Vent Directly Below".

b) For direct-vent boilers mechanical-vent heating

boilers or domestic hot water equipment where the bottom of the vent terminal and the intake is installed four feet or above grade the following requirements must be satisfied:

1) If there is not one already present, a carbon

monoxide detector and alarm shall be placed in the living area outside the bedrooms, The carbon monoxide detector and alarm shall comply with NFPA 720 (2005 Edition).

2) A carbon monoxide detector shall:

a) Be located inn the area where the boiler or

equipment is located: b) Have battery back-up power: c) Be a minimum comply with NFPA 720

(2005 Edition).

3) A product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer's instructions. A copy of the installation instructions shall remain with the boiler or equipment at the completion of the installation.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 7

Product description3

3 Product description

9 10 11

Fig. 1 Logamax plus GB142-24/30 (left) and GB142-45/60 (right)

pos. 1: Drawer with control unit pos. 2: Universal Burner Automat (UBA3) pos. 3: Control unit BC10 pos. 4: Gas valve pos. 5: Cover pos. 6: Flue measuring points pos. 7: Parallel flue pos. 8: Burner

pos. 9: Latches of which two have locks pos. 10: Sighting glass pos. 11: Heat exchanger pos. 12: Back cover pos. 13: Air intake for the fan pos. 14: Fan pos. 15: Condensate trap pos. 16: External Connection Board (under the cover) pos. 17: Pressure sensor

10 11

3 6

110

120

100

130

140

Fig. 2 Basic Controller Logamatic BC10

pos. 1: Main switch pos. 2: DHW temperature knob pos. 3: LED "DHW status" pos. 4: Display pos. 5: Space heating water temperature knob pos. 6: LED "Heating system status"

1) ECO mode means that the temperature inside the hot water tank is 140 °F (60 °C), with a hysteresis (ΔT) of 18 °F (10 °C) instead of 9 °F (5 °C)

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8 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

1011

130

110

150

170

190

812

pos. 7: Under the cover a RC system controller can be installed pos. 8: LED "Burner Operation" pos. 9: Service Tool connector pos. 10: "Service" pos. 11: "Chimney sweep" pos. 12: "Reset"

e button

d button

c button

4 Dimensions and connections

Dimensions and connections 4

20" (500 mm)

12" (300 mm)

4" (100 mm)

1.8" (46 mm)

18.7" (475 mm)

6.2"

(158 mm)

0.25" (6 mm)

4.7" (119 mm)

28" (712 mm)

22" (560 mm)

3" (75 mm)

7.5" (190 mm)

DE FG

1.2" (30 mm)

2.2" (55 mm)

16" (420 mm)

3" (75 mm)

6" (150 mm)

4.3" (110 mm)13.2" (335 mm)

6" (150 mm)

3" (75 mm)

> 6"

(150 mm)

Fig. 3 Dimensions and connections for boiler GB142-24/30 (dimensions in inches)

Air intake (inside diameter 3'')

Flue gas connection (inside diameter 3'')

AA (A) AKO (E) GAS (D)

Condensate water outlet, Ø 1.3” (Ø 32 mm) outside

diameter

Gas connection, ¾” NPT

One Ø 1.0” (Ø 25.4 mm) inside x 1'' NPT threaded compression fitting is delivered enclosed with boiler packaging

LA (B) RK (G) VK (F) WB (C)

Return, Ø 1.0”

= =

Supply, Ø 1.0”

Wall bracket

(Ø 25.4 mm)

NOTICE

Observe the lateral minimum distances of the boiler (12” = 300 mm) and the necessary distances (24” (600 mm) at the front and 4” (100 mm) at the top) for removing the casing and for servicing.

Closet clearances are: 4” (100 mm) to the right, 4” (100 mm) at the top and 6” (150 mm) to the left.

> 4" (100 mm)

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 9

Dimensions and connections4

20" (500 mm)

12" (300 mm)

4" (100 mm)

1.8" (46 mm)

18.7" (475 mm)

6.2"

(158 mm)

0.25" (6 mm)

4.7" (119 mm)

7.5" (190 mm)

28" (712 mm)

1.2" (30 mm)

> 6"

(150 mm)

13.2" (335 mm)

35.4" (900 mm)

4.3" (110 mm)

9.7" (246 mm)

16" (420 mm)

DE F G

2.2" (55 mm)

3" (75 mm)

20.7" (526 mm)

3" (75 mm)

> 4" (100 mm)

Fig. 4 Dimensions and connections for boiler GB142-45/60 (dimensions in inches)

Air intake

AA (A) AKO (E) GAS (D)

Combustion air

Condensate water outlet, Ø 1.3” (Ø 32 mm)

Gas connection, ¾” NPT

LA (B) RK (G) VK (F) WB (C)

One Ø 1.0” (Ø 25.4 mm) inside x 1'' NPT threaded compression fitting is delivered enclosed.

Return, Ø 1.0”

= =

Supply, Ø 1.0”

Wall bracket

(Ø 25.4 mm)

NOTICE

Observe the lateral minimum distances of the boiler (12” = 300 mm) and the necessary distances (24” (600 mm) at the front and 4” (100 mm) at the top) for removing the casing and for servicing.

Closet clearances are: 4” (100 mm) to the right, 4” (100 mm) at the top and 6” (150 mm) to the left.

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10 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

5 Packaging and transportation

5.1 Scope of delivery

Packaging and transportation 5

The boiler is delivered fully assembled.

z When receiving the delivery, check if the packaging is

intact.

z Check that all the items listed in see table 1 are included

in the delivery.

5.2 Transporting the boiler

CAUTION

The boiler may be damaged when it is improperly secured.

– Only transport the boiler using the right

transportation equipment, such as a handtruck with a fastening belt or special equipment for manoeuvering 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.

z Packaged boilers must always be lifted and carried to

their destination by two people, or you must use a handtruck or special equipment to transport them to their destination.

z Transport the boiler to the room where it is to be installed.

Fig. 5 Items supplied with unit

Pos. Parts Quantity Packaging

1 Boiler with casing 1 1 box

2 Wall bracket 1

3 Technical documents

including:

- User's Instructions

- Installation Instructions

- wall mounting template

- Servicing Instructions

4 Compression fittings 2

5 AM10 with outdoor sensor 1

6 Flue gas adapter 1

7 Propane conversion kit 1

8 Boiler connection kit,

including the DHW sensor

9 GB142 Boiler manifold

including:

- low loss header

- pressure relief valve

- tridicator

- DHW connections

- Grundfoss 15-58 3-speed boiler circulator

- supply and return shutoff ball valves

Table 1 Items supplied with unit

The user’s instructions (in a special format) is located in the boiler drawer

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 11

Installation6

6 Installation

6.1 Requirements for the installation room

DANGER

– Install the heating system in a frost-free

room.

– 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 spraycans, solvents and detergents, paints, adhesives).

– Do not allow too much dust to collect on the

boiler.

6.2 Fitting the boiler

Observe the installation clearances of the combustion air/ flue gas system.

NOTICE

– To protect the connection orifice you must

not remove the styrofoam bottom panel. – Do not lift the boiler by the drawer. – Do not remove the transport safety clamps

(see fig. 6) from the drawer at this time. – Protect the boiler and the combustion

air/flue gas orifice against pollution during

installation.

z Remove the packaging materials and dispose of them.

z Use the mounting template to mark the drill holes.

z Install the wall bracket taking into account the necessary

service clearances.

z Remove the transport safety clamps (fig. 6).

Fig. 6 Removing the transport safety clamps

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12 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

z Use the radiator key to unlock the two latches a quarter

turn (fig. 7, pos. 1).

z Open the latches (fig. 7, pos. 2).

z Remove the casing by lifting it upwards and then pulling

it forwards (fig. 7, pos. 3); do not hold the casing by the latches.

z Hold the boiler by the rear boiler casing and place it on

the wall bracket.

z Level out the boiler.

6.3 Making the gas connection

DANGER

Only carry out work on gas lines if you are licensed for such work.

Fig. 7 Removing the casing

Installation 6

z Determine proper size gas pipe for the installation using

see table 2 and see table 3. Do not forget the pipe fitting losses and observe proper size of the fittings.

z Install the furnished ¾” gas cock on the gas connection.

z Connect the gas pipe to the gas cock (fig. 8, pos. 1) so

that it is free from any strain.

NOTICE

When installing the gas supply connection, it must comply with local regulations or, if such regulations do not exist, with the National Fuel Gas Code, ANSI Z 223.1. In Canada, the gas supply connection must comply with local regulations or, if such regulations do not exist, with CAN/CSA B149.1, Natural Gas and Propane Installation Code.

A sediment trap must be provided upstream of the gas controls.

Fig. 8 Making the gas connection

Length of

pipe (feet)

¾" 1" 1 ¼" 1 ½"

10 278 520 1,060 1,600

20 190 350 730 1,100

30 152 285 590 890

40 130 245 500 760

50 115 215 440 670

75 93 175 360 545

100 79 160 305 480

150 64 120 250 380

Table 2 Gas Pipe Capacity for different pipe sizes

1 Maximum pipe capacity in ft3/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)

Gas Volume Capacity

(ft3 / hr)

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 13

Installation6

6.4 Fitting the heating circuit supply and return pipes

NOTICE

– To protect the entire heating system we

recommend installing a dirt particle filter in the return circuit. When retrofitting the boiler to an existing heating system this filter is required.

– Install shut-off valves immediately before and

after the dirt particle filter to allow the filter to be cleaned.

z Fit a filling and drain cock in the heating system supply

pipe if required.

z Also fit an adequately sized safety valve in the system

that meets all applicable codes and regulations.

Steel pipe

diameter in inches

¾ 2.1 4.1 0.5 1.25

1 2.6 5.2 0.6 1.60

1 ¼ 3.5 6.9 0.8 2.15

1 ½ 4.0 8.0 0.9 2.50

Table 3 Equivalent length for pipe fittings in feet

Equivalent length for Pipe Fittings in feet

Type of pipe fitting

90°-Elbow Tee

(flow thru

branch)

Equivalent length in feet

Gate valve Gas cocks

NOTICE

When using oxygen-permeable pipes, e. g. for radiant floor heating systems, you must separate the system using heat exchangers. Buderus recommends hydraulically isolating snowmelt systems using heat exchangers.

z Thoroughly flush all pipes and radiators. Use of a

Buderus approved boiler cleaner is recommended.

z Refer to the installation template for the pipe connection

dimensions.

z Fit the compression fittings (fig. 9, pos. 1 and 2) first to

the Hydronic set (see fig. 10, 11 and 12) and then to the boiler.

z Connect the expansion tank to the system.

z Connect the pipes so that they are free from strain.

Connecting boiler with DHW tank

z Connect the external hot-water tank according to the

Installation instructions of the hot-water tank and fittings concerned.

Fig. 9 Pump manifold installation

pos. 1: Compression fitting (heating system supply pipe) pos. 2: Compression fitting (heating system return pipe) pos. 3: DHW supply pos. 4: DHW return pos. 5: Relief valve

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14 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Installation 6

GB142

Piping examples

The following illustrations are two Installation examples.

NOTICE

The following illustrations are simplified conceptual illustrations only.

Piping and field components must be field verified.

z A hot water boiler installed above radiation level or as

required by the Authority having jurisdiction, must be provided with a low water cutoff device either as a part of the boiler or at the time of boiler installation.

Fig. 10 is a schematic representation of fig. 9.

NOTICE

If this boiler is installed in a closed water supply system with an external indirect DHW tank, such as one having a backflow preventer in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control this situation.

Relief valve

The indirect DHW tank must have a temperature and pressure relief valve installed. The relief valve shall comply with the Standard for

Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22-CSA 4.4.

z Install the relief valve according fig. 10.

The relief valve must comply with following specifications:

– dimensions: height 2¼ inch (57.15 mm),

width 2 inch (50.8 mm). – 30 Psi (2 bar) discharge pressure. – discharge is ¾ inch (19.1 mm) female in

diameter.

FLUE GAS

GB142

AIR INTAKE

pump manifold

2 3

Fig. 10 Schematic representation of the boiler with the

hydronic set

pos. 1: DHW supply pos. 2: drain valve pos. 3: pump manifold shut-off valves pos. 4: secondary supply pos. 5: DHW return pos. 6: secondary return

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 15

Installation6

GB142

Additional

DHW Tank

GB142

Additional

DHW Tank

WARNING

No valve is to be placed between the relief valve and the tank. Discharge of the relief valve must be conducted to a suitable place for disposal when relief occurs and no reducing coupling or other restriction may be installed in the discharge line.

FLUE GAS

GB142

AIR INTAKE

Additional

Optional

DHW

Tank

Ta nk

zones

Fig. 11 Schematic representation of the boiler with the

hydraulic set connected to an optional hot water tank with one or multiple zones including one pump and zone valves

pos. 1: pressure relief valve pos. 2: PT meter (pressure and

temperature meter) pos. 3: drain valve pos. 4: DHW pump

Aditional zones

Radiant

pos. 5: secondary pump pos. 6: shut-off valve pos. 7: shut-off valve pos. 8: zone valve pos. 9: primary pump

NOTICE

Primary boiler pump must have an internal check valve.

FLUE GAS

GB142

AIR INTAKE

Additional

Optional

DHW

Tank

Ta nk

zones

Radiant

Aditional zones

Fig. 12 Schematic representation of the boiler with the

Hydronic set connected to an optional hot water tank with one or multiple zones and zone pumps

pos. 1: pressure relief valve pos. 2: PT meter (pressure and

temperature meter) pos. 3: drain valve

pos. 4: DHW pump pos. 5: shut-off valve pos. 6: shut-off valve pos. 7: zone pump pos. 8: primary pump

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16 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

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, or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149, Installation Codes, or applicable provisions of the local building codes.

CAUTION: BOILER DAMAGE AND OPERATIONAL FAILURES !

Due to insufficient or lacking openings for combustion air and/or ventilation of the boiler room.

Provisions for combustion air and ventilation are always required, regardless whether the combustion air is taken from the outside (sealed combustion) or inside (room air for combustion).

Insufficient ventilation of the boiler room can lead to high air temperatures. This can result in boiler damage.

– Make sure that intake and exhaust openings

are sufficiently sized and no reduction or closure of openings takes place.

– When the problem is not resolved, do not

operate the boiler.

– Please note these restrictions and its

dangers to the operator of the boiler.

Installation 6

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.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 17

Installation6

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 determination. 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 commence 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 3 inches (75 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 3 inches (75 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 crosssectional area as the free area of the opening to which they connect.

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18 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

6.6 Installation of the flue gas adapter (included in the scope of delivery)

Before installing the exhaust and air intake system, it is necessary to remove the transport safety device and to install the flue gas adapter.

NOTICE

The transport safety device has been installed to prevent unwanted movement of the heat exchanger during transport.

z Remove the transport safety device with the two screws

(see fig. 13).

z Screw on the flue gas adapter using six screws (see

fig. 14).

Installation 6

Fig. 13 Removing the transport safety device

Fig. 14 Connecting the flue gas adapter

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 19

Installation6

6.7 Installation of the Exhaust and Air Intake system.

NOTICE:

Consult local and state codes pertaining to special building code and fire department requirements. Adhere to national code requirements.

NOTICE:

Observe the listed maximum lengths of vent system, which are boiler model dependent. The maximum permissible lengths are listed in see table 4, page 25.

An optional concentric vent/air intake body (see fig. 18 and

26) can be used for the installation of a vertical venting

system as well as for a horizontal venting system. The concentric vent/air intake body can be ordered by Buderus Hydronic Systems, part no. BRYKGAVTO601CV. Other optional vent kits are: 383-500-397 Plastic Vent Kit PAZ1900019 V1000 Aluminum Vent Kit.

The boiler can also be operated with separate air intake and exhaust piping (see fig. 19 and fig. 26).

The termination shall be at least 4 ft (1,220 mm) for the U.S. and 6ft. (1,830 mm) for Canada away from a gas utility meter, service regulator or the like (for room air applications only).

The termination shall terminate at least 4 ft (1,220 mm) below, 4 ft (1,220 mm) horizontally from, or 1 ft (305 mm) above any door, window, or gravity air inlet into any building.

Vent must be at least 12 inches (305 mm) above grade, anticipated snow line or roof surface (Canada 18” (457 mm) minimum) (see fig. 16).

Vent termination must be at least 7 ft (2,135 mm) above a public walkway (see fig. 17).

Vent must be 3 ft (915 mm)above any forced air intake within 10 ft (3,050 mm) (see fig. 17).

Do not extend exposed vent pipe outside the building beyond recommended distance. Condensate could freeze and block vent pipe.

Vent should terminate at least 3 ft (915 mm) away from adjacent walls, inside corners and 5ft (1525 mm) below roof overhang (see fig. 17).

It is not recommended to terminate vent above any door or window, condensate can freeze causing ice formations.

Do not use chimney as a raceway if another boiler or fireplace is vented into or through chimney.

Fig. 15 Vent pipes

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20 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Installation 6

All vent pipes must be glued, except for the flue gas adapter (fig. 15, pos. 1) which is screwed into place and the first connection to the flue gas adapter (fig. 15, pos. 2). Installed you can slide the pipe onto the adapter, properly supported and the exhaust pipe must be pitched a minimum of a ¼ inch per foot back to the boiler. This allows the condensate to drain away.

All combustion air and vent pipe materials and fittings must comply with the following:

Item Material United states Canada

PVC schedule 40 ANSI/ASTM D1785

Vent or air pipe and fitting

Pipe cement/primer

* Components of the certified vent systems must not be interchanged with other vent systems or unlisted pipe fittings Plastic components, and specified

primers and glues of the certified vent system must be from a single system manufacturer and not intermixed with other system manufacturer's vent system parts.

PVC-DWV ANSI/ASTM D2665

CPVC schedule 40 ANSI/ASTM F441

ABS-DWV schedule 40 ANSI/ASTM D2661

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

ABS ANSI/ASTM D2235

CSA or BH Gas venting systems, ULC S636 * certified only

NOTICE

Do not use cellular core pipe.

NOTICE

Ensure that a condensate drain is always installed at the exhaust connection see chapter "7 Connecting the condensate drain"

12" (300 mm)

minimum

EXHAUST

12" (300 mm)

minimum

on page 26

NOTICE

INTAKE

12" (300 mm)

minimum

A minimum clearance of 4 feet horizontally from and in no case above and below, unless a 4-foot horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment

12" (300 mm)

minimum

Fig. 16 Vent and air pipe position (1) of a sealed combustion

system

12" (300 mm)

minimum

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 21

Installation6

(1525 mm)

(915 mm)

(1220 mm)

(915 mm)

Forced

(2135 mm)

(305 mm)

(1220 mm)

(305 mm)

Air Inlet

at least 1 ft (305 mm) above grade and snow line

Exhaust terminal must be at least 3 ft (915 mm) above forced air inlet within 10 ft (3050 mm)

Gravity Air Inlet

Fig. 17 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

10"- 0" MIN

(250 mm - 0 mm MIN)

NOTICE

Place pipe supports every 5 feet (1525 mm) of horizontal run, beginning with support near

12" (300 mm) OVER MAXIMUM SNOW LEVEL OR 24" (600 mm)

WHICHEVER IS

GREATER

boiler.

INTAKE

EXHAUST

NOTICE

The condensate water must be drained in

3" (80 mm)

accordance with the applicable rules. See chapter 7 „Connecting the condensate drain“.

(305 mm)

NOTICE

Periodic cleaning of the vent terminal and air-intake screens is mandatory.

Fig. 18 Vertical venting system (sealed combustion)

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22 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

10"- 0" MIN

(250 mm - 0 mm MIN)

12" (300 mm) OVER

MAXIMUM SNOW LEVEL

OR 24" (600 mm) WHICHEVER IS

GREATER

Installation 6

EXHAUST

INTAKE

3" (80 mm)

Fig. 20 Vertical parallel venting system (sealed

combustion) - Situation 1

10"- 0" MIN

(250 mm - 0 mm MIN)

12" (300 mm) OVER

MAXIMUM SNOW LEVEL

OR 24" (600 mm) WHICHEVER IS

GREATER

3" (80 mm)

EXHAUST

Fig. 19 Horizontal venting system (room air only) -

Situation 1

INTAKE

3" (80 mm)

EXHAUST

INTAKE

3" (80 mm)

Fig. 22 Vertical parallel venting system (sealed

combustion) - Situation 2

Fig. 21 Horizontal venting system (sealed combustion) -

Situation 2

EXHAUST

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 23

Installation6

EXHAUST

10"- 0" MIN

(250 mm - 0 mm MIN)

12" (300 mm) OVER MAXIMUM SNOW LEVEL OR 24" (600 mm)

WHICHEVER IS

GREATER

3" (80 mm)

INTAKE

min. 12"

EXHAUST

INTAKE

3" (80 mm)

12"

(300 mm)

minimum

12"

(300 mm)

minimum

12" (300 mm) minimum

12" (300 mm)

minimum

12" (300 mm) minimum

Fig. 24 Vertical venting system (room air only)

INTAKE

3" (80 mm)

EXHAUST

Fig. 26 Horizontal venting system (sealed combustion)

Fig. 23 Horizontal parallel venting system (sealed

combustion)

10"- 0" MIN

(250 mm - 0 mm MIN)

12" (300 mm) OVER MAXIMUM

SNOW LEVEL OR 24" (600 mm)

WHICHEVER IS

EXHAUST

GREATER

3" (80 mm)

INTAKE

3" (80 mm)

Fig. 25 Vertical exhaust and horizontal intake venting system

(sealed combustion)

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24 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Do not exceed the total equivalent venting length of 100 feet (30,480 mm) (GB142-24/30/45) and 60 feet (18,288 mm) (GB142-60) maximum requirement each for the intake and exhaust piping.

Installation 6

See table 4 for the Friction Loss Equivalent in piping and fittings.

Example:

When you end up using 3 x 45°-elbows and the concentric vent kit, then the total venting length may not exceed 88 feet (26.82 m) (GB142-24/30/45) or 48 feet (14.63 m) (GB142-60).

3 x 45°-elbow = 3 x 3 ft (0.91 m) = 9 ft (2.73 m)

concentric vent kit = 3 ft (0.91 m)

Total friction loss equivalent = 12 ft (3.66 m)

Total venting length for this example is: GB142-24/30/45 = 100 ft (30.48 m) - 12 ft (3.66 m) = 88 feet (26.82 m) GB142-60 = 60 ft (18.29 m) - 12 ft (3.66 m) = 48 feet (14.63 m).

NOTICE

The minimum covering wall thickness is 1" (25 mm). The maximum covering wall thickness is 16" (406 mm).

Fittings or Piping Equivalent

feet m

45 degree elbow 3 0.91

90 degree elbow 5 1.52

plastic pipe per foot 1 0.30

concentric vent kit 3 0.91

Table 4 Friction Loss Equivalent in piping and fittings

CAUTION !

Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

NOTICE

For Direct venting properly reassemble and reseal the vent and air-intake systems.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 25

Connecting the condensate drain7

7 Connecting the condensate drain

NOTICE

The condensate must be drained from the boiler and from the flue in accordance with the applicable rules and regulations.

No condensate drain is integrated into the boiler. It is required to install the furnished 3” x ¾” drain tee as an external condensate drain. See fig. 27. Install this drain tee as close as possible to the boiler exhaust connection.

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 CSA or ULC certified PVC or CPVC pipe, fittings and cement.

If the condensate outlet of the boiler is lower than the drain, a condensate pump must be used. The condensate produced by the boiler has a pH value between 3 and 4. Install a neutralization unit if required by the local code.

Fig. 27 Condensate drain

EXHAUST

3" (80 mm)

INTAKE

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26 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

8 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

Installations should also conform with CSA C22. 1 Canadian Electrical Code Part 1 if installed in Canada.

8.1 External connection board connections

Make all electrical connections inside the external connection box.

z Remove the cover of the external connection box

(fig. 28).

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, Electrical Code.

Electrical connections 8

Fig. 28 Removing the cover from the external connection box

z Install a 120V cable to the boiler (see fig. 29, pos. 1).

z Lead the cable through the cable guide (see fig. 29,

pos. 2).

Terminals 1 – 6 (fig. 30) are low-voltage connections and terminals 7 – 10 (fig. 30) are 120 Volt connections.

CAUTION RISK OF ELECTRIC SHOCK.

Once the main power supply is on then there is 120V on terminals 7 – 10 (can only be used with the correct configuration of the control unit and specific system hydraulics), if the main switch of the BC10 basic controller is switched on.

RC terminal

Connector for installation of an RC controller for indoor reset operation or a module like the AM10.

FA terminal

This is the terminal where you connect the outdoor temperature sensor. Only necessary for outdoor weather responsive operation.

WA terminal

For connection of a potential free thermostat or relay panel end switch.

Connection for an external DHW tank sensor

Netz

Fig. 29 external connection board

RCFAWA

DWV

PK PS

1234 5 6 7 8 9 10

Fig. 30 Connections to external connection board

Abbr. Color Component

RC orange RC room controller connection or for an

AM10 or other module

FA blue Outdoor-temperature sensor

WA green Potential-free On/Off thermostat

FW gray DHW temperature sensor

EV red External switching contact, potential-free

for floor heating safety etc.

DWV green Connection for external 3-way valve

PK green Primary loop pump 120V 60Hz

PS gray DHW tank pump 120V 60Hz

PZ lilac DHW recirculating pump 120V 60Hz

Netz white Main power connection 120V 60Hz

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 27

Electrical connections8

EV terminal (external switching contact)

This terminal can be used for example for the safety switch of floor heating. This protects the floor heating against too high boiler water temperatures (external manual reset high limit). The boiler is shut down when the external switching contact is opened.

The normally closed contacts of a LWCO will shut down burner operation but allow the pump to continue to operate in case of a low water condition.

DWV

Terminal for connection of an external 3-way valve.

Connector for the primary loop pump 120V 60Hz.

Connector for the DHW tank pump 120V 60Hz.

Connector for the DHW recirculating pump 120V 60Hz.

Netz

Main power connector 120V 60Hz.

120-volt connections

CAUTION

Make sure that the power consumption of each of the terminals 7 – 9 (see circuit diagram) does not exceed 250 W or 5 Amp.

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28 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Electrical connections 8

CAUTION

Label all wires prior to disconnection when servicing. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

High Voltage

Earth

120 VAC

Function module

120 VAC

Function module

6 5

16-pole connector

(120 VAC)

LN3

7 4

Operating switch

Mains supply

120 VAC 60 Hz

Circulating pump

120 VAC, max. 250 VA

DHW circulator

120 VAC, max. 250 VA

Boiler circulator

120 VAC, max. 250 VA

External 3-way valve

External switch contact

Potential-free e.g.

for floor heating

DHW sensor

On/Off temperature

control, potential-free

Outdoor-temperature

sensor

white greengrey

lilac

PENL

PENLPENL

14 13

PZGrid

16131

63 61

25 24

PS PK

External connection for specialist servicing company

Pin 1

16-pole connector

PENL

Pin 81

KIM

white red grey blue orangegreen

21213

EV FW

DWV

537923

266364757436375857

545146

81-pole connector

Connection box UBA 3.0

Pin 16

Pin 1

Modulating room controller

Supply sensor

Safety-temperature sensor

Return sensor

sensor

3 2 1

Pressure

Ionization

78 65 1234

BC10 connector

1234

70 61 62

Bus

Function module

Earth

120 VAC

120 VAC 120 VAC

120 VAC

Hot

1 2

1 2 3

2 3

ignitor

surface

24 VAC

0 VAC

24 VRAC

10 VAC 10 VAC

230 VAC 230 VAC

6 7

120

VAC

41 2 3

Transformer

fitting

Gas burner

Fan unit

1 2 3

81-pole connector

1 28 90 81 25 52 27

23 79 53

76 49

16 44

17 45

(AC 0, 10, 24 and 120 V)

69 68 67

Fig. 31 Electric circuit diagram

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 29

Start-up procedure9

9 Start-up procedure

There are several steps involved in starting up the boiler.

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.

This appliance does not have a pilot. It is equipped with an ignition device

which automatically lights the burner. Do not try to light the burner by hand,

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.

Use only your hand to push in or turn the gas control knob. Never use tools.

If the knob will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

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 INSTRUCTION

1. STOP! read the safety information above on this label.

2. Turn off all electric power to the appliance.

3. Set the thermostat or other operating control to lowest setting.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

5. Close main gas shut off valve.

6. Wait (5) minutes to clear out any gas. Then smell for gas. Including near the floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.

7. Open main shut off valve.

8. Set the thermostat or other operation control to desired setting.

9. Turn on all electric power to the appliance.

10. 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.

2. Set the thermostat or other operating control to lowest setting.

3. Close main gas shut off valve.

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30 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

9.1 Testing for gas leaks

Prior to start-up of the boiler you must check the external tightness of the gas supply valve and confirm this in the start-up report.

WARNING

– 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 commissioning and maintenance activities.

– Carry out a proper leak test. – Only use approved leak detection agents for

leak detection.

z Disconnect the heating system from the power supply.

z Check the exterior tightness of new conduit sections up

to and including the direct sealing point on the gas burner fitting. The maximum test pressure allowed on the input of the gas burner fitting is 14 inch W.C. (35 mbar).

Start-up procedure 9

9.2 Filling the boiler

Set the main switch to "1". P0.0 appears in the display of the BC10 telling you that there is no system pressure.

z Fill the heating system to a pressure of around 20 psi

(1.5 bar).

NOTICE

Observe the space heating water requirements as described in paragraph 1.4 on page 6.

z Observe the pressure on the BC10 or the P/T gauge in

the pump manifold for the heating circuit. The fill pressure of the system should be at least the required inlet pressure for the expansion tank plus 7.2 psi (0.5 bar). The minimum pressure is 15 psi (1.0 bar) (on a cold system). The maximum pressure is 44 psi (3.0 bar) (if the heating medium temperature is at its highest possible level). If this pressure is exceeded, the pressure relief valve will open.

NOTICE

If a relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct the situation. Never plug the relief valve.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 31

Start-up procedure9

For first time start up it is necessary to set the DHW temperature knob and the space heating water temperature knob to the desired setting (see subsection 10.3.2 and 10.3.3). Factory setting is "0".

WARNING

There is a hot water scald potential if the BC10 is set too high.

9.3 Filling the condensate trap

z Make sure that you fill the condensate trap with water.

This is to prevent exhaust gases from entering the room.

z Remove the condensate trap (see fig. 32).

z Fill with water and refit the condensate trap in reverse

order.

110

100

120

130

140

130

110

150

170

190

9.4 Bleeding the gas supply valve

z Loosen the screw plug on the testing nipple for the gas

connection and venting (fig. 33, pos. 1) by two turns and fit a hose.

z Slowly open the gas shut-off valve.

z Run the gas that is discharged through a water bath.

z Close the gas shut-off valve when no more air is

released.

z Remove the hose and tighten the screw plug again.

9.5 Checking the combustion air/flue gas connection

Check the following points:

– Is the prescribed combustion air/flue system used? – Have the instructions for configuring the flue system as

specified in the relevant Installation instruction for the flue gas system been observed?

Fig. 32 Filling water into the condensate trap

Fig. 33 Bleeding the gas supply conduit

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32 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

9.6 Checking the orifices

CAUTION

The burner must only be commissioned if the correct orifices are fitted (see table 6).

z Convert the burner fitting to another gas type

if required (see chapter 14 "Converting the boiler to propane", page 52).

Start-up procedure 9

9.7 Inlet gas pressure

z Open at least one thermostatic radiator valve if present

to allow water to flow through the boiler. Do not switch on the boiler.

z Close the gas shut-off valve. Loosen the screw plug on

the inlet gas pressure testing nipple by two turns (fig. 34, pos. 1).

z Connect the pressure gauge connection hose to the

testing nipple (fig. 34, pos. 2).

z Slowly open the gas shut-off valve.

The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psi (3.5 kPa).

The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi (3.5 kPa).

Boiler

capacity

24 kW Natural gas 4.45 (0.174)

30 kW Natural gas 4.45 (0.174)

45 kW Natural gas 5.40 (0.213)

60 kW Natural gas 7.50 (0.293)

Table 6 Gas orifice diameter

Type of gas supply

LPG P 3.35 (0.131)

LPG

P 3.35 (0.131)

LPG P 4.05 (0.158)

LPG

P 5.40 (0.213)

Gas orifice diameter

in mm (inch)

Fig. 34 Measuring the inlet gas pressure

z Briefly press on the control panel cover to open it.

Fig. 35 Opening the control panel

z Switch on the heating system by setting the main switch

to position "1" (see chapter 10 "BC10 basic controller", page 39).

z Press the "Chimney Sweep"

d button and hold it (for

approx. two seconds) until the display shows a decimal point.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 33

Start-up procedure9

z Measure the gas connection pressure as soon as the

"Burner" LED lights and enter this value in the start-up report.

The inlet gas pressure must be:

– for natural gas - min. 3.5 to 10.5 inch W.C (8.7 to

26.1 mbar), nominal supply pressure 7.0 inch W.C. (17,4 mbar)

– for LPG - min. 8.0 to 13.0 inch W.C. (19.9 to 32.3 mbar),

nominal supply pressure 11.0 inch W.C. (27.4 mbar).

z Repeatedly press the "Service"

temperature indication is displayed.

z Press the "Chimney Sweep"

measurement procedure.

z Close the gas shut-off valve.

z Remove the connection hose again and tighten the

screw plug on the testing nipple.

z Open the gas shut-off valve again.

CAUTION

– Contact the relevant gas utility company if the

required inlet gas pressure is not available.

– Install a gas pressure regulator before the

gas burner fitting if the supply pressure is too high.

e button until the

d button to end the

9.8 Checking and adjusting the gas/air ratio

z Switch off the heating system using the main switch.

z Loosen the screw plug on the measuring nipple for the

burner pressure by two rotations (fig. 36, pos. 1).

z Set the pressure gauge to zero.

z Use a hose to connect the plus terminal of the pressure

gauge to the burner pressure measuring nipple (fig. 36, pos. 2).

Fig. 36 Checking the gas/air ratio

z Switch on the heating system using the main switch.

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34 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

z Press the "Chimney Sweep" d button and hold it (for

approx. two seconds) until the display shows the decimal point.

Start-up procedure 9

z Press and hold the "Chimney Sweep"

d and "Service"

e buttons (for approx. five seconds) until the display

shows "Lxx" (e. g. L80).

z Set the boiler to partial load "L30" by pressing the

"Chimney Sweep" "Reset"

z Read out the differential pressure.

The differential pressure (p W.C. (- 5 Pa) (±0.02 inch W.C. = ± 5 Pa) (read-out on pressure gauge: -0.04 – 0 inch W.C. = -10 – 0 Pa).

z Enter the value measured in the start-up report.

z If the gas/air ratio is not correct it can be adjusted using

the adjustment screw (fig. 37, pos. 1). The adjustment screw is located behind the cover screw.

z Repeatedly press the "Service"

temperature indication is displayed.

z Press the "Chimney Sweep"

point is cleared from the display.

c button (lower values).

d button (higher values) or the

– p

Gas

) must be -0.02 inch

Air

e button until the

d button until the decimal

= higher values = lower values

Fig. 37 Setting the gas/air ratio

z Switch off the heating system using the main switch.

z Remove the measurement set-up, tighten the screw in

the burner pressure measuring nipple.

z Switch on the heating system using the main switch.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 35

Start-up procedure9

9.9 Carrying out a leak test in operating conditions

z Check all gaskets and joints in the burner gas circuit for

leaks while the burner is operational, using a foaming agent.

DANGER

Leaks may be caused to pipes and screw connections during start-up activities if flammable gas explodes.

– Only use approved leak detection agents for

leak detection such as a soapy water solution.

CAUTION

due to a short circuit.

– Cover damageable parts 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.

9.10 Measuring the carbon monoxide content (CO)

z Measure the carbon monoxide content on the flue gas

sampling point (fig. 38).

The CO values in an air-free condition must be below 400 ppm or 0.04 vol. %. Values of 400 ppm and up indicate that the burner adjustment may be wrong, the gas burner fitting or the heat exchanger are dirty or that there may be burner faults.

z You must establish and resolve the cause. The boiler

must be operational when you do this.

9.11 Function testing

z You must check the functioning and, if readjustment is

possible, the adjustment of all control, regulating and safety devices when carrying out start-up tests, annual inspections or maintenance as required.

z You must also test the gas and water lines for leaks.

Fig. 38 Flue gas sampling point

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36 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

9.12 Measuring the ionization current

z Switch off the heating system using the main switch.

z Disconnect the plug and socket connection of the moni-

toring cable and connect the measuring device in series (fig. 39). Select the µA direct current range on the measuring device. The measuring device must have a resolution of at least 1 µA.

Start-up procedure 9

z Switch on the heating system using the main switch.

z Press the "Chimney Sweep"

approx. two seconds), until the display shows the decimal point.

z Press and hold the "Chimney Sweep"

d button and hold it (for

d and "Service"

e buttons, until the display shows "Lxx" (e. g. L80).

z Set the boiler to partial load "L30" by pressing the

"Chimney Sweep" "Reset"

z Measure the ionization current. When the boiler is in

partial load mode the ionization current must be > 5 µA DC.

z Enter the value measured in the start-up report.

z Repeatedly press the "Service"

temperature indication is displayed.

z Press the "Chimney Sweep"

measurement procedure.

z Switch off the heating system using the main switch.

z Remove the measuring device and restore the plug and

socket connection.

c button (lower values).

d button (higher values) or the

e button, until the

d button to end the

Fig. 39 Measuring the ionization current

= higher values = lower values

z Switch on the heating system again using the main

switch.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 37

Start-up procedure9

z Push against the drawer (fig. 40) to close the control

panel.

9.13 Testing the Ignition Safety shut off device

z Switch off the heating system using the main switch.

z Disconnect the plug and socket connection of the moni-

toring cable.

z Switch on the heating system using the main switch.

z Press the "Chimney Sweep"

approx. two seconds), until the display shows the decimal point.

z 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 "6A" code can be seen in the display.

After the last start-up attempt, the boiler will lock out. The "6A" code is blinking in the display.

z Connect the plug and socket connection of the moni-

toring cable.

z Press the reset button.

z Check if the boiler starts-up.

z Press the "Chimney Sweep" button return to normal

operating conditions.

d button and hold it (for

Fig. 40 Closing the control panel

9.14 Installing the casing

z Install the casing and close the latches (fig. 41).

Do not lift the casing by the latches!

z Lock the latches using the radiator key.

9.15 Informing the owner, handing over the technical documents

z Show the owner how the heating system works and how

the boiler can be operated. Hand over the technical documents.

Fig. 41 Installing the casing

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38 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

10 BC10 basic controller

10.1 Operating the BC10 basic controller

BC10 basic controller 10

3 6

110

100

120

130

140

110

1011

Fig. 42 BC10 basic controller – Controls

pos. 1: Main switch pos. 2: DHW temperature knob pos. 3: LED "DHW status" pos. 4: Display pos. 5: Space heating water temperature knob pos. 6: LED "Heating system status"

10.1.1 Switching the heating system on and off

Switching on the heating system

130

150

170

190

812

pos. 7: Under the cover a RC system controller can be installed

(not available). pos. 8: LED "Burner Operation" pos. 9: Service Tool connector pos. 10: "Service" pos. 11: "Chimney sweep" pos. 12: "Reset" c button

e button

d button

z Set the main switch on the BC10 basic controller to

position "1" (On).

Switching off the heating system

z Set the main switch on the BC10 basic controller to

position "0" (Off).

10.1.2 Displaying the operating conditions of the burner and resetting the burner or resetting burner faults

Displaying the operating conditions of the burner

The LED indicates the operating condition of the burner.

LED Condition Explanation

On Burner

operational

Off Burner off The water in the boiler has reached the

Table 7 LED indication

The water in the boiler is being heated.

required temperature or there is no heat request.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 39

BC10 basic controller10

Resetting the boiler or resetting faults

If the boiler is down due to a fault, you can reset the boiler by pressing the "Reset" so-called lock-out faults. There is another type of fault, socalled blocking faults, that reset themselves when the cause has been remedied.

c button. This is only possible for

z Press the "Reset"

The display shows "rE" while resetting. It is only possible to reset the boiler when a lock-out code (blinking fault code) is visible in the display.

NOTICE

If the burner returns to fault mode after resetting the boiler, you must resolve the fault using the servicing section in this document. Contact your supplier if necessary.

10.1.3 Displaying the heating system status and/or faults

The display of the BC10 basic controller shows the status of the heating system.

In the event of a fault the display immediately shows the fault or the warning in the form of an error code (see subsection 15.2). The status display will flash if the fault is a lock-out fault.

z Press the "Service"

displays or to read out the service and error codes.

z Resolve the fault see subsection 15.3.

The following status displays can be seen depending on the operating conditions:

c button to reset the boiler.

e button to switch between status

Displays

(examples)

140

P21

Values Meaning Operating condition/Remedy

number 0 ... 199 2)Current boiler water temperature (in °F)

> P15 Current system pressure (in psi) Normal operating conditions

-H

Table 8 Possible status displays

Standard display for this operating condition. This display appears after 5 minutes if no button is pressed.

The temperature is higher as 199° when 199 is blinking in the display.

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40 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

BC10 basic controller 10

Displays

(examples)

P12

(changing)

-H 140

P12

(flashing)

207

140

Values Meaning Operating condition/Remedy

P3 ... P12 Warning:

System pressure is too low (between 3 and 12 psi = 0.2 and 0.8 bar)

number 0 ... 199 2)Current boiler water temperature (in °F)

P3 ... P12 Current system pressure (in psi)

< P3 Fault: system pressure is far too low (< 3 psi =

< 0.2 bar)

Error code

number > 200

number 0 ... 199

< P3 Current system pressure (in psi)

Remedy the error see servicing section

Current boiler water temperature (in °F)

Warning

Heating system remains operational between 12 psi and 3 psi (0.8 and 0.2 bar). Fill the heating system and restore the minimum filling pressure (≥ 14.5 psi = ≥ 1.0 bar). The system pressure is shown for 10 minutes after which the standard display returns.

Fault

Burner and boiler circuit pump are not operational. Frost protection is active up to 2 psi (0.1 bar).

The heating system will only become operational again if the pressure is back to

14.5 psi (1.0 bar). Fill the heating system and restore the minimum filling pressure (≥ 14.5 psi =

≥ 1.0 bar). The system pressure is shown for

10 minutes after which the standard display returns.

A12

(partially

flashing)

207

140

P21

816

-H 140

P21

(flashing)

Combination of letters and digits

number > 199

number 0 ... 199

> P15 Current system pressure (in psi)

A00 ... A99 Service code System faults

number > 800

number 0 ... 199 Current boiler water temperature (in °F)

> P15 Current system pressure (in psi)

Service code Fault

Error code Remedy the error using the servicing section in

this manual

Current boiler water temperature (in °F)

Error code Remedy the error using the service section in this manual

Fault

No communication between BC10 and automatic gas burner.

Lock-out faults (flashing display) must be reset by pressing the "Reset"

Blocking faults reset automatically as soon as the cause has been removed.

Remedy any blocking faults that remain active for a long time using the service section in this manual.

System faults are faults in the heating system that do not affect the burner operation.

Fault

Remedy the error using the service section in this manual.

Check the connections to both devices. Check the communication lines.

c button.

Table 8 Possible status displays

Standard display for this operating condition. This display appears after 5 minutes if no button is pressed.

The temperature is higher as 199° when 199 is blinking in the display.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 41

BC10 basic controller10

10.2 Carrying out additional tasks

10.2.1 Carrying out a flue gas test

The "Chimney Sweep"

The heating control system works at the maximum flow temperature for 30 minutes. This is set on the BC10 basic controller using the "maximum heater temperature" knob. During flue gas testing the decimal point lights up in the display.

d button is used for the flue gas test.

z Press and hold the "Chimney Sweep"

(< 5 seconds) until the decimal point is displayed.

z Carry out the flue gas test.

z Press the "Chimney Sweep"

flue gas test.

10.2.2 Selecting partial load operation (e. g. during flue gas testing)

You can operate the boiler at a reduced boiler capacity during flue gas testing. This reduction is only effective for the duration of the flue gas test.

z Press the "Chimney Sweep"

until the decimal point shows in the status display. This will switch on the flue gas test.

z Press and hold the "Chimney Sweep"

d button to interrupt the

d button (max. 2 seconds)

d button

d and "Service"

e buttons (for approx. 5 seconds) to enter the partial

load mode.

z Press the "Reset"

percentage.

Example: boiler capacity reduced to 50 % of the rated boiler capacity.

c button to reduce the boiler capacity

L50.

z Press the "Chimney Sweep"

boiler capacity percentage.

z When test is completed, press the "Service"

until the temperature indication is displayed.

z Press the "Chimney Sweep"

point is cleared from the display.

10.2.3 Switching the heating system to manual mode

In manual mode the heating system can be operated independently of an external control unit. The boiler is operated with the heating system temperature set on the right knob serving as the target value.

A blinking decimal point is displayed while manual mode is active.

z Press the "Chimney Sweep"

5 seconds) until the decimal point in the status display flashes.

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42 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

d button to increase the

e button

d button until the decimal

d button (for more than

z Turn the knob to set the maximum space heating system

temperature.

BC10 basic controller 10

130

110

150

170

190

z Press the "Chimney Sweep"

d button to exit manual

mode.

WARNING

– Turn the "space heating system

temperature" knob to limit the heating system temperature to the permissible flow temperature for the floor heating circuit (e. g. 86 – 104 °F = 30 – 40 °C), so pipes will not overheat.

DANGER

The heating system can freeze up if a power failure occurs or after switching off the power supply, because manual operation then is no longer active.

– You must re-activate manual operation after

switching on the system to keep the heating system operational (especially if there is a risk of frost).

10.3 Configuring the boiler

Regu-

lator

setting

Table 9 Heating capacity

boiler cap.

in %

L30 L40 L50 L60 L70 L80 L90

L--

24 kW

kW btu kW btu kW btu kW btu

7.2 24,566 8.7 29,684 13.5 46,062 18.0 61,542

9.6 32,755 11.7 39,920 18.0 61,416 24.0 82,080

12.0 40,944 14.8 50,498 24.5 83,619 30.0 102,630

14.4 49,133 17.8 60,734 27.0 92,178 36.0 123,192

16.8 57,322 20.9 71,311 31.5 107,573 42.0 143,766

19.2 65,510 23.9 81,547 36.0 122,976 48.0 164,352

21.6 73,699 27.0 92,124 40.5 138,389 54.0 184,950

24.0 81,888 30.0 102,360 45.0 153,810 60.0 205,560

Heating capacity (±5 %)

boiler cap.

30 kW

boiler cap.

45 kW

boiler cap.

60 kW

10.3.1 Adjusting the heating capacity

Setting the heating capacity depending on the maximum heat requirement (see table 9).

z Press and hold the "Chimney Sweep"

d and "Service"

e buttons until an "L" with a double-digit value (e. g.

L80) or an "L" followed by two dashes (L--) is displayed.

Factory setting "L--".

z Set the heating capacity by pressing the "Chimney

Sweep" button (lower values).

z Press the "Service"

d button (higher values) or the "Reset" c

e button to confirm the setting.

L--

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 43

BC10 basic controller10

110

10.3.2 Setting the DHW temperature value

z Turn the "DHW temperature" rotary knob to set the

desired temperature of the hot water in the hot-water tank.

100

120

130

140

Condition Explanation LED

0 Off No hot water supply (only heating mode). Off

Eco

Economy mode, Hot water temperature 140 °F (60 °C)

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 Direct setting on BC10 in °F The temperature set on the BC10 is a temperature that cannot be changed using a

RC thermostat.

Aut Entry via thermostat

(presetting)

The temperature is set on the thermostat (e. g. RC30). If no thermostat is connected, the maximum DHW temperature is 140 °F (60 °C).

Table 10 Settings of "DHW temperature" knob

This function has been optimized for boilers with combined DHW heating (combi-units).

The heating program (timer) of the room control unit remains active, as a result of which no hot water is heated during night-time operation.

The LED under the rotary knob lights up if the DHW temperature is below the target value (heat request for DHW).

10.3.3 Entering the space heating water temperature

130

z Turn the "space heating water temperature" knob to set

the upper limit value of the heater water for the heating operation. This limitation does not apply to DHW prepa-

110

150

170

190

ration.

Condition Explanation LED

0 Off No supply to heating system (only DHW heating operation). Off

86 – 190 Direct setting on BC10 in °F

(86 – 190 °F = 30 – 90 °C)

Aut Entry via thermostat

(presetting)

The temperature set on the BC10 is a temperature that cannot be changed using a RC thermostat. Supply temperature does not rise above the set temperature.

The temperature is automatically determined on the basis of the heating characteristic. If no thermostat is connected, the maximum heater temperature is 190 °F (90 °C).

Table 11 Settings of "space heating water temperature" rotary knob

The LED under the rotary knob lights up when the heating system is switched on and heat is requested. In summer mode the heating system is switched off (LED off).

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44 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

10.3.4 Setting the pump post-purge period

A pump must be connected to PK (see fig. 29, pos. 7) of the external connection board in order to be able to set the pump run over time.

CAUTION

– Set the boiler primary pump post-purge

period to 24 hours if the heating system is controlled by room temperature sensor and there is a risk of parts of the heating system that are outside the coverage of the room thermostat freezing (e. g. radiators in a garage; constant circulation).

BC10 basic controller 10

z Press and hold the "Chimney Sweep"

d and "Service"

e buttons until the display shows "L--".

z Press the "Service"

The heating system has been factory-set to a pump postpurge period of 5 minutes.

z Press the "Chimney Sweep"

set the pump post-purge period. The pump post-purge period can be set from 5 – 60 minutes (F5 - F60) or to 24 hours (F1d).

z Press the "Service"

NOTICE

On thermostat only systems a 5 to 10 minute post-purge setting is recommended to purge heat from the boiler.

e button. The display shows "F05".

d or "Reset" c buttons to

e button to confirm the setting.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 45

Shutting down the system11

11 Shutting down the system

DANGER

The heating system may freeze if it is not operational in times of frost.

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.

DANGER

Should overheating occur or gas supply fail to shut off, turn off the manual gas control valve to the boiler.

11.1 Shut down the heating system using the control unit

Shut down your heating system using the BC10 basic controller. When the BC10 basic controller is shut down, the burner is also switched off automatically. Further information on how to operate the BC10 basic controller can be found in chapter 10 "BC10 basic controller", page 39.

z Switch off the heating system using the main switch.

z Close the main shut-off valve or the gas shut-off valve.

11.2 Shutting down the heating system in the event of an emergency

You must immediately close the main shut-off valve or gas shut-off valve and disconnect the power from the heating system.

z Close the main shut-off valve.

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46 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

12 Inspection

We advise you to offer your customer an annual inspection and maintenance contract (for the contents of this contract, see page 59 and page 60).

If inspection reveals that maintenance work is necessary you can carry this out as required (see chapter 13 "Maintenance", page 49).

CAUTION

– Check and clean the heating system once a

year.

– Carry out a maintenance overhaul if

necessary. Immediately repair defects to avoid damage to the heating system!

WARNING

Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system 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

accidental restarting.

Inspection 12

z Periodically examine the venting systems and cleaning

of the screens in the vent terminal.

z Also periodically inspect the low water cutoffs, including

flushing of float types and clean the condensate collections and disposal system.

12.1 Preparing the boiler for inspection

z Switch off the heating system using the main switch.

z Remove the cover from the boiler (fig. 7, page 13).

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 professional.

12.2 Visual inspection for general signs of corrosion

z Check all gas and water pipes for signs of corrosion.

z Replace any pipes that are corroded.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 47

Inspection12

12.3 Internal leak testing

z Switch off the heating system using the main switch.

z Test for internal leaks of the gas burner fitting on the inlet

side, applying a test pressure of 7.0 inch W.C. (17.4 mbar) in case of natural gas and 11.0 mbar (27.4 mbar) in case of LPG.

After one minute the pressure must not have dropped by more than 3.8 inch W.C. (10 mbar).

z If the pressure has dropped more, you must check all

gaskets and joints upstream of the gas burner fitting for leaks using a foaming agent. Repeat the pressure test if no leaks are found. If the pressure has again dropped by more than 3.8 inch W.C. (10 mbar) per minute you will have to replace the gas burner fitting.

12.4 Measuring the ionization current

See subsection 9.12 "Measuring the ionization current", page 37.

12.5 Measuring the inlet gas pressure

See subsection 9.7 "Inlet gas pressure", page 33.

12.6 Checking and adjusting the gas/air ratio

See subsection 9.8 "Checking and adjusting the gas/air ratio", page 34.

12.7 Carrying out a gas leak test in operating conditions

See subsection 9.9 "Carrying out a leak test in operating conditions", page 36.

12.8 Measuring the carbon monoxide content (CO)

See subsection 9.10 "Measuring the carbon monoxide content (CO)", page 36.

12.9 Carrying out a pressure test of the heating system

See chapter 9 "Start-up procedure", page 30.

12.10 Checking the functioning and the safety of the air intake and flue gas conduit

See subsection 9.5 "Checking the combustion air/flue gas connection", page 32.

12.11 Checking venting systems

Check air intake and flue gas for obstruction or damage.

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48 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

13 Maintenance

CAUTION

There is no need to lubricate the combustion motor as it is permanently lubricated.

z Switch off the heating system using the main switch.

z Close the gas shut-off valve.

z Remove the casing.

13.1 Cleaning the heat exchanger, burner and condensate trap

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.

z Dismantle the hot surface ignitor and the ionization elec-

trode.

z Loosen the fastening nuts (fig. 43, pos. 1).

z Remove the earth cable (fig. 43, pos. 2).

Maintenance 13

Fig. 43 Removing the hot surface ignitor and the ionization

electrode

z Remove the retaining plate.

z Pull the hot surface ignitor (fig. 43, pos. 3) and the ioniza-

tion electrode (fig. 43, pos. 4) out of the heat exchanger.

z Loosen the threaded connection to the gas control valve

(fig. 44, pos. 1) and pull the plug (fig. 44, pos. 2) from the gas valve terminal block.

z Pull the plug from the fan unit (fig. 44, pos. 3).

Fig. 44 Removing the connections

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 49

Maintenance13

z Loosen both sets of retaining clips (fig. 44, pos. 4 and 5)

of the burner cover and remove the burner cover with the fan unit and the gas burner fitting (fig. 45, pos. 1).

z Remove the gas/air distributor plate (fig. 45, pos. 2), the

orifice plate (GB142-24, GB142-30 and GB142-60 only, fig. 45, pos. 3) and the burner (fig. 45, pos. 4). Note that the orifice plate of the GB142-60 has a different shape.

z Clean the gas/air distributor plate, the orifice plate

(GB142-24, GB142-30 and GB142-60 only) and the burner using compressed air.

z Remove the baffle plate and clean it using compressed

air (fig. 46).

Fig. 45 Cleaning the burner cover, gas/air distributor plate,

orifice plate and burner

z Flush the heat exchanger with water.

z Re-assemble all parts in reverse order of disassembly.

NOTICE

It is important to inspect and properly replace the rubber gaskets.

z Switch on the heating system using the main switch.

z Press the "Chimney Sweep"

point is displayed. Leave the boiler on for approx. 10 minutes.

d button until the decimal

Fig. 46 Baffle plate

Fig. 47 Cleaning the heat exchanger

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50 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

z Switch off the heating system using the main switch.

z Dismantle the boiler again and flush the heat exchanger

with water.

z Pull the condensate trap from the condensate plate

(fig. 48, pos. 1).

z Loosen the condensate trap from the connection (fig. 48,

pos. 2) and remove it.

z Use a bristle brush to clean the condensate trap.

z Flush the condensate trap.

z Fill the condensate trap with water before re-installing it.

z Check the condensate trap gasket for damage and

replace it if necessary.

z Re-assemble all parts in reverse order of disassembly.

Maintenance 13

Fig. 48 Condensate trap

13.2 Checking and adjusting the gas/air-ratio

See chapter 9.8 "Checking and adjusting the gas/air ratio", page 34.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 51

Converting the boiler to propane14

14 Converting the boiler to propane

To convert the boiler to propane, the following instructions must be adhered to:

DANGER

if flammable gas explodes.

Only carry out work on gas conduits and fittings if you are licensed for such work.

z Turn off the gas supply.

z Switch off the heating system using the main switch.

z Disconnect the electrical power to the boiler.

z Set the thermostat or other operating control to lowest

setting.

z Remove the casing (fig. 49).

z Loosen the screw connection on the gas valve (fig. 44,

pos. 1, page 49) and pull the plug (fig. 44, pos. 2, page 49) from the gas valve.

z Pull both plugs from the fan unit (fig. 44, pos. 3,

page 49).

z Loosen both retaining clips (fig. 44, pos. 4, page 49) on

the burner cover and remove the burner cover together with the fan unit and the gas valve.

z Loosen the three crosshead screws and remove the gas

valve from the fan unit (fig. 50, pos. 1).

z Remove the gas orifice (fig. 50, pos. 2).

GB142-24/30 GB142-45/60

Fig. 49 Remove the casing

Fig. 50 Replacing the gas orifice

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52 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Converting the boiler to propane 14

z Fit the right orifice for the new type of gas supply (see

table 12). Make sure not to damage the O-rings.

z Re-assemble all parts in reverse order of disassembly.

z Carry out the start-up activities and complete a new start-

up report.

z Also check all joints and gaskets affected by the installa-

tion activities while carrying out the tightness test in operating conditions.

z Place a new sticker underneath the existing rating plate

sticker indicating the type of gas supply installed. Fill out the required information on the conversion label.

z Fit the casing again.

Boiler

capacity

24 kW Natural gas 4.45 (0.174)

30 kW Natural gas 4.45 (0.174)

45 kW Natural gas 5.40 (0.213)

60 kW Natural gas 7.50 (0.293)

Table 12 Gas orifice diameter

Type of gas supply

LPG P 3.35 (0.131)

LPG

P 3.35 (0.131)

LPG P 4.05 (0.158)

LPG

P 5.40 (0.213)

Gas orifice diameter

in mm (inch)

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 53

Appendix15

[-/h.}

15 Appendix

15.1 Operating messages

z Press the "Service" e button a number of times to switch

between the various status displays.

Display Meaning

Normal mode

[-/h/\| [=/h/\|

Normal mode

[0/a/\| [0/c/\| [0/e/\| [0/h.\| [0/l/\| [0/u/\| [0/y/\|

Test mode

[-/a.\|

Dot displayed in right-

hand bottom corner

=/-

Boiler in space heating mode *

Boiler in DHW heating mode

Burner interval circuit, burner will start automatically after 10 minutes

Burner is started

More capacity was delivered than required

Standby

Gas burner fitting is opened

Initializing/ pre purge

Flow temperature higher than set

Boiler in flue gas test

Manual mode

Reset

[r/e/\|

Table 13 Normal operating messages

* “- H” May also appear when the boiler is in frost protection mode. There has been a continuous DHW demand and CH request for more then one hour.

The boiler then switches to CH mode. The operating code flashing in the display after the service button is pressed is A01/ 818. To enable the DHW, restart the boiler.

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54 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Blinking dot in right-

hand bottom corner

Boiler in manual mode

Reset (after holding the "Reset" c button for 5 seconds, the heating system is returned to its switch-on condition)

15.2 Error messages

z Press the "Service" e button to display the service code

(e. g. "3A").

z Press the "Service"

(e. g. "207").

The error message is a combination of the service code (e. g. "3A") and the error code (e. g. "207"). You can only resolve the error message using the Service chapter in this manual.

INSTRUCTION FOR INSTALLERS

The display may also show system faults (e. g. "A11"). In principle, they are identified by the initial letter "A" and they refer to faults between the boiler and the additionally available electronic components.

e button to display the error code

Appendix 15

Display Meaning

2 Water flow / water pressure

E207System pressure too low < 3 psi (0.2 bar). F271Temperature difference between safety and supply

sensors too much or no temperature increase after starting the burner.

L266Test of pump operation via a pressure increase in the

heating system (during pump start).

P Temperature increase of safety sensor or supply

sensor too high.

U Temperature difference between supply and return

sensor too much.

Y Pump feedback fault.

3 Fan speed

A264Fan unit failed during operation. F273Continuous 24 hour operation. L214Fan shut down during security test. P216Fan unit is running too slowly. Y215Fan unit is running too fast.

4 Temperatures

A218Supply sensor over 220 °F (105 °C). E278Sensor test failed L220Safety sensor affected by short circuit or higher than

266 °F (130 °C).

P 221 Loose contact or defective safety sensor. U 222 Supply sensor affected by short circuit. Y 223 Loose contact or faulty supply sensor.

Display Meaning

6 Flame monitoring

A 227 No ionization message after ignition. C 228

L306The flame went out during the heating phase. P 229 Hot-surface ignitor on for too long.

7 Grid voltage

C 231 The grid power was interrupted after an error.

L261

8 External switching contact

Y External switching contact, e. g. temperature

9 System faults

A235Communication fault between UBA and KIM.

H 237

P 239 UBA fault. L 234

U233KIM out of order. Y Communication fault between BC10 basic

E System faults

1, A, C, F, H, L,

Ionization measured before burner start.

306

UBA fault.

280

safety switch for floor heating, has taken place.

UBA fault.

267 272

Faulty gas burner fitting cable connection.

238 239

controller and UBA.

Internal UBA fault.

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 55

Appendix15

15.3 Technical specifications

General specifications Unit boiler cap.

24 kW

Gas category Natural gas

Rated thermal load for Natural gas btu/hr 25,700 – 84,800 31,800 – 106,000 46,000 – 149,000 66,000 – 214,800

Rated heating capacity for heating curve 176/140 °F (80 – 60 °C)

Rated heating capacity for heating curve 122/86 °F btu/hr 25,300 – 83,300 30,700 – 102,400 45,100 – 146,300 64.800 – 211,600 (50 – 30 °C)

Boiler efficiency rating max. capacity for heating curve 176/140 °F (80 – 60 °C)

Boiler efficiency rating max. capacity for heating curve 122/86 °F (50 – 30 °C)

CSA output btu/hr 76,300 95,400 144,800 178,900

Heating

Max. flow temperature °F (°C) 194 (90) 194 (90) 194 (90) 194 (90)

Heater water temperature °F (°C) 86 – 190 (30 –

Max. operating overpressure of boiler psi (bar) 43.5 (3) 43.5 (3) 58 (4) 58 (4)

Heat exchanger heating circuit volume gallons (l) 0.7 (2.5) 0.7 (2.5) 1.0 (3.6) 1.3 (4.7)

Pipe connections

Gas connection inch ¾” NPT ¾” NPT ¾” NPT ¾” NPT

Heating system water connection inch (mm) 1.0” NPT (25.4) 1.0” NPT (25.4) 1.0” NPT (25.4) 1.0” NPT (25.4)

Condensate water connection inch (mm) Ø 1.3” (Ø 32) Ø 1.3” (Ø 32) Ø 1.3” (Ø 32) Ø 1.3” (Ø 32)

Flue gas values

Condensate water quantity for natural gas G20, 104/86 °F (40/30 °C)

pH value condensate water pH approx. 4.1 approx. 4.1 approx. 4.1 approx. 4.1

Flue gas mass flow rate at full load g/s 10.0 12.6 19.4 25.9

Flue gas temperature 176/140 °F (80/60 °C), full load °F (°C) 150 (66) 167 (75) 150 (66) 150 (66)

Flue gas temperature 176/140 °F (80/60 °C), partial load °F (°C) 135 (57) 137 (58) 135 (57) 135 (57)

Flue gas temperature 122/86 °F (50/30 °C), full load °F (°C) 113 (45) 118 (48) 96 (36) 96 (36)

Flue gas temperature 122/86 °F (50/30 °C), partial load °F (°C) 91 (33) 91 (33) 91 (33) 91 (33)

content, full load, natural gas G20 % 9.2 9.2 9.3 9.3

content, full load, LPG G31, propane % 10.0 10.0 10.0 10.0

Standard emission factor CO mg/kWh ≤ 15 ≤ 15

Standard emissions factor NO

Free fan unit feed pressure inch W.C.

Flue gas connection

Ø Flue system, dependent on the air in the room inch (mm) 3 (80) 3 (80) 3 (80) 3 (80)

Ø Flue system, independent of the air in the room inch (mm) 3/3 (80/80)

Electric data

main voltage V, Hz 120, 60 120, 60 120, 60 120, 60

Fuses amps 5 amps 120V

Electrical protection rating IP X4D IP X4D IP X4D IP X4D

Electrical power consumption, at full load W 96 117 64 82

Electrical power consumption, at partial load W 22 22 20 22

btu/hr 22,700 – 75,200 28,100 – 91,500 40,600 – 131,500 58,200 – 189,800

%88888888

%97979797

90), can be set on BC10 basic

controller

gallons

per hour

mg/kWh ≤ 20 ≤ 20

(Pa)

2.6 3.3 4.7 7.1

up to 0.023

(up to 60)

parallel

slow blow

boiler cap.

30 kW

Natural gas Natural gas Natural gas

86 – 190 (30 –

90), can be set on BC10 basic con-

troller

up to 0.039 (up to 100)

3/3 (80/80)

parallel

5 amps 120V

slow blow

boiler cap.

45 kW

86 – 190 (30 –

90), can be set on BC10 basic

controller

≤ 15 ≤ 15

≤ 20 ≤ 20

up to 0.054

(up to 140)

3/3 (80/80)

parallel

5 amps 120V

slow blow

boiler cap.

86 – 190 (30 –

90), can be set on BC10 basic

controller

up to 0.054

(up to 140)

3/3 (80/80)

parallel

5 amps 120V

slow blow

60 kW

Table 14 Technical specifications

If the heating capacity is limited to max. 80% (L80).

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56 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Appendix 15

General specifications Unit boiler cap.

24 kW

Boiler dimensions and weight

Height × Width × Depth inch

(mm)

Weight lbs (kg) 110 (50) 110 (50) 143 (65) 158 (72)

28 × 22 × 18.7

(712 x 560 x 475)

boiler cap.

30 kW

28 × 22 × 18.7

(712 x 560 x 475)

boiler cap.

45 kW

28 × 35.4 × 18.7

(712 x 900 x 475)

boiler cap.

60 kW

28 × 35.4 × 18.7

(712 x 900 x 475)

Table 14 Technical specifications

If the heating capacity is limited to max. 80% (L80).

Type of gas supply

Factory pre-setting of the gas control valve

Natural gas Delivered factory-set: Natural Gas

LPG P Suitable for propane after conversion (also see

the chapter "Conversion to another type of gas supply"). Information on gas type instruction plate: Set to gas category: Propane.

Table 15 Factory setting of the gas control valve

Thermal power gas boiler

GB142-24

GB142-30

Type of gas supply

Natural gas 4.45 (0.174) 423.072A

LPG P 3.35 (0.131) 423.072A

Natural gas 4.45 (0.174) 423.072A

LPG P 3.35 (0.131) 423.072A

Gas orifice

diameter in mm

(inch)

Venturi article

number

GB142-45

Natural gas 5.40 (0.213) 423.170A

LPG P 4.05 (0.158) 423.170A

Natural gas 7.50 (0.293) 423.173A

GB142-60

LPG P 5.40 (0.213) 423.173A

Table 16 Gas orifice diameter

z The gas orifice diameter is marked on the gas orifice

(in mm).

z The venturi article number is marked on both clips of the

venturi (see fig. 51, pos. 1 and 2).

Fig. 51 Venturi article number

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 57

Reports16

16 Reports

16.1 Start-up report

Put your signature and the date at the bottom of the start-up report.

Start-up activities Page Measured values Remarks

1. Fill the heating system and check that all connections are tight – Inlet pressure of expansion tank (observe the Installation Instructions

for the expansion tank) – Pressurize the system – Fill the condensate trap

2. Carry out a gas tightness test 30

3. Note down the gas characteristics: Wobbe index Operating heat value

4. Convert the boiler to another type of gas supply (only if allowed) 52

5. Vent the gas supply conduit 32

6. Check the combustion air/flue gas connection 32

7. Measure the gas connection pressure (flow pressure) 33 ________ inch W.C.

8. Check and adjust the gas/air ratio 34 ________ inch W.C.

9. Measure the carbon monoxide content (CO) 36 __________ ppm

10. Check and if necessary adjust the carbon monoxide content (CO2) __________ %

11. Measuring the ionization current 37 __________ µA

30 30

__________ psi

30 __________ kWh/m³

__________ kWh/m³

12. Make the necessary settings on the thermostat 39

13. Carry out function testing 36

14. Fitting the casing 38

15. Inform the owner; hand over the technical documents 38

Confirm proper start-up

Company stamp/signature/date

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58 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Reports 16

16.2 Inspection report

z Please indicate the inspection activities that you have

carried out and enter the values measured.

Inspection activities page Date: ______ Date: ______ Date: ______

1. Test the general condition of the heating system

2. Carry out a visual inspection and test the functions of the heating system

3. Test all gas and water conduits and fittings for: – their tightness during operation – visible corrosion – signs of aging – fill the condensate trap

48 47

4. Check the burner, the heat exchanger and the condensate trap for pollution. First shut down the heating system

5. Check the burner and the ignition and ionization electrodes. First shut down the heating system

6. Measure the ionization current 37 _______ µA _______ µA _______ µA

7. Measure the gas connection pressure (flow pressure) 33 _______ psi _______ psi _______ psi

8. Check the gas/air ratio 34 _____ inch W.C. _____ inch W.C. _____ inch W.C.

9. Carry out a gas tightness test in operating conditions 48

10. Measure the carbon monoxide content (CO) 48 _______ ppm _______ ppm _______ ppm

11. Check the water pressure of the heating system – Inlet pressure of expansion tank (also see the

Installation Instructions for the expansion tank)

– Filling pressure

12. Check the operation and safety of the air intake and flue pipe 32

13. Check that the thermostat is set in line with the needs (see documents with thermostat)

14. Final check of inspection activities, note down the measurement and test results

3030_______

_______ psi _______ psi

15. Confirm proper inspection

Company

stamp/signature

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 59

Company

stamp/signature

Company

stamp/signature

Reports16

16.3 Maintenance report

z Sign for the maintenance activities that you have carried

out and enter the date.

Needs-dependent maintenance activities Page Date: _____________ Date: _____________

1. Clean the burner, the heat exchanger and the condensate trap. First shut down the heating system

2. Check and adjust the gas/air ratio CO

content with full load

content with partial load

3. Confirm proper maintenance

34 _____________ inch W.C.

_______________ % _______________ %

Company stamp/

Signature

_____________ inch W.C. _______________ % _______________ %

Company stamp/

Signature

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60 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Spare parts 17

17 Spare parts

Below is a list of the spare parts for this boiler. Look up the position number in the exploded view drawing on the next two pages for the illustration. Spare parts may be ordered from Buderus.

Pos. Description Product No.

Casing 24/30 kW 7099988

Casing 45/60 kW 7099901 2 Casing latches left (2 pc) 7099039 3 Casing latches right (2 pc) 7099038

Casing seal 24/30 kW 7098752 4

Casing seal 45/60 kW 7098798 5 Wall mounting bracket 7098364

Back panel 24/30 kW 7099001 6

Back panel 45/60 kW 7099903 7 Cap air vent 7100250 8 Exhaust adapter 3” – 3” 28268 9 Seal ring Ø 3” 77470s

10 Seal ring Ø 80 mm 7096475 11 Flue gas collector 7098857 12 Oval seal 7098858

Heat exchanger 24/30 kW 7746900159

Heat exchanger 45 kW 7746900160

Heat exchanger 60 kW 7746900161

14 Heat exchanger baffle 24/30 kW 7098828

Seal condensate collector 24/30 kW 7098834

Seal condensate collector 45 kW 7098838

Seal condensate collector 60 kW 67900522

Condensate collector + sealing 24/30 kW 7098840

Condensate collector + sealing 45 kW 7098844

Condensate collector + sealing 60 kW 67900521

17 Clamp 7098848 18 Sensor NTC 7100136 19 Revision set air vent ** 7098822 20 Sight glass 7098575

Burner box 24/30 kW 7099057

Burner box 45 kW 7098875

Burner box 60 kW 67900525

22 Safety sensor 78194

Seal burner 24/30 kW 7098916

Seal burner 45 kW 7098920

Seal burner 60 kW 67900526

Gas/air distribution plate 24/30 kW 7100922

Gas/air distribution plate 45 kW 7098926

Gas/air distribution plate 60 kW 67900527

Orifice plate 24/30 kW 7100920

Orifice plate 60 kW 7746700120

Burner 24/30 kW 7099003

Burner 45 kW 7098932

Burner 60 kW 67900528

27 Gas-air inlet 7099004 28 Seal fan 7099023 29 Ionization electrode 78195 30 Hot surface ignitor 7099006 31 Shield hot surface ignitor 7100229 32 Mounting plate 7098852 33 Seal mounting plate (5 pc) 7098850

Pos. Description Product No.

Air inlet pipe; 24/30 kW 7099024

Air inlet pipe; 45/60 kW 7099023

35 Seal Ø50 mm (5 pc) 7099058

Venturi 24/30 kW 7099020

Venturi 45 kW 7099925

Venturi 60 kW 7099931 37 Seal set (4 pc) 7099021 38 Fan 78184 39 Gas control valve 7099025 40 Gas supply pipe GB142 USA 76685 41 Spring (5 pc) 7100549 42 Seal 2x16x22 (5 pc) 7098778

Orifice Ø 4.45 24/30 kW 7099016 43

Orifice Ø 5.40 45 kW 76690

Orifice Ø 7.50 60 kW 76686 44 Condensate trap 75978 45 Seal condensate trap (5 pc) 7100742

Supply pipe CH; 24/30/45 kW 75990 47

Supply pipe CH; 60 kW 75991

Return pipe 24/30/45 kW 709965 48

Return pipe 60 kW 709945 49 Pressure sensor ** 7101436 50 Bottom plate 7099049 51 Transformer 120V 78191 52 Grommet 7099050 53 External connection board 7099042 54 External connection board cover 7099046 55 Fuse 5 AF slow blow 73904s 56 UBA cover 7099047 57 UBA3 - 120V 7099707 58 Drawer 7099043 59 Drawer front 7099037 60 Controller connection plate 78186 61 On/off switch 7099041 62 Controller cover 73698

Boiler ident. module 24 kW 78223

Boiler ident. module 30 kW 78224 63

Boiler ident. module 45 kW 78225

Boiler ident. module 60 kW 78226 64 Cable harness low voltage 78193 65 Cable harness high voltage 7099957 66 O-ring (10 pc) 38434s 67 Sealing bush (set) 7099002 68 Cable harness of on/off switch 7099072 69 Cable harness BX holder 7099070 70 Fuse holder 38345 71 Seal Ø60 mm (5 pc) 7098878 72 O-ring set orifice 7099018 73 Seal (5 pc) 7099059 74 Set screw M5x20 (5 pc) 7099065

** not shown in exploded views

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 61

Spare parts17

Pos. Description Product No.

75 Cap 24/30 kW 79105 76 Double nipple THR x COMPR 75977 77 Cabel saddle (10 pc) 7098810 78 Bolt M6x16 (2 pc) 7099078 79 Clip pressure sensor 7101370 80 Drainplug 7099364 81 Cap connection piece 38498 82 Clip (5 pc) 73651s 83 Centering ring (5 pc) 73480s 84 Coupling nut pump 73481s 85 Seal pump (10 pc) 15022s 86 Coupling nut pump 15020

87 Conversion set pump 73149 *** Conversion kit propane 24/30 kW 76687 *** Conversion kit propane 45 kW 76688 *** Conversion kit propane 60 kW 7746900156

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62 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Exploded view Logamax plus GB142-24/30

Spare parts 17

41 42

84 85

85 86

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Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007 63

Spare parts17

Exploded view Logamax plus GB142-45/60

74 72

85 86

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64 Installation instructions Logamax plus GB142-24/30/45/60 • version 10/2007

18 Index

Index 18

Baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

BC10 basic controller Burner

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . . . . 8, 39

Carbon monoxide content . . . . . . . . . . . . . . . . . . . . . 36

Casing CO values Combustion air/flue gas connection Condensate Condensate trap Condensate water drain Connection 120 volts Connections (for gas, flue gas and water)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . 32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . 49, 51

. . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . 28

. . . . . . 9, 10

DHW recirculating pump . . . . . . . . . . . . . . . . . . . . . . 27

DHW tank pump DHW temperature Dimensions Disposal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

. . . . . . . . . . . . . . . . . . . . . . . . . . . 27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 10

Inspection report . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Installation room Internal leak testing Ionization current Items supplied with unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . .12

. . . . . . . . . . . . . . . . . . . . . . . . . .48

. . . . . . . . . . . . . . . . . . . . . . . . . . . .37

. . . . . . . . . . . . . . . . . . . . . . .11

Mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Maintenance report Manual mode

. . . . . . . . . . . . . . . . . . . . . . . . . .60

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Operating messages . . . . . . . . . . . . . . . . . . . . . . . . .54

Orifice plate Outdoor-temperature sensor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

. . . . . . . . . . . . . . . . . . .27

Part-load operation . . . . . . . . . . . . . . . . . . . . . . . . . .42

Primary loop pump Pump slowing-down period

. . . . . . . . . . . . . . . . . . . . . . . . . .27

. . . . . . . . . . . . . . . . . . . .45

Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Errors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Faults

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Flue gas test Frost

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 46

Function testing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Gas leak tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Gas nozzles Gas supply conduit Gas supply pressure Gas/air distributor plate Gas/air ratio

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

. . . . . . . . . . . . . . . . . . . . . . . . . . 32

. . . . . . . . . . . . . . . . . . . . . . . . . 33

. . . . . . . . . . . . . . . . . . . . . . . 50

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 49, 56

Heating system water Hot-water target value

. . . . . . . . . . . . . . . . . . . . . . . . 46

. . . . . . . . . . . . . . . . . . . . . . . . 44

Resetting the burner . . . . . . . . . . . . . . . . . . . . . 39, 40

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Service codes Signs of corrosion Space heating water temperature Start-up report Switching contact, external Switching on the heating system

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

. . . . . . . . . . . . . . . . . . . . . . . . . . .47

. . . . . . . . . . . . . . .44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

. . . . . . . . . . . . . . . . . . . .27

. . . . . . . . . . . . . . . .39

Technical specifications . . . . . . . . . . . . . . . . . . . . . . .56

Tightness test Tools

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Transportation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

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Installation Instructions Logamax plus GB142-24/30/45/60 • version 10/2007 65

Notes

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66 Installation Instructions Logamax plus GB142-24/30/45/60 • version 10/2007

Notes

We reserve the right to make any changes due to technical modifications! Buderus • http://www.buderus.net

Installation Instructions Logamax plus GB142-24/30/45/60 • version 10/2007 67

Heating Contractor:

PRODUCTS MANU)ACTURED BY

BBT Thermotechnik GmbH

35573 WHW]ODU

www.buderus.de

Bosch Thermotechnology Corp.

50 Wentworth Avenue

Londonderry, NH 03053

Tel: 603-552-1Ɣ)D[

www.buderus.net

Bosch Thermotechnology Corporation reserves the right to make changes without notice

due to continuing engineering and technological advances.

721.502A – 4848 – 10/2007

Buderus Buderus Logamax plus GB142-24/30/45/60 INSTALLATION INSTRUCTIONS (7215 0200 – 10/2007 US/CA (en))

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Safety and general instructions

1.1 Designated use

1.2 Hazard definitions

1.3 The following instructions must be observed

1.4 Observe these instructions for space heating water

1.6 Disposal

2 Regulations and guidelines

3 Product description

4 Dimensions and connections

5 Packaging and transportation

5.1 Scope of delivery

5.2 Transporting the boiler

6 Installation

6.1 Requirements for the installation room

6.2 Fitting the boiler

6.3 Making the gas connection

6.4 Fitting the heating circuit supply and return pipes

6.5 Combustion Air and Ventilation Openings

6.6 Installation of the flue gas adapter (included in the scope of delivery)

6.7 Installation of the Exhaust and Air Intake system.

7 Connecting the condensate drain

8 Electrical connections

8.1 External connection board connections

9 Start-up procedure

9.1 Testing for gas leaks

9.2 Filling the boiler

9.3 Filling the condensate trap

9.4 Bleeding the gas supply valve

9.5 Checking the combustion air/flue gas connection

9.6 Checking the orifices

9.7 Inlet gas pressure

9.8 Checking and adjusting the gas/air ratio

9.9 Carrying out a leak test in operating conditions

9.10 Measuring the carbon monoxide content (CO)

9.11 Function testing

9.12 Measuring the ionization current

9.13 Testing the Ignition Safety shut off device

9.14 Installing the casing

9.15 Informing the owner, handing over the technical documents

10 BC10 basic controller

10.1 Operating the BC10 basic controller

10.1.1 Switching the heating system on and off

10.1.2 Displaying the operating conditions of the burner and resetting the burner or resetting burner faults

10.1.3 Displaying the heating system status and/or faults

10.2.1 Carrying out a flue gas test

10.2.2 Selecting partial load operation (e. g. during flue gas testing)

10.2.3 Switching the heating system to manual mode

10.3 Configuring the boiler

10.3.1 Adjusting the heating capacity

10.3.2 Setting the DHW temperature value

10.3.3 Entering the space heating water temperature

10.3.4 Setting the pump post-purge period

11 Shutting down the system

11.1 Shut down the heating system using the control unit

11.2 Shutting down the heating system in the event of an emergency

12 Inspection

12.1 Preparing the boiler for inspection

12.2 Visual inspection for general signs of corrosion

12.4 Measuring the ionization current

12.5 Measuring the inlet gas pressure

12.6 Checking and adjusting the gas/air ratio

12.7 Carrying out a gas leak test in operating conditions

12.8 Measuring the carbon monoxide content (CO)

12.9 Carrying out a pressure test of the heating system

12.10 Checking the functioning and the safety of the air intake and flue gas conduit

12.11 Checking venting systems

13 Maintenance

13.1 Cleaning the heat exchanger, burner and condensate trap

13.2 Checking and adjusting the gas/air-ratio

14 Converting the boiler to propane

15 Appendix

15.1 Operating messages

15.3 Technical specifications

16 Reports

16.1 Start-up report

16.2 Inspection report