Buderus Logamax plus GB162-80 kW, Logamax plus GB162-100 kW Service Instructions Manual

Service Instructions

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.

WARNING!

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

NOTICE!

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

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

vicinity of this or any other appliance.

– What to do if you smell gas

• 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.

Condensing gas boiler

6 720 614 965 (11/2012) US/CA

Notice:

• This manual is available in the English and French language.

• This manual must be retained for future reference.

Logamax plus
GB162-80 kW/100 kW

For the contractor

Please read these
instructions carefully
before servicing!

Product Description

10

17

7

1

32

31

20

27

15

29

5

34 2

8

26

25

9

11

12

13

15

14

22

21

18

19

24

23

28

6

33

3637

3538

16

30

39

42

40

41

34

43

Product Description

section 1 Product description

Fig. 1 Logamax plus GB162 with pump group

2

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

Product Description

section 2 Legend

1: BC10 basic controller receptacle
2: Installation option for room controller, e.g. RC35
3: Cover with user manual compartment
4: BC10 basic controller, can be expanded e.g. by the RC35

room controller
5: Connection box (low-voltage and 120 VAC connections)
6: Fan harness and mains lead of the pump
7: Condensate drain outlet
8: Condensate collector
9: Boiler front door
10: Automatic air vent
11: Retaining clips
12: Air intake for the fan
13: Gas pipe
14: Flue gas pipe
15: Door lock
16: Flue measuring point
17: Measuring point for air intake
18: Flue gas connection
19: Air intake connection
20: Fan
21: Gas valve
22: Venturi
23: Burner cover
24: Flow temperature sensor
25: Ionization electrode
26: Sight glass
27: Glow ignitor
28: Safety temperature sensor
29: Heat exchanger
30: Pressure sensor
31: Return temperature sensor
32: Universal Burner Automatic Version 3 (UBA 3)
33: Drawer with function module integration options
34: Cover shield
35: Condensate trap

Pump group (scope of delivery):

36: Isolating valve, blue (CH boiler return) with pump, drain

valve, check valve and thermometer
37: Manual gas shutoff valve, yellow (GAS)
38: Isolating valve, red (CH boiler supply) with drain valve,

pressure gauge, thermometer and pressure relief valve
39: Pressure gauge
40: Isolating valve
41: Thermometer (optional accessory)
42: Drain valve
43: Pressure relief valve 30 PSI (2 bar)

(or 50 PSI [3.45 bar] = optional)

The pump group also includes an insulation cover (see also
pump group installation instructions).

Low loss header (scope of delivery, single appliance only)

44: Low loss header (not illustrated)

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

3

Contents

section 3 Contents

Section page

Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Layout of this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Remedying faults using this document . . . . . . . . . . . . . . . . . . . . . . . 6

Logamax plus GB162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Safety and general instructions . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Regulations and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

General regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Regulations in Massachusetts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Normal Operation menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Flue Gas Test menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Service Mode menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Manual Operation menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Settings menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Removing the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Display readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Display settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Display codes and other symptoms . . . . . . . . . . . . . . . . . . . . . . . . 21

6 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7 Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Hanging the control panel from the boiler . . . . . . . . . . . . . . . . . . . . 56

Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Switching off main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Closing cover of the BC10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Switching off power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Opening boiler door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Closing isolating valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Draining the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Opening isolating valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Closing boiler door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Filling and bleeding the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Switch on power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Switching on main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Checking/replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Checking the fan unit; operation (120 VAC) . . . . . . . . . . . . . . . . . . 61

Checking the fan unit; power supply cord (120 VAC) . . . . . . . . . . . 62

Checking the fan unit; tacho cable . . . . . . . . . . . . . . . . . . . . . . . . . 62

Checking and/or replacing the fan unit . . . . . . . . . . . . . . . . . . . . . . 63

Checking the pump; mechanical obstruction . . . . . . . . . . . . . . . . . 64

Checking the pump; activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Checking the pump; power supply cord . . . . . . . . . . . . . . . . . . . . . 65

Checking the pump; tacho cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Checking the pump; pollution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Replacing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Checking the supply, safety, return and DHW temperature sensors 68
Checking the supply, safety, return and DHW temperature

sensors; cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Replacing the feed, safety and return sensors . . . . . . . . . . . . . . . . 71

Replacing the DHW temperature sensor . . . . . . . . . . . . . . . . . . . . 72

Section page

Checking the flue gas sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Checking the flue gas sensor; cable . . . . . . . . . . . . . . . . . . . . . . . . 73

Replacing the flue gas sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Checking the glow ignitor; activation . . . . . . . . . . . . . . . . . . . . . . . . 74

Checking the glow ignitor; resistance . . . . . . . . . . . . . . . . . . . . . . . 75

Checking the glow ignitor; power supply cord . . . . . . . . . . . . . . . . . 75

Replacing the ignition unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Measure the ionization current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Checking the ionization electrode; short circuit . . . . . . . . . . . . . . . . 77

Checking the ionization electrode; cable . . . . . . . . . . . . . . . . . . . . . 78

Checking the ionization electrode . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Checking the ionization circuit; ground lead . . . . . . . . . . . . . . . . . . 79

Checking the gas valve; power supply plug . . . . . . . . . . . . . . . . . . 79

Checking the gas valve; activation . . . . . . . . . . . . . . . . . . . . . . . . . 79

Checking the gas valve; electrical resistance of the power

supply cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Checking the gas valve; internal electrical resistance . . . . . . . . . . . 80

Replacing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Checking the ON/OFF controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Checking the RC regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Checking an external switch contact . . . . . . . . . . . . . . . . . . . . . . . . 83

Measuring the difference between the static and dynamic

gas supply pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Bleeding the gas supply pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Measuring and adjusting the gas/air ratio . . . . . . . . . . . . . . . . . . . . 84

Checking the transformer; internal electrical resistance . . . . . . . . . 85

Checking the transformer; power supply cord and low-voltage cord 86

Replace transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Checking the wire harness; connections . . . . . . . . . . . . . . . . . . . . . 87

Checking the cotrol panel; supply voltage . . . . . . . . . . . . . . . . . . . . 87

Replacing the automatic air purging system . . . . . . . . . . . . . . . . . . 88

Replacing/cleaning the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Replacing/cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Checking/replacing the pressure sensor; pollution . . . . . . . . . . . . . 89

Replacing/cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 89

Replacing the UBA 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

8 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Electrical wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Legend of electrical wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . 93

Power rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Sensor resistance readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Technical Specifications of GB162-boilers at sea level (0-4,000 ft) 94

Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Spare parts list (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Exploded view Logamax plus GB162-80 kW/100 kW . . . . . . . . . . . 97

Exploded view pump group Logamax plus GB162-80 kW/100 kW . 98

4

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

1 General

Operation4

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

14

section 22 Normal Operation menu

Step 1

./D

Display reading: Currently measured heating system flow temperature in °C.
See also section 30 "Display readings", page 22.

Step 2 Continue in Normal Operation menu? Yes:

o

Step 3

No:

o

Step 1

Step 3 zPress the "

e

" button.

Step 4

.?D

Display reading: Currently measured heating system water pressure in bar.
See also section 30 "Display readings", page 22.

Step 5 zPress the "

e

" button.

Step 6

.:/D

Random operating code. In this case: Operating code: The boiler is in heating mode.
See also section 32 "Display codes and other symptoms", page 22, and further.

Step 7 Have at least 5 seconds passed without a button being pressed and/or has the mains voltage been interrupted ? Yes:

o

Step 1

No:

o

Step 8

Step 8 zPress the "

e

" button.

o

Step 1

section 23 Flue Gas Test menu

Step 1

./D

Display reading: Currently measured heating system flow temperature in °C.
See also section 30 "Display readings", page 22.

Step 2 Activate flue gas test? Yes:

o

Step 3

No:

o

Step 1

Step 3 To activate the flue gas test:

zPress and hold the "

d

" button for more than 2 but not longer than 5 seconds.

Step 4

./0

Display reading: Current heating system flow temperature in °C.

As soon as a non

-

flashing dot is shown in the bottom right-hand corner of the display, the flue gas test has been
activated. This means that the boiler is in heating mode at a capacity of 100 % for a maximum period of 30 minutes.
The maximum heating system flow temperature set on the BC10 basic controller now applies. DHW mode is not
possible during the flue gas test.

Step 5 zPress the "

e

" button.

Step 6

.?0

Display reading: Currently measured heating system water pressure in bar.
See also section 30 "Display readings", page 22.

Step 7 zPress the "

e

" button.

Step 8

.4/0

Operating code: A flue gas test is being carried out or the boiler is in service m ode.

Flue gas test: The boiler is in heating mode at a capacity of 100 % for a maximum of 30 minutes.

The maximum heating system flow temperature set on the BC10 basic controller now applies.
Service mode: The boiler is in heating mode at a reduced capacity for a period of 30 minutes.
The maximum heating system flow temperature set on the BC10 basic controller now applies.
DHW mode is not possible during the flue gas test or during service mode.
See also section 32 "Display codes and other symptoms", page 22, and further.

Step 9 Press the "

e

" button.

Step 10

./0

Display reading: Currently measured heating system flow temperature in °C.
See also section 30 "Display readings", page 22.

Step 11 Have 30 minutes passed or has the mains voltage been interrupted? Yes:

o

Step 1

No:

o

Step 12

Step 12 Deactivate flue gas test? Yes:

o

Step 13

No:

o

Step 5

Step 13 To deactivate the flue gas test:

zPress and hold the "

d

" button for more than 2 seconds until the dot disappears.

o

Step 1

Section

Subsection with ID number

Operating step with number

Cross-reference to
subsection or

operating step

section 4 General information

General 1

section 5 Layout of this document

About these instructions

These servicing instructions contain important information for

the safe and professional servicing of the boiler with boiler input

rating of 80 kW and 100 kW.

The name of the boiler is made up of the following components:

– Logamax plus: heating boiler typical

– GB162: single boiler without domestic hot water supply

– 80 kW/100 kW: maximum heating capacity is 80 or 100 kW.

GB162 Natural Gas Propane Gas

80 kW 290,000 btu/hr 270,000 btu/hr

100 kW 333,000 btu/hr 315,000 btu/hr

Table 1 max. input rate

These servicing instructions are intended for professional

installers, who have the necessary training and experience for

working on heating and gas systems.

Cascade installation

Special cascade units (accessories) have been developed to

enable this boiler to be installed in a cascade system. Every

cascade unit includes an installation frame, horizontal headers,

connection pipes for the boiler, main gas pipe and a vertical low

loss header.

Cascade units are available for installing the boilers inline or

back-to-back. These cascade units make installing a cascade

system easier and less labor intensive.

Please contact Buderus for further information about cascade

systems.

Updating of documentation

The following technical documentation is available for the

Logamax plus GB162-80 kW/100 kW:

– Installation Instructions

– User’s Manual

– Service Instructions.

Please contact us if you have any suggestions for improvement

or corrections.

Subject to technical modifications

Slight changes may be made without prior notice to the illustra-

tions, process steps and technical data as a result of our policy

of continuous improvement.

This document consists of various sections. They have been
divided into subsections.

Every subsection is marked with a grey frame. An ID number is
always provided in the top left-hand corner. References in the
document are based on these ID numbers.

In addition, a subsection may be divided into various numbered
operating steps. Reference to a certain operating step is
always made within the same subsection. If an operating step
involves the taking of a yes/no decision, the right-hand side of
the table indicates which operating step or subsection you
should proceed with (cross-reference).

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

5

General1

section 6 Remedying faults using this document

FAULTS CAN BE REMEDIED USING THIS DOCUMENT, BY
FOLLOWING A 3-STEP PLAN. IT IS IMPORTANT THAT THE
SAME SEQUENCE IS FOLLOWED EVERY TIME.

Step 1: Symptoms

Step 2: Diagnosis

Step 3: Action

Step 1: chapter 5 Symptoms

Symptom = every indication which may be relevant in order to
recognize faults or errors.

An important symptom is the display indication on the BC10
basic controller of the boiler, but all other symptoms must also
be taken into consideration. In most cases, the display indica­tion (e.g. the locking fault code
from the BC10 basic controller, but the user of the boiler must
also be asked whether other symptoms have occurred. Exam­ples of such symptoms are "the boiler makes whistling noises in
the morning" or "the room does not reach the required temper­ature". The display indications and their meanings as well as
other symptoms are described in section 29 "Display codes and
other symptoms" on page 21.

There are three types of display indication:

– display reading (section 27 "Display readings" on page 21)

– display setting (section 28 "Display settings" on page 21)

– display code (section 29 "Display codes and other

symptoms" on page 21).

There are three types of display code:

– operating code

This code gives the status of the boiler. No action is
necessary.

– blocking fault code

The boiler is locked and will only restart after a manual reset.
The pump will operate continuously for frost protection.

– locking fault code

The boiler resumes normal operation when the fault has
cleared.

Every display code (e.g. the locking fault code
consists of:

– a main code (in this case [2/l/\|)

– a subcode (in this case

After reading the main code, the subcode can be called up by
pressing the service key.

[2/l/\| [2/6/6|) can easily be read

[2/l/\| [2/6/6|)

[2/6/6|).

Step 3: chapter 7 Actions

Action = remedying the cause of the fault or error.

After laying down the diagnosis, the fault can be remedied by
means of chapter 7 "Actions" on page 56.

section 7 Logamax plus GB162

The Logamax plus GB162 condensing gas boiler is a fully up­to-date central heating boiler, designed to provide a high level
of convenience, maximum energy savings, optimum care for
the environment and advanced safety features – all in a single
device.

This is why the boiler is equipped with the very latest electron­ics. The electronic system consists of the UBA 3 (= Universal
Burner Automat 3) (see section 1, [32]) and the connected con­trol panel, the BC10 (= Basic Controller 10) (see section 1, [4]).

The main task of this electronic system is to control and ensure
the safe operation of the central heating boiler.

In addition, it is possible to call up display readings, settings and
codes on the display of the BC10. The display settings can be
changed after calling them up. Also see section 23 and
section 28.

The working of the boiler during normal operation mode is
explained in more detail in chapter 4 "Operation" on page 10.
This chapter provides a step-by-step explanation of the boiler
operation under normal operating conditions.

Step 2: chapter 6 Diagnosis

Diagnosis = establishing the cause of the fault or error on the
basis of the symptoms.

A diagnosis (chapter 6 "Diagnosis" on page 30) can be made
after determining all symptoms.

The right-hand column of the symptoms overview (section 5
"Symptoms" on page 21) refers to the corresponding diagnosis
box. The diagnosis box can be used next to easily find the
cause of the fault.

6

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

2 Safety and general instructions

section 8 Safety and general instructions

Please observe these instructions in the interest of your own

safety.

Designated use

The boiler was designed for heating water for a central heating

system and generating domestic hot water.

The boiler is suitable for connection to fully pumped, sealed

water systems ONLY.

The boiler can be installed either as a single system or as part

of a multiple system (cascade system) with a maximum of 8

boilers connected together.

These boilers may not be installed in places over 4,000 ft. above

sea level.

Hazard definitions

The following defined terms are used throughout the documen-

tation to bring attention to the presence of hazards of various

risk levels. Notices give important information concerning the

operation of the product.

DANGER

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

WARNING

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

CAUTION

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

CAUTION

Risk of electric shock.

Indicates presence of hazards due to electric shock.

NOTICE

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

Safety and general instructions 2

The following instructions must be observed

– The boiler must only be used for its designated purpose,

observing the Installation Instructions.

– Only use the boiler in the combinations and with the accesso-

ries and spares listed.

– Maintenance and repairs must only be carried out by trained

professionals.

– You are only permitted to operate the condensing gas boiler

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

– Please note that local approval of the flue system and the

condensate connection to the public sewer system may be
required.

– If boiler installation is provided as replacement heater,

DO NOT connect new boiler venting to an existing vent
system, if it is shared with other appliances.

You must also observe:

– The local building regulations stipulating the installation rules

at the time of installation.

– The local building regulations concerning the air intake and

outlet systems and the chimney connection.

– The regulations for the power supply connection.

– The technical rules laid down by the gas utility company con-

cerning the connection of the gas burner fitting to the local
gas main.

– The instructions and standards concerning the safety equip-

ment for the water/space heating system.

– The Installation Instructions for building heating systems.

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

tank or connections will not result in damage to the area 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.

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

tem of the defect and the associated hazard in writing.

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

7

Safety and general instructions2

DANGER

if flammable gas explodes.

Beware if you smell gas: there may be an explosion
hazard!

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

 Do not store or use gasoline or other 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.

WARNING

Danger of fatal accident from explosive fumes.

 Only carry out work on gas pipes and fittings if

you are properly registered.

WARNING

Dangerous flue gas can escape if the air supply is
insufficient.

 Make sure that air vents are not reduced in size

or obstructed.

 The boiler may only be operated after the defect

has been remedied.

 Warn the user of the system of the defect ver-

bally and in writing.

Heating system requirements

– Installing a dirt trap like a y-strainer and a desludging device

is required. This must be installed in the heating system in the
immediate vicinity of the boiler, in an easily accessible posi­tion between the boiler and the lowest point in the return of
the system.

– Clean the dirt trap at every annual service.

– Never use salt bedding type exchangers (ion exchangers) to

soften the water.

– The low loss header and boiler connection set must be

installed (supplied with the boiler).

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

heating systems, you must separate the system using sec­ondary heat exchangers.

Heating system water quality

The quality of the system water is very important. Poor water
quality can damage heating systems due to scale formation and
corrosion. For further details, please see the accompanying
"Water quality requirements for Logamax plus GB162-80 kW/
100 kW" manual.

CAUTION

Risk of system damage due to unsuitable heating
system water.

 If oxygen-permeable pipes are used, e.g. for

underfloor heating systems, the systems must
be separated from one another by plate heat
exchangers. Unsuitable heating system water
promotes sludge and corrosion formation. This
can result in heat exchanger malfunction and
damage.

Pump test

If the boiler has not been operational for approx. 4 weeks, the
pump will automatically run for 10 seconds every 24 hours. This
pump test is first carried out 24 hours after the main power has
been connected to the boiler.

Freeze protection

The boiler has integrated freeze protection that switches the
boiler ON at a space heating (CH) water temperature of 45 °F
(7 °C) and switches it OFF at a CH supply temperature of 59 °F
(15 °C).

This feature does not protect the central heating system from
freezing. If there is a risk of radiators or pipe sections freezing
up, we recommend setting the pump run-over time to 24 hours.

Tools, materials and further equipment

For the installation and maintenance of the boiler you will need
the standard tools for space heating, gas and water fitting.
In addition, a hand truck with a fastening belt is useful.

Disposal

– Dispose of the boiler packaging in an environmentally sound

manner.

– Dispose of components of the heating system (e. g. boiler or

control device), that must be replaced in an environmentally
responsible manner.

8

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

3 Regulations and guidelines

section 9 General regulations

The installation must conform to the requirements of the author-

ity having jurisdiction or, in the absence of such requirements,

to the latest edition of the National Fuel Gas Code, ANSI

Z223.1./NFPA 54. In Canada, installation must be in accor-

dance with the requirements of CAN/CSA B149.1, Natural Gas

and Propane Installation Code. Where required by the authority

having jurisdiction, the installation must conform to the Stan-

dard for Controls and Safety Devices for Automatically Fired

Boilers, ANSI/ASME CSD-1. Install CO detectors per local

regulations. Boiler requires yearly maintenance.

Operating Limits of the boiler:

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

Max. operating pressure: 30 psi (2.6 bar)

– with optional pressure relief valve 50 psi (3.45 bar).

The hot water distribution system must comply with all applica-

ble codes and regulations. When replacing an existing boiler, it

is important to check the condition of the entire hot water distri-

bution system to ensure safe operation.

section 10 Regulations in Massachusetts

Massachusetts Installations Only:

(a) For all side wall side horizontally vented gas fueled equip-

ment installed in every dwelling, building or structure used in

whole or in part for residential purposes, including those owned

or operated by the Commonwealth and where the side wall

exhaust vent termination is less than seven (7) feet above fin-

ished grade in the area of the venting, including but not limited

to decks and porches, the following requirements shall be

satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS.
At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gasfitter
shall observe that a hard wired carbon monoxide detector
with an alarm and battery back-up is installed on the floor
level where the gas equipment is to be installed. In addition,
the installing plumber or gasfitter shall observe that a battery
operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling,
buiding or structure served by the side wall horizontal
vented gas fueled equipment. It shall be the responsibility of
the property owner to secure the services of qualified
licensed professionals for the installation of hard wired car­bon monoxide detectors.
a. In the event that the side wall horizontally vented gas

fueled equipment is installed in a crawl space or an attic,
the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent
floor level.

b. In the event that the requirements of this subdivision can

not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply
with the above requirements; provided, however, that
during said thirty (30) day period, a battery operated car­bon monoxide detector with an alarm shall be installed.

Regulations and guidelines 3

2. APPROVED CARBON MONOXIDE DETECTORS.
Each carbon monoxide detector as required in accordance
with the above provisions shall comply with NPA 720 and be
ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be
permanently mounted to the exterior of the building at a min­imum height of eight (8) feet above grade directly in line with
the exhaust vent terminal for the horizontally vented gas
fueled heating appliance or equipment. The sign shall read,
in print size no less than one-half (½) inch in size, “GAS
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side
wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspections, the
inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of
248 CRM 5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from
248 CRM 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment
Not Required To Be Vented” in the most current edition
of NFPA 54 as adopted by the board: and

2. Product Approved side wall horizontally vented gas
fueled equipment installed in a room or structure sepa­rate from the dwelling, building or structure used in whole
or in part for residential puposes.

(c) MANUFACTURERS REQUIREMENTS - GAS EQUIP­MENT VENTING SYSTEM REQUIRED.
When the manufacturer of Product Approved side wall horizon­tally mounted gas equipment provides a venting system design
or venting system components with the equipment, the instruc­tions provided by the manufacturer for the installation of the
equipment and venting shall include:

1. Detailed instructions for the installation of the venting
system or the venting system components: and

2. A complete parts list for the venting system design or
venting system.

(d) MANUFACTURERS REQUIREMENTS - GAS EQUIP­MENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of Product Approved side wall horizon­tally vented gas fueled equipment does not provide the parts for
the venting of flue gases, but identifies “special venting sys­tems”, the following requirements shall be satisfied by the man­ufacturer:

1. The referenced “special venting systems” shall be
included with the appliance or equipment installation
instructions: and

2. The “special venting systems” shall be Product Approved
by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.

(e) A copy of all instructions for all Product Approved side wall
horizontally vented gas fueled equipment, all venting instruc­tions, all parts lists for venting instructions, and/or venting
design instructions shall remain with the appliance or equip­ment at the completion of the installation.

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

9

Operation4

1

1

23 4

7

8910

26

11

5

140

130

120

90

100

130

170

150

90

190

110

110

4Operation

section 11 General

section 14

General points

The heating boiler is fitted with a control panel, the BC10 basic
controller. The BC10 can be used to control the heating system.

In addition, it is possible to call up display readings, settings and
codes on the display of the BC10. The display settings can be
changed after calling them up. See chapter 5 "Symptoms" on
page 21.

section 12

The control panel has the following elements:

1: Main power switch

2: "Reset" button

3: "Chimney sweep" button

4: "Service" button

5: Service Tool Connector

6: LED "Burner operation"

7: LED "Central heat demand"

8: Space heating water temperature knob

9: Display

10: DHW temperature knob

11: LED "DHW demand"

 Briefly press the access cover of the BC10 to open it.

section 13

The control panel is located on the left, behind the access cover
[2].

The Operating Instructions are located in a compartment on the
back of the access cover [1].

Main power switch

The main power switch [1] is used to switch the mains power to
the heating boiler on and off.

"Reset" button

With certain faults you may have to restart the boiler by pressing
the "Reset" button [2]. This is only required in the event of a
"locking" fault (can be recognized by a flashing error code in the

display). During a reset, the display shows [\/r/e|.

Blocking errors (which can be recognized by a non-flashing
error code) are reset automatically as soon as their cause has
been removed.

"Chimney sweep" button

The "Chimney sweep" button [3] is used to activate a flue gas
test, the service mode or manual operation.

The flue gas test enables the boiler to be run in full-load oper­ation manually for a short period. See also section 20, "Flue
Gas Test menu", page 13.

The service mode enables the boiler to be run in part-load
operation manually for a short period. The service mode should
be used to carry out measurements and settings on the boiler.
See also section 21, "Service Mode menu", page 14.

10

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

Operation 4

1

1

23 4

7

8910

26

11

5

140

130

120

90

100

130

170

150

90

190

110

110

1

1

23 4

7

8910

26

11

5

140

130

120

90

100

130

170

150

90

190

110

110

1

1

23 4

7

8910

26

11

5

140

130

120

90

100

130

170

150

90

190

110

110

section 15

The manual operation mode enables the boiler to be run
manually for a long period. Manual operation should be used for
situations where the controller has not been installed yet, or
where the controller is out of order. See also section 22,
"Manual Operation menu", page 15.

A maximum heating system supply temperature in accordance
with the setting of the space heating water temperature knob
(section 14, [8]) on the BC 10 applies during the flue gas test,
service and manual operation.

DAMAGE TO THE INSTALLATION

with floor heating: by the pipework being over­heated.

 Use the space heating water temperature

knob [8] to limit the maximum heating system
supply temperature to the permitted heating
system supply temperature of the floor heating
circuit. This is usually approximately 104 °F
(40 °C).

DAMAGE TO THE INSTALLATION

due to frost while manual operation is switched on.

After a power failure or after switching off the main
voltage, the heating system may freeze since man­ual operation is no longer active.

 Re-activate manual operation after switching on

the heating system, so that the system is perma­nently in operation.

section 16

LED "Burner operation"

The LED "Burner operation" [6] lights up when the burner of the
heating boiler is active and it is extinguished when the burner is
no longer in operation.

The LED "Burner operation" indicates the burner status.

LED Status Explanation

On Burner operational The heating water is being heated.

The heating water has reached the

Off Burner off

required temperature range and there
is no heat demand.

section 17

"Service" button

The "Service" button [4] is used to display the heating system
supply temperature, the water pressure on the heating system
etc. See also section 27 "Display readings", section 28 "Display
settings" and section 29 "Display codes and other symptoms".

USER INSTRUCTION

If there is a risk of radiators or pipe sections freezing
up, we recommend setting the pump run-over time
to 24 hours. See section 28 "Display settings".

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

LED "Central heat demand"

The LED "Central heat demand" [7] lights up as soon as there
is a heat demand from the control system and is extinguished
as soon as there is no longer a heat demand.

11

Operation4

Space heating water temperature knob

The Space heating water temperature knob [8] is used to set the
maximum heating system supply temperature. The unit is °F.
See table 2.

Knob

position

85–194 The maximum heating system supply temperature in °F.

Aut

table 2

1)

Display

The display [9] can show display readings, display settings and
display codes. If a fault occurs the display will immediately show
the accompanying fault code. If a locking fault has occurred, the
display code will flash.

Explanation

0 Heating mode off (but still DHW operation possible).

The maximum heating system supply temperature is

1)

194 °F (90 °C).

for use with Buderus controls

section 18 Menu structure

The boiler menu structure can be browsed on the BC10 using
the "Reset", "Chimney sweep" or "Service" buttons (section 17,
[2], [3] and [4]) and the display (section 17, [9]).

The boiler menu structure consists of 5 menus:

– Normal Operation menu (section 19, page 13);

– Flue Gas Test menu (section 20, page 13);

– Service Mode menu (section 21, page 14);

– Manual Operation menu (section 22, page 15);

– Settings menu (section 23, page 15).

DHW temperature knob

The DHW temperature knob [10] is used to set the DHW
temperature as required. The unit is °F. See table 3.

Knob

position

0

ECO Do not use this setting!

85–115

115 – 140

Aut

Meaning

DHW mode is off (but
heating operation may still
be possible).

The required DHW
temperature in °F.

The required DHW
temperature in °F.

The required DHW

1)

temperature is 140 °F
(60 °C).

Legionella
indication

Legionella propagation
ruled out

Very low risk if hot water
is used daily

Legionella propagation
ruled out. This position is
recommended.

Legionella propagation
ruled out.

table 3

1)

for use with Buderus controls

LED "DHW demand"

The LED "DHW demand" [11] lights up as soon as water is
being heated as the result of a hot water demand and is extin­guished as soon as the heating system for DHW mode is
switched off.

12

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

Operation 4

section 19 Normal Operation menu

Step 1 [\/7/5| Display reading: Currently measured heating system supply temperature in °F.

See also section 27 "Display readings", page 21.

Step 2 Continue in Normal Operation menu? Yes:

Step 3

Step 4 [p/2/2| Display reading: Currently measured heating system water pressure in PSI.

Step 5  Press the "

Step 6 [-/h/\| Random operating code. In this case: Operating code: The boiler is in heating mode.

Step 7 Have at least 5 seconds passed without a button being pressed and/or has the main voltage been interrupted ? Yes:

Step 8  Press the "e" button. → Step 1

 Press the "

e" button.

See also section 27 "Display readings", page 21.

e" button.

See also section 29 "Display codes and other symptoms", page 21, and further.

section 20 Flue Gas Test menu

Step 1 [\/7/5| Display reading: Currently measured heating system supply temperature in °F.

See also section 27 "Display readings", page 21.

Step 2 Activate flue gas test? Yes:

Step 3 To activate the flue gas test:

 Press and hold the "

Step 4

Step 5  Press the "

Step 6

Step 7  Press the "

Step 8

Step 9 Press the "

Step 10

Step 11 Have 30 minutes passed or has the main voltage been interrupted? Yes:

Step 12 Deactivate flue gas test? Yes:

Step 13 To deactivate the flue gas test:

[\/7/5] Display reading: Current heating system supply temperature in °F.

As soon as a non
activated. This means that the boiler is in heating mode at a capacity of 100 % for a maximum period of 30 minutes.
The maximum heating system supply temperature set on the control panel now applies. DHW mode is not possible
during the flue gas test.

e" button.

[p/2/2| Display reading: Currently measured heating system water pressure in PSI.

See also section 27 "Display readings", page 21.

e" button.

[-/a/\] Operating code: A flue gas test is being carried out or the boiler is in service mode.

Flue gas test: The boiler is in heating mode at a capacity of 100 % for a maximum of 30 minutes.

The maximum heating system supply temperature set on the control panel now applies.
Service mode: The boiler is in heating mode at a reduced capacity for a period of 30 minutes.
The maximum heating system supply temperature set on the control panel now applies.
DHW mode is not possible during the flue gas test or during service mode.
See also section 29 "Display codes and other symptoms", page 21.

e" button.

[\/7/5] Display reading: Currently measured heating system supply temperature in °F.

See also section 27 "Display readings", page 21.

 Press and hold the "

d" button for more than 2 but not longer than 5 seconds.

-flashing dot is shown in the bottom right-hand corner of the display, the flue gas test has been

d" button for more than 2 seconds until the dot disappears.

→ Step 3

No: → Step 1

→ Step 1

No: → Step 8

→ Step 3
→ Step 1

No:

→ Step 1

No:

→ Step 12
→ Step 13

No:

→ Step 5
→ Step 1

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

13

Operation4

section 21 Service Mode menu

Step 1 [\/7/5| Display reading: Currently measured heating system supply temperature in °F.

See also section 27 "Display readings", page 21.

Step 2 Activate service mode? Yes:

No:

Step 3 To activate service mode, step 1:

 Press and hold the "

Step 4

Step 5 To activate service mode, step 2:

Step 6

Step 7  Press and hold the "

Step 8

Step 9  Press the "

Step 10

Step 11  Press the "

Step 12

Step 13  Press the "

Step 14

Step 15  Press the "

Step 16

Step 17  Press the "

Step 18

Step 19  Press the "

Step 20

Step 21 Have 30 minutes passed or has the main voltage been interrupted? Yes:

Step 22 Service mode is deactivated.

Step 23 Deactivate service mode? Yes:

Step 24 To deactivate the service mode:

Step 25 The boiler performance is then reduced according to the settings made in the "Settings" menu

[\/7/5] Display reading: Currently measured heating system supply temperature in °F.

As soon as a non
mode at 100 % performance for a maximum of 30 minutes. The maximum heating system supply temperature set
on the control panel now applies. DHW mode is not possible during service mode operation.

 Press and hold the "

[l/?/?] Display setting: Maximum capacity setting during heating mode as a %.

See also section 28 "Display settings", page 21. In this case:
Service mode has been activated. You can now temporarily lower the boiler performance to partial load to check ­and if relevant adjust- the gas/air ratio or the ionization current.

[l/2/0] with a 100 kW boiler.

[l/2/0] or [l/2/5] Display setting: Minimum capacity setting during service mode as a %.

Within a couple of seconds the boiler will be modulated back to 20 % of its capacity in case of an 80 kW boiler and
25 % in case of a 100 kW boiler. The maximum heating system supply temperature set on the control panel now
applies (section 1, [4]). Check the gas/air ratio or the ionization current and if necessary set the gas/air ratio
according to section section 119 "Measuring and adjusting the gas/air ratio", page 84 or section 104 "Measure the
ionization current", page 76.

e" button.

[f/\5] Display setting: required pump run-over time after the end of the heating operation in minutes.

See also section 28 "Display settings", page 21.

e" button.

[c/\1] Display setting: required DHW mode position (on/off).

This setting has priority over -for example- a possible DHW mode (On/Off) setting on a room thermostat.

See also section 28 "Display settings", page 21.

e" button.

[\/7/5] Display reading: Currently measured heating system supply temperature in °F.

See also section 27 "Display readings", page 21.

e" button.

[p/2/2| Display reading: Currently measured heating system water pressure in PSI.

See also section 27 "Display readings", page 21.

e" button.

[-/a/\] Operating code: The boiler is in service mode.

See also section 29 "Display codes and other symptoms", page 21, and further.

e" button.

[\/7/5] Display reading: Currently measured heating system supply temperature in °F.

See also section 27 "Display readings", page 21.

 Press and hold the "

page 15.

d" button for more than 2 but not longer than 5 seconds.

-flashing dot is shown in the bottom right-hand corner of the display, the boiler will run in heating

d"+ "e" buttons for more than 2 seconds.

[l/?/?] = 100 %

c" button until the display shows for boilers at sea level [l/2/5] with a 80 kW boiler or

See also section 28 "Display settings", page 21.

No:

No:

d" button for more than 2 seconds until the dot disappears.

in section 23,

→ Step 3
→ Step 1

→ Step 22
→ Step 23
→ Step 25
→ Step 24
→ Step 15

→ Step 1

14

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

Operation 4

section 22 Manual Operation menu

Step 1 [\/7/5| Display reading: Currently measured heating system supply temperature in °F

See also section 27 "Display readings", page 21.

Step 2 Activate manual operation? Yes:

No:

Step 3 To activate manual operation:

 Press and hold the "

Step 4

Step 5  Press the "

Step 6

Step 7  Press the "

Step 8

Step 9  Press the "

Step 10

Step 11 Has the main voltage been interrupted? Yes:

Step 12 Deactivate manual operation? Yes:

Step 13 To deactivate manual operation:

[\7/5}Display reading: Currently measured heating system supply temperature in °F.

As soon as a flashing dot is shown in the bottom right-hand corner of the display, manual operation is active. This
means that the boiler is permanently in heating mode. The maximum heating system supply temperature set on the
control panel now applies (section 1, [4]). The LED "Central heat demand" lights up.

e" button.

[p/2/2}Display reading: Currently measured heating system water pressure in PSI.

See also section 27 "Display readings", page 21.

e" button.

[-/h/\| Operating code. The device is in manual operation mode. See also section 29 "Display codes and other

symptoms", page 21. During manual operation the "Settings" menu in section 23 from step 3 can be used to
temporarily change the target boiler performance. DHW mode is possible during manual operation.

CAUTION: If the boiler performance has been changed temporarily, it must be reset after ending manual operation,
according to the "Settings" menu, section 23, page 15

e" button.

[\7/5}Display reading: Currently measured heating system supply temperature in °F.

See also section 27 "Display readings", page 21.

 Press and hold the "

d" button for more than 5 seconds.

No:

No:

d" button for more than 2 seconds until the dot disappears.

→ Step 1
→ Step 1

→ Step 1
→ Step 12
→ Step 13
→ Step 5
→ Step 1

section 23 Settings menu

Step 1 [\/7/5| Display reading: Currently measured heating system supply temperature in °F.

See also section 27 "Display readings", page 21.

Step 2 Open the "Settings" menu? Yes:

No:

Step 3 To open the Settings menu:

 Press and hold the "

Step 4

Step 5 Adjust boiler performance? No:

Step 6 Lower: Decrease the target boiler performance with the "

Step 7  Press the "

Step 8

[l/?/?| Display setting: target boiler performance as a %.

See also section 28 "Display settings", page 21.
As soon as the display shows
parameter shown on the display.

[l/2/5| = 25 % for an 80 kW heating boiler and [l/2/0| = 20 % for a 100 kW heating boiler.

Higher: Increase the target boiler performance with the "
Otherwise, this concerns the factory-adjusted setting.

e" button.

[f/\5] Display setting: Target pump run-over time after heating mode has elapsed in minutes.

Set the second parameter as soon as the display shows
Recommendation: Do not set a pump run-over time of less than

d"+ "e" buttons for more than 2 seconds.

[l/?/?|, the "Settings" menu is open. The boiler performance can be set using the first

Yes:

c" button. The minimum setting for boilers at sea level is

d" button. The maximum setting is [l/?/?| = 100 %.

[f/\/5|.

[f/\/5| (= 5 minutes).

→ Step 3
→ Step 1

→ Step 7
→ Step 6

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

15

Operation4

section 23 Settings menu (continued)

Step 9 Set the pump run-over time after heating operation has ended? Yes: → Step 10

No:

→ Step 11

Step 10 Lower: Decrease the target pump run-over time after the end of heating operation with the "

The minimum setting is

Higher: Increase the target pump run-over time after the end of heating operation with the "
The minimum setting is

Step 11  Press the "

Step 12

Step 13 Set the DHW mode status? Yes:

Step 14  Set the DHW mode On or Off with the "

Step 15 Have at least 5 seconds passed without a button being pressed and/or has the main voltage been interrupted ? Yes:

Step 16  Press the "

Step 17

[c/\1] Display setting: required DHW mode position (on/off).

Set the third parameter as soon as the display shows

Note! If

[\/7/5| Display reading: Currently measured heating system supply temperature in °F.

Any adjustments that you have made have been confirmed.

e" button.

See also section 28 "Display settings", page 21.

[c/\/0| is set, the frost protection for the internal or external hot water tank heater is switched off.

e" button.

See also section 27 "Display readings", page 21.

[f/\/0| = 0 minutes. The factory default setting is 5 minutes.

[f/1/d| = 24 hours.

[c/\/1|.

c" or "d" buttons. [c/\/1| is "On", [c/\/0| is "Off".

c" button.

d" button.

No:

No:

→ Step 14
→ Step 15

→ Step 17
→ Step 16

→ Step 1

16

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

Operation 4

section 24 Operation

Start-up phase

Step 1  Switch “On” the power supply to the boiler.

Step 2  Turn the main power switch on the BC10 to position "1" (On), also see section 14.

Step 3 The LED of the UBA 3 (section 1, [32]) lights up for 1 second. This means that the UBA 3 is reading the KIM.

Step 4

Step 5

Step 6

Step 7  Press the "

Step 8 [p/2/2| Display reading: Currently measured heating system water pressure in PSI.

Step 9  Press the "

Step 10 [0/u/\| Operating code: The boiler starts up after activation of the mains power supply or completion of a

Step 11 Has the air-side pre-purge phase been completed without any problems? Yes:

Step 12  Now remedy the fault by following the section relating to the error code that is now displayed. See also section 29.

Step 13 [0/h/\| Operating code. The boiler is in standby mode. No current heat requirement.

Step 14 Start of pump over-run time for the heating system. The pump over-run time for the heating system can be adjusted

Step 15 Has the preset pump over-run time expired? Yes:

Step 16 Is there a DHW heating system which has generated a heat demand? Yes: → Step 29

Step 17 Is there a current heat demand from the room or external temperature-dependent controller? Yes: → Step 48

Step 18 Is the current heating-system supply temperature lower than 45 °F (7 °C)? Yes: → Step 65

Step 19 The pump stops.

Step 20 Has the pump been out of use for more than 24 hours? Yes:

Step 21 Is there a DHW heating system which has generated a demand? Yes: → Step 29

When installing a new KIM or a new UBA 3, the LED will flash at a high frequency for max. 10 seconds while the data
is being exchanged.

[8.8.8] Operating code: The display is tested during starting up, immediately after switching on the main

voltage. This code is displayed for a maximum of 1 second.

See also section 29 "Display codes and other symptoms", page 21.

[\/-/\| Operating code: A communication test is carried out during starting up.

This display code flashes to check the communication between the UBA 3 (section 1, [32]) and the

control panel (section 1, [4]) for 3-5 times during a period of 3-5 seconds while starting up.

If a new UBA3 or a new KIM was fitted, this code will flash for max. 10 seconds.

See also section 29 "Display codes and other symptoms", page 21.

[\/7/5| Display reading: Currently measured heating system supply temperature in °F.

See also section 27 "Display readings", page 21.

e" button.

See also section 27 "Display readings", page 21.

e" button.

system reset.

Start of water-side flow check: The pump will carry out max. 4 attempts to restore the water flow.
Start of air-side pre-purge phase. The fan unit runs at about 60 % of maximum speed for 15 seconds.

See also section 29 "Display codes and other symptoms", page 21.

→ Step 13

No: → Step 12

→ Step 1

As soon as a locking fault occurs (indicated by a flashing display code), the pump is activated to run continuously,
thus minimizing the risk of the heating system freezing up.

Readiness for operation

See also section 29 "Display codes and other symptoms", page 21.

as per section 23. Factory-adjusted setting: 5 minutes

→ Step 19

No: → Step 16

No: → Step 17

No: → Step 18

No: → Step 15

→ Step 24

No: → Step 21

No: → Step 22

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

17

Operation4

section 24

Step 22 Is there a current heat demand from the room or external temperature-dependent controller? Yes: → Step 48

No: → Step 23

Step 23 Is the current heating-system supply temperature lower than 45 °F (7 °C)? Yes: → Step 65

No: → Step 20

Step 24 The pump is run for 10 seconds in order to prevent it from seizing up.

Step 25 Have ten seconds elapsed? Yes:

Step 26 Is there a DHW heating system which has generated a demand? Yes: → Step 29

Step 27 Is there a current heat demand from the room or external temperature-dependent controller? Yes: → Step 48

Step 28 Is the current heating-system supply temperature lower than 45 °F (7 °C)? Yes:

DHW operating phase

Step 29 The LED "DHW demand" on the control panel (section 1, [4]) lights up.

Step 30

Step 31

Step 32 Maximum four ignition attempts are carried out. Does the ionization current exceed 1.4 microamperes within these

Step 33 [-/h/\| Operating code: The device is in DHW mode.

Step 34 Is there still a heat demand? Yes:

Step 35 Is the heating-system supply temperature 45 °F (25 °C) higher than the preset DHW temperature or higher than

Step 36 [0/y/\| Operating code: The supply temperature sensor has measured a current heating supply temperature

Step 37 The LED "Burner operation" is extinguished.

Step 38 The fan unit (section 1, [20]) continues to run for max. 30 seconds.

Step 39 Has the heating system supply temperature fallen sufficiently? Yes:

Step 40 The gas valve (section 1, [21]) is closed and the burner is shut down.

Step 41 The LED "Burner operation" is extinguished.

Step 42 The LED "DHW demand" is extinguished.

Step 43

Step 44 Have approx. 30 seconds elapsed? Yes:

[0/c/\| Operating code. The boiler prepares for a burner start-up whenever a heat demand arises. The fan unit

(section 1, [20]) and the pump are started. The glow ignitor (section 1, [27]) is activated.

[0/l/\| Operating code. The gas valve (section 1, [21]) is activated.

See also section 29 "Display codes and other symptoms", page 21.

4 ignition attempts?

See also section 29 "Display codes and other symptoms", page 21.

The LED "Burner operation" on the control panel (section 1, [4]) lights up. The startup load on the boiler is approx.
50 % for the purposes of flow monitoring and is then modulated up or down. The degree of modulation of the pump
will hardly vary during DHW mode; the pump will be running almost continuously at 100 %.

200°F (93°C)?

higher than the supply temperature setting on the control panel (section 1, [4]), or higher than the
supply temperature calculated according to the heating curve or higher than the supply temperature
calculated according to the DHW mode.

[0/h/\| Operating code. The boiler is in standby mode. There is no current heat demand.

Start of pump over-run time via the tank for a period of approx. 60 seconds.
Start of air-side purging phase of the fan unit (section 1, [20]) for approx. 30 seconds.
See also section 29 "Display codes and other symptoms", page 21.

→ Step 19

No: → Step 26

No: → Step 27

No: → Step 28

→ Step 65
→ Step 25

No:

→ Step 33

Yes:
No: → Step 12

→ Step 35

No: → Step 40
Yes: → Step 36
No: → Step 33

→ Step 29

No: → Step 39

→ Step 45

No: → Step 44

18

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

Operation 4

section 24

Step 45 The fan unit (section 1, [20]) stops.
Step 46 Have approx. 60 seconds elapsed? Yes: → Step 47

No: → Step 46

Step 47 The pump stops. See also section 29 "Display codes and other symptoms", page 21.

Boiler operating phase

Step 48 The LED "Central heat demand" lights up.

Step 49

Step 50

Step 51 Maximum of four ignition attempts are carried out. Does the ionization current exceed 1.4 microamperes within these

Step 52 [-/h/\| Operating code. The device is in heating mode.

Step 53 Is there still a heat demand from the room or external temperature-dependent controller? Yes:

Step 54 Is the heating-system supply temperature higher than the target setting?

Step 55

Step 56 The LED "Burner operation" is extinguished.

Step 57 The fan unit (section 1, [20]) continues to run for max. 30 seconds.

Step 58 Has the heating system supply temperature fallen sufficiently? Yes:

Step 59 The LED "Central heat demand" is extinguished.

Step 60

Step 61 The LED "Burner operation" is extinguished.

Step 62 Start of pump over-run time for the heating system. The pump over-run time for the heating system can be adjusted

Step 63 Have approx. 30 seconds elapsed? Yes:

Step 64 The fan unit (section 1, [20]) stops. → Step 15

[0/c/\| Operating code. The boiler prepares for a burner start-up whenever a heat demand arises. The fan

unit (section 1, [20]) and the pump are started. The glow ignitor (section 1, [27]) is activated.

See also section 29 "Display codes and other symptoms", page 21.

[0/l/\| Operating code. The gas valve (section 1, [21]) is activated.

See also section 29 "Display codes and other symptoms", page 21.

4 ignition attempts?

See also section 29 "Display codes and other symptoms", page 21.

The LED "Burner operation" on the control panel (section 1, [4]) lights up. The startup load on the boiler is approx.
50 % for the purposes of flow monitoring and is then modulated up or down. The pump modulation degree will vary
strongly during heating operation.

When working with an external temperature-dependent controller, the target setting is calculated by the controller;
when working with a room temperature control device it is set on the control panel (section 1, [4]).

[0/y/\| Operating code: The supply temperature sensor as measured a current heating supply temperature

higher than the supply temperature setting on the control panel (section 1, [4]), or higher than the

supply temperature calculated according to the heating curve or higher than the supply temperature

calculated according to the DHW mode.

See also section 29 "Display codes and other symptoms", page 21.

[0/h/\| Operating code. The boiler is in standby mode. There is no current heat demand.

See also section 29 "Display codes and other symptoms", page 21. The gas valve (section 1, [21]) is closed

and the burner (section 1, [23]) is shut down.

as per section 23. Factory-adjusted setting: 5 minutes.
Start of air-side flushing phase of the fan unit (section 1, [20]) for approx. 30 seconds.

→ Step 52

Yes:
No: → Step 12

→ Step 54

No: → Step 59

Yes:

→ Step 55

No: → Step 52

→ Step 49

No: → Step 58

→ Step 64

No: → Step 63

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

19

Operation4

Frost-protection operating phase

Step 65 The LED "Central heat demand" lights up.

Step 66

Step 67

Step 68 Maximum of four ignition attempts are carried out. Does the ionization current exceed 1.4 microamperes within these

Step 69 [-/h/\| Operating code: The device is in heating mode.

Step 70 Is the current heating-system supply temperature higher than 59 °F (15 °C)? Yes:

[0/c/\| Operating code. The boiler prepares for a burner start-up whenever a heat demand arises.

The fan unit (section 1, [20]) and the pump are started. The glow ignitor (section 1, [27]) is activated.

See also section 29 "Display codes and other symptoms", page 21.

[0/l/\| Operating code. The gas valve (section 1, [21]) is activated.

See also section 29 "Display codes and other symptoms", page 21.

4 ignition attempts?

See also section 29 "Display codes and other symptoms", page 21.
The LED "Burner operation" is lit up. The boiler is in heating mode.

Yes:
No: → Step 12

No:

→ Step 69

→ Step 59
→ Step 69

20

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

Symptoms 5

5 Symptoms

section 25 Symptoms

You can find a further explanation of the symptoms in section 6 on page 6.

section 26 Removing the control panel

To make it easier to operate the BC10 when the boiler door is open and to make it easier to read the display, the BC10 can be
temporarily attached to the boiler in a suspended position while carrying out service activities. See section 68, page 56.

section 27 Display readings

Display
reading

[\/7/5|

[p/2/2|

section 28 Display settings

Display

setting

[l/9/9|

[l/9/9|

[f/\/5|

[c/\/1|

Meaning Unit Range

Display reading Current heating system supply

temperature in °F.

Display reading Current heating system water
pressure in PSI.

Meaning Unit Range

Display setting: Logamax plus GB162-80 kW target

boiler performance as a %

Display setting: Logamax plus GB162-100 kW
target boiler performance as a %

Display setting: Target pump over-run time in
minutes after heating mode has ended.
Recommendation:Do not set a pump over-run time
of less than

Display setting: required DHW supply position
(on/off). This setting has priority over -for example­a possible DHW mode (On/Off) setting on a room
thermostat.
Note! If the setting
protection of the DHW heating system has also been
switched off.

[f/\/5| (= 5 minutes).

[c/\/0| has been made, the frost

°F

PSI

%

%

Min.

[\/4/8|

[p/0/0|

[l/2/5|

[l/2/0|

[f/0/0|

–

–

–

–

–

[2/6/6|

[p/5/8|

[l/9/9|

[l/9/9|

[f/6/0|

[c/\/0|

"Off" /

/

/

/

[l/?/?]

[l/?/?]

[f/1/d|

[c/\/1|

100 %

100 %

24 hours

"On"

Factory

setting

[l/?/?]

[l/?/?]

[f///5|

[c/\/1|

section 29 Display codes and other symptoms

Display code LED on

Main

display

z

code

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

z

Sub-

display

code

Meaning

z

No display code Off No indication on the display of

No display code Off On devices with DHW opera-

No display code Off On devices with DHW opera-

No display code Off No indication on the display of

Reset

required?

UBA 3

Other symptoms Diagnosis

the BC10 (section 1, [4]).

tion:
no or insufficient DHW;
radiators, convectors, etc. may
be heated without current heat
demand.

tion:
hot water may be available, no
heating operation.

On devices without DHW
operation:
no heating operation.

the BC10 (section 1, [4]).

→ section 31

→ section 32

→ section 33

→ section 34

21

Symptoms5

section 29 Display codes and other symptoms

Display code LED on

z

e

e

Main

display

code

[\/-/\|

[\/-/\|

[\/\/\]

[\/\/}

[-/a/\]

2)

[-/h/\|

z

e

e

Sub-

display

code

[2/0/8|

1)

[2/0/0|

1)

Meaning

z

Operating code: A communication test is car­ried out while starting up. This display code
flashes to check the communication between
the UBA 3 (section 1, [32]) and the control
panel (section 1, [4]) 3-5 times during a period
of 3-5 seconds while starting up. If a new UBA
3 or a new KIM has been fitted, this display
code will flash for max. 10 seconds.

Fault code: If this code continues to flash on
the display, there is a fault in the communica­tion between the UBA 3 (section 1, [32]) and
the control panel (section 1, [4]).

Operating code:The boiler is in flue gas test
or service mode.

Flue gas test: The boiler is in heating mode at
a performance capacity of 100 % for a period
of 30 minutes. The maximum heating system
supply temperature set on the control panel
now applies (section 1, [4]).

Service mode: the boiler will run in heating
mode at a reduced performance capacity for
30 minutes. The maximum heating system
supply temperature set on the control panel
now applies (section 1, [4]).

DHW mode is not possible during the flue gas
test or during service mode.

Operating code: The boiler is in manual oper­ation mode.

Operating code:The boiler is in flue gas test
or service mode.

Flue gas test: the boiler will run in heating
mode at 100 % performance capacity for
30 minutes. The maximum heating system
supply temperature set on the control panel
now applies (section 1, [4]).

Service mode: the boiler will run in heating
mode at a reduced performance capacity for
30 minutes. The maximum heating system
supply temperature set on the control panel
now applies (section 1, [4]).

DHW mode is not possible during the flue gas
test or during service mode.

Operating code: The boiler is in heating
mode.

Reset

required?

Other symptoms Diagnosis

UBA 3

Off or

flashing

at 8 Hz

Off or

flashing

at 8 Hz

No heating operation and no
DHW.

Off No DHW operation.

Off

Off No DHW operation.

Off

→ section 66

e

e

e

e

[-/h/\|

[=/h/\|

[0/a/\|

[0/a/\|

e

[2/0/0|

3)

e

e

e

1)

[2/0/1|

1)

[2/0/2|

1)

[3/0/5|

1)

22

Operating code: The boiler is in manual oper­ation mode.

Operating code: The boiler is in DHW mode. Off

Operating code:The switch optimization pro-

gram is activated. This program is activated if
a hot water request from an RC regulator or an
ON/OFF controller occurs more frequently
than once every 10 minutes. This means that
the boiler cannot be restarted until at least
ten minutes have elapsed since initial startup
of the burner.

Operating code:The heating boiler cannot
start up temporarily after DHW mode has
ended.

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

Off

Off The target room temperature

possibly is not reached.

Off

→ section 35

section 29 Display codes and other symptoms

Display code LED on

z

e

e

e

Main

display

code

[0/c/\|

[0/e/\|

[0/h/\|

z

e

e

e

Sub-

display

code

[2/8/3|

1)

[2/6/5|

1)

[2/0/3|

1)

Meaning

z

Operating code:The heating boiler prepares
for a burner start-up whenever a heat demand
has occurred. The fan unit (section 1, [22]) and
the pump are started.

The glow ignitor (section 1, [29]) is activated.

Operating code: The time-proportional pro­gram is activated.

The time-proportional program is activated as
soon as the required modulating control per­formance is lower than the bottom limit of the
device performance.

During the time-proportional program the
burner (section 1, [4]) is switched on and off
repeatedly during a period of 10 minutes. The
period in which the burner is switched on
depends on the difference between the
required performance of the modulating con­trol and the lower limit of the device perfor­mance. As soon as the burner has been
switched on, the boiler runs at minimum
capacity and the display of the control panel
(section 1, [4]) shows [-/h/\|.

As soon as the burner is switched off, the oper­ating code [0/e/\| is indicated in the display.

Example: The device performance is 25 kW,
the bottom limit of the device performance is at
20 % and the required modulating control per­formance is 5 %. This means that the burning
time is then a quarter of the total time frame of
10 minutes, i.e. the burning time is 2.5 min­utes. The Off time is then 10 min. - 2.5 min. =

7.5 min.

Operating code: The boiler is in standby
mode. No heat demand is created.

Symptoms 5

Other symptoms Diagnosis

UBA 3

Reset

required?

Off

Off

Off

e

e

e

e

e

[0/l/\|

[0/u/\|

[0/y/\|

[0/y/\|

[0/y/\|

e

e

e

e

e

[2/8/4|

1)

[2/7/0|

1)

[2/0/4|

1)

[2/7/6|

[2/7/7|

Operating code: The gas valve (section 1,
[21]) is activated.

Operating code: The boiler starts up after
activation of the mains power supply or com­pletion of a system reset.

Start of the water-side supply check:

The pump will carry out max. 4 attempts to
restore the water flow.

Start of air-side pre-purging phase:

The fan (section 1, [20]) runs for 15 seconds at
about 60 % of its maximum speed (applies to
all Logamax plus GB162 devices).

This code is displayed for a maximum of
4 minutes.

Operating code: The supply temperature
sensor (section 1, [24]) has detected that the
current heating-system supply temperature is
higher than the temperature entered at the
control panel (section 1, [4]), or that it is higher
than the heating-system supply temperature
calculated according to the heating curve, or
that it is higher than the heating-system supply
temperature calculated for DHW mode.

Blocking fault code: The supply temperature

e

sensor (section 1, [24]) has measured a cur­rent heating supply temperature higher than
203 °F (95 °C).

Blocking fault code: The safety temperature

e

sensor (section 1, [28]) has measured a cur­rent supply temperature higher than 203 °F
(95 °C).

No

5) 7)

No

5) 7)

Off

Off

Off The target room temperature

possibly is not reached.

Off The target room temperature

possibly is not reached.

Possibly no DHW operation.

Off The target room temperature

possibly is not reached.

Possibly no DHW operation.

→ section 36

→ section 37

→ section 37

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

23

Symptoms5

section 29 Display codes and other symptoms

Display code LED on

z

e

e

e

e

e

e

e

e

e

e

e

e

e

Main

display

code

[0/y/\|

[1/a/\|

[1/c/\|

[1/u/\|

[1/y/\|

[2/e/\|

[2/f/\|

[2/f/\|

[2/l/\|

[2/p/\|

[2/u/\|

[2/y/\|

[2/y/\|

z

e

e

e

e

e

e

e

e

e

e

e

e

e

Sub-

display

code

[2/8/5|

[3/1/6|

[2/1/0|

[3/1/7|

[3/1/8|

[2/0/7|

[2/6/0|

[2/7/1|

[2/6/6|

[2/1/2|

[2/1/3|

[2/8/1|

[2/8/2|

Meaning

z

Blocking fault code:The return temperature

e

sensor (section 1, [31]) has measured a cur­rent return water temperature higher than
203 °F (95 °C).

Locking fault code: The flue gas sensor tem-

e

perature is too high.

Locking fault code: The safety temperature

e

switch has measured an excessively high tem­perature and is open, or no connection is made
between contacts 50 and 78 of the UBA 3
mounting base.

CAUTION: The boiler can have a flue gas ther­mostat or a connection between contacts 50
and 78 of the UBA 3 mounting base, depend­ing on the boiler type.

Locking fault code: The flue gas sensor con-

e

tacts have shorted.

Locking fault code: The flue gas sensor con-

e

tacts are open.

Blocking fault code: The heating system

e

water pressure is too low and is less than
3 PSI. Neither the boiler nor the pump are
started up.

As soon as the water pressure of the heating
system is 14 PSI or more, the display code
[2/e/\| [2/0/7| will disappear and both the boiler
and the pump will start running.

As soon as the water pressure of the heating
system is less than 6 PSI, the boiler perfor­mance for both the heating operation and the
DHW mode will be limited.

Blocking fault code: The supply temperature

e

sensor (section 1, [24]) has not measured any
heating water temperature increase after a
burner start.

Operating code blocking fault code:

e

The temperature difference of the heating
water measured between the supply
(section 1, [24]) and safety temperature sen­sors (section 1, [28]) is too much.

Locking fault code: The pressure sensor

e

(section 1, [30]) failed to measure a pressure
increase on the heating side during any of four
attempts.

Blocking fault code: The supply temperature

e

sensor (section 1, [24]) has measured
a heating water temperature increase of more
than 9 °F/sec (5 °C/sec).

Blocking fault code: The temperature differ-

e

ence measured between the supply tempera­ture sensor (section 1, [24]) and the return
temperature sensor (section 1, [31]) is more
than 90 °F (50 °C).

Operating code:The pump speed was found

e

to be too high or too low while starting
up [0/u/\|.

The modulating function of the pump is
switched off. The pump continues to run, but
the pump speed is fixed.

Operating code: The tacho signal of the

e

pump is missing.

Other symptoms Diagnosis

UBA 3

Reset

required?

No

5) 7)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

No Off No heating operation and no

No Off No heating operation and no

No Off No heating operation and no

Yes

4) 6) 7) 8)

No

5) 7)

No

5) 7)

No Off No heating operation and no

No Off No heating operation and no

Off The

target room temperature pos­sibly is not reached.

Possibly no DHW operation.

flashing

flashing

flashing

flashing

flashing

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

DHW.

DHW.

DHW.

No heating operation and no

1Hz

DHW.

Off No heating operation and no

DHW.

Off No heating operation and no

DHW.

DHW.

DHW.

→ section 37

→ section 38

→ section 39

→ section 40

→ section 40

→ section 41

→ section 37

→ section 37

→ section 42

→ section 37

→ section 37

→ section 43

→ section 44

24

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

section 29 Display codes and other symptoms

Display code LED on

z

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

Main

display

code

[3/a/\|

[3/c/\|

[3/f/\|

[3/l/\|

[3/p/\|

[3/y/\|

[4/a/\|

[4/c/\|

[4/e/\|

[4/f/\|

[4/l/\|

[4/p/\|

[4/u/\|

[4/y/\|

[5/c/\|

11)

z

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

Sub-

display

code

[2/6/4|

[2/1/7|

[2/7/3|

[2/1/4|

[2/1/6|

[2/1/5|

[2/1/8|

[2/2/4|

[2/7/8|

[2/1/9|

[2/2/0|

[2/2/1|

[2/2/2|

[2/2/3|

[2/6/8|

Meaning

z

Blocking fault code: The fan unit tacho signal

e

(section 1, [20]) or the fan unit voltage has
failed during the operating phase.

Locking fault code: The fan unit (section 1,

e

[20]) is running irregularly while starting up.

Blocking fault code: the boiler has been

e

switched off for a couple of seconds, since it
had been operational for 24 hours. This is a
safety check.

Locking fault code: The fan unit tacho signal

e

(section 1, [20]) or the fan unit main voltage is
not available during the pre-operative
phase [0/c/\|.

Locking fault code: The fan unit (section 1,

e

[20]) is running too slowly.

Locking fault code: The fan unit (section 1,

e

[20]) is running too fast.

Locking fault code: The supply temperature

e

sensor (section 1, [24]) has measured a heat-
ing supply temperature higher than 221 °F
(105 °C).

Locking fault code: The safety temperature

e

switch has measured an excessively high tem­perature and is open, or no connection is made
between contacts 22 and 24 of the UBA 3
mounting base.

The boiler can have a safety temperature
switch or a connection between contacts 22
and 24 of the UBA 3 mounting base, depend­ing on the boiler type.

Locking fault code:The sensor test has

e

failed.

Locking fault code: The safety temperature

e

sensor (section 1, [28]) has measured a sup­ply temperature higher than 221 °F (105 °C).

Locking fault code: The contacts of the

e

safety temperature sensor (section 1, [28])
have shorted to each other, the contacts of the
safety temperature sensor have shorted to
ground or the contacts of the safety tempera­ture sensor have measured a supply water
temperature of over 266 °F (130 °C).

Locking fault code: The contacts of the

e

safety temperature sensor (section 1, [28]) are
open.

Locking fault code:The contacts of the sup-

e

ply temperature sensor (section 1, [24]) have
shorted.

Locking fault code: The contacts of the sup-

e

ply temperature sensor (section 1, [24]) are
open.

Operating code: The Service Tool was con-

e

nected at the time indicated.

Other symptoms Diagnosis

UBA 3

Reset

required?

No Off No heating operation and no

Yes

4) 6) 7) 8)

No

5) 7)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

No Off

flashing

flashing

flashing

flashing

flashing

flashing

flashing

flashing

flashing

flashing

flashing

flashing

DHW.

No heating operation and no

1Hz

DHW.

Off → section 47

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

Symptoms 5

→ section 45

→ section 46

→ section 45

→ section 48

→ section 49

→ section 37

→ section 50

→ section 51

→ section 37

→ section 52

→ section 53

→ section 53

→ section 53

e

e

[5/h/\|

[5/h/\|

10)

e

[2/6/8|

1)

ee

Operating code: Component test phase using

e

the Service Tool.

Blocking fault code: There is no communica­tion between RCC and UBA 3 (section 1, [32]).

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

No Off

No Off No heating operation.

25

Symptoms5

section 29 Display codes and other symptoms

Display code LED on

z

e

e

e

e

e

e

e

e

Main

display

code

[5/l/\|

10)

[6/a/\|

[6/a/\|

[6/c/\|

[6/c/\|

[6/l/\|

[6/p/\|

[7/c/\|

Sub-

display

z

code

ee

e

[2/2/7|

e

[2/2/7|

e

[2/2/8|

e

[3/0/6|

e

[2/2/9|

e

[2/6/9|

e

[2/3/1|

Meaning

z

General fault code: A blocking or locking
boiler fault has occurred.

Blocking fault code: Insufficient flame activity

e

(ionization current) was measured during the
first, second or third burner ignition attempt
(section 1, [23]).

Locking fault code: Insufficient flame activity

e

(ionization current) was measured during the
fourth burner ignition attempt (section 1, [23]).

Locking fault code: Flames (ionization cur-

e

rent) were measured after a heat demand
occurred, but before opening the gas valve
(section 1, [21]).

Locking fault code: Flames (ionization cur-

e

rent) were detected after switching off the
burner (section 1, [23]).

Blocking fault code: Insufficient flame activity

e

(ionization current) was measured during the
burner procedure.

Locking fault code: The glow ignitor

e

(section 1, [29]) was activated too long (for
more than 10 minutes).

Locking fault code:

e

The power supply was interrupted during a
locking fault

[4/a/\| [2/1/8|, [4/c/\| [2/2/4|,

Reset

required?

Yes/No Off

No

5) 7)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

No

5) 7)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Other symptoms Diagnosis

UBA 3

flashing

flashing

flashing

flashing

flashing

flashing

Possibly no heating operation
and no DHW.

1Hz

Off → section 54

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

Off No heating operation and no

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

→ section 54

→ section 55

→ section 56

→ section 57

→ section 58

→ section 59

e

e

e

e

e

e

e

e

e

e

[7/h/\|

[7/l/\|

[7/l/\|

[8/y/\|

[8/8/8|

[9/a/\|

[9/h/\|

[9/h/\|

[9/h/\|

[9/l/\|

[9/l/\|

e

e

e

e

e

e

e

e

e

e

[3/2/8|

[2/6/1|

[2/8/0|

[2/3/2|

1)

[2/3/5|

[2/3/7|

[2/6/7|

[2/7/2|

[2/3/4|

[2/3/8|

[4/e/\| [2/7/8|, [4/f/\| [2/1/9|,
[4/l/\| [2/2/0|, [4/u/\| [2/2/2| or
[4/y/\| [2/2/3|.

Blocking fault code: The main voltage has

e

briefly been interrupted.

Locking fault code: The UBA 3 (section 1,

e

[32]) is defective.

Locking fault code: The UBA 3 (section 1,

e

[32]) is defective.

Operating code:The external switch contact

has opened.

Operating code: Display test while starting
up, immediately after switching on the main
voltage. This code is displayed for a maximum
of 1 second.

Locking fault code: The KIM is too new for

e

the UBA 3 (section 1, [32]).

Locking fault code: The UBA 3 (section 1,

e

[32]) or the KIM is defective.

Locking fault code: The UBA 3 (section 1,

e

[32]) or the KIM is defective.

Locking fault code: The UBA 3 (section 1,

e

[32]) or the KIM is defective.

Locking fault code: The contacts of the gas

e

valve (section 1, [21]) are open.

Locking fault code: The UBA 3 (section 1,

e

[32]) or the KIM is defective.

No

5) 7)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Off → section 60

flashing

flashing

flashing

flashing

flashing

flashing

flashing

flashing

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

Off No heating operation and no

DHW.

On

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

→ section 66

→ section 66

→ section 61

→ section 62

→ section 66

→ section 66

→ section 66

→ section 63

→ section 66

26

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

section 29 Display codes and other symptoms

Display code LED on

z

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

Main

display

code

[9/p/\|

[9/u/\|

[a/0/1|

[a/0/1|

[a/0/1|

[a/0/1|

[a/0/1|

[a/0/1|

[a/0/1|

[a/0/1|

[a/1/1|

[a/1/1|

[a/1/1|

[a/1/1|

[a/1/1|

[a/1/1|

[a/1/8|

[a/2/1|

[a/2/2|

[a/2/3|

[a/3/2|

z

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

Sub-

display

code

[2/3/9|

[2/3/3|

[8/0/0|

[8/0/8|

[8/0/9|

[8/1/0|

[8/1/1|

[8/1/6|

[8/2/8|

[8/1/6|

[8/0/6|

[8/1/6|

[8/4/0|

[8/4/1|

[8/1/5|

[8/1/6|

[8/2/5|

[8/1/6|

[8/1/6|

[8/1/6|

[8/0/7|

Meaning

z

Locking fault code: The UBA 3 (section 1,

e

[32]) or the KIM is defective.

Locking fault code: The UBA 3 (section 1,

e

[32]) or the KIM is defective.

Blocking fault code: The contacts for the out-

e

door-temperature sensor are open or have
shorted.

Blocking fault code: The contacts for the

e

DHW temperature sensor are open or have
shorted.

Blocking fault code: The contacts for the

e

DHW temperature sensor 2 are open or have
shorted.

Blocking fault code: DHW mode was active

e

for 4 hours without any interruption, while a
heat demand occurred as well. The DHW
heating system has been switched off after this
period of 4 hours, while the boiler is in heating
mode.

Blocking fault code: Thermal disinfection has

e

been switched off.

Blocking fault code: The UBA 3 bus is over-

e

loaded.

Blocking fault code: The water pressure indi-

e

cation of the heating system does not work.

Blocking fault code: No communication

e

between the room thermostat and the control
panel (section 1, [4]).

Blocking fault code: The room thermostat

e

sensor indicates a fault.

Blocking fault code: No communication with

e

the RC35 takes place.

Blocking fault code: Select RC35 as one of

e

the heating circuit addresses.

Blocking fault code: Activate at least one

e

heating circuit address via the service menu.

Blocking fault code: The switch module sen-

e

sor indicates a fault.

Blocking fault code: No communication with

e

the switch module.

Blocking fault code: Two RC room thermo-

e

stats are connected; they have been assigned
the wrong heating circuit addresses.

Blocking fault code: There is no communica-

e

tion between heating circuit address 1 and the
corresponding room thermostat.

Blocking fault code: There is no communica-

e

tion between heating circuit address 2 and the
corresponding room thermostat.

Blocking fault code: There is no communica-

e

tion between heating circuit address 3 and the
corresponding room thermostat.

Blocking fault code: The supply temperature

e

sensor of heating circuit address 2 indicates a
fault.

Other symptoms Diagnosis

UBA 3

Reset

required?

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

No Off A minimum outdoor tempera-

No Off Heating operation, but no hot

No Off Heating operation, but no hot

No Off Heating operation, but no hot

No Off The tank has not been disin-

No Off No heating operation and no

No Off No heating operation and no

No Off The BC10 settings are not

No Off

No Off

No Off

No Off

No Off Heating system supply tem-

No Off The heating circuit pump is run

No Off

No Off

No Off

No Off

No Off The mixer is not activated any-

flashing

1Hz

flashing

1Hz

No heating operation and no
DHW.

No heating operation and no
DHW.

ture of - 40 °F (- 40 °C) is
assumed. This may cause the
room temperature to be too
high.

water.

water.

water.

fected.

DHW.

DHW.

shown on the RC thermostat.

perature at heating circuit
addresses too low.

continuously.

more and stays in its last posi­tion.

Symptoms 5

→ section 66

→ section 66

→ section 64

→ section 65

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

27

Symptoms5

section 29 Display codes and other symptoms

Display code LED on

z

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

Main

display

code

[a/3/2|

[a/3/3|

[a/3/3|

[a/5/1|

[a/5/1|

[a/5/1|

[a/5/1|

[c/a/\|

[c/0/\|

[c/0/\|

[c/u/\|

[c/y/\|

[e/l/\|

[e/\/\|

9)

[h/\/7|

[p/-.-|

z

e

e

e

e

e

e

e

e

e

e

e

e

e

e

e

Sub-

display

code

[8/1/6|

[8/0/7|

[8/1/6|

[8/1/2|

[8/1/3|

[8/1/4|

[8/1/6|

[2/8/6|

[2/8/8|

[2/8/9|

[2/4/0|

[2/4/1|

[2/9/0|

[2/4/2|

to

[2/8/7|

Meaning

z

Blocking fault code:No communication with

e

the mixer module of heating circuit 2. Faulty
communication via communication bus.

Blocking fault code: The supply temperature

e

sensor of heating circuit address 3 indicates a
fault.

Blocking fault code: No communication with

e

heating circuit address 3 takes place.

Blocking fault code: The solar collector

e

module has not been adjusted correctly.

Blocking fault code: The solar collector sen-

e

sor indicates a fault.

Blocking fault code: The solar collector sen-

e

sor indicates a fault.

Blocking fault code: No communication with

e

the solar collector module.

Locking fault code:The return temperature

e

sensor (section 1, [31]) has measured a return
water temperature higher than 221 °F
(105 °C).

Locking fault code: The pressure sensor

e

contacts (section 1, [30]) are open.

Locking fault code: The pressure sensor

e

contacts (section 1, [30]) have shorted.

Locking fault code: The contacts of the

e

return temperature sensor (section 1, [31])
have shorted to each other or the contacts of
the return sensor have shorted to ground.

Locking fault code: The contacts of the

e

return temperature sensor (section 1, [31]) are
open.

Blocking fault code: The UBA 3 (section 1,

e

[32]) or the KIM is defective.

Locking fault code: The UBA 3 (section 1,

e

[32]) or the KIM is defective.

Operating code: The heating system water

pressure is too low and is less than 12 PSI.
A fluctuating current water pressure may be
shown (e.g. [p/0.5|).

As soon as the water pressure of the heating
system is 14 PSI or more, the display code
[h/\7| will disappear.

As soon as the water pressure of the heating
system is less than 6 PSI, the boiler perfor­mance for both the heating operation and the
DHW mode will be limited.

Operating code: The water pressure of the
heating system is beyond the measuring range
of the pressure sensor (section 1, [30]).

Other symptoms Diagnosis

UBA 3

Reset

required?

No Off The mixer module is operated

No Off

No Off

No Off

No Off

No Off

No Off

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

Yes

4) 6) 7) 8)

no

5) 7)

Yes

4) 6) 7) 8) 9)

No Off Possibly no heating operation

No Off

flashing

flashing

flashing

flashing

flashing

flashing

in emergency operation mode.
The heating circuit pump is run
continuously.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

No heating operation and no

1Hz

DHW.

Off No heating operation and no

DHW.

No heating operation and no

1Hz

DHW.

and no DHW.

→ section 37

→ section 65

→ section 65

→ section 53

→ section 53

→ section 66

→ section 66

→ section 41

→ section 65

28

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

Symptoms 5

section 29 Display codes and other symptoms

Display code LED on

Main

display

z

code

[\/r/e|

1

) Not visible on the control panel

2

) Or any random display indication with a permanent dot in the bottom right-hand corner.

3

) Or any random display indication with a flashing dot in the bottom right-hand corner.

4

) The cause of the fault must be remedied first.

5

) This fault code may deactivate again automatically after a specific time (without reset). Heating and DHW are now available once more.

6

) The display values, e.g. the heating system water pressure, are also shown as flashing codes.

7

) If more faults occur simultaneously, the relevant display codes are shown one after another. If one of these display codes is a flashing display code, the other display

codes will also flash.

8

) When this boiler fault occurs the pump is activated to run continuously, thus minimizing the risk of the heating system freezing up.

9

) [e/\/\| + random digit or letter.

10

) Only visible on certain RC room thermostats.

11

) Only visible on the Service Tool.

z

Sub-

display

code

Meaning

z

Operating code:Reset is carried out. After
pressing the "Reset" button this code is dis­played for 5 seconds.

Reset

required?

UBA 3

Other symptoms Diagnosis

Off

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!

29

Diagnosis6

6 Diagnosis

section 30 Diagnosis

You can find a further explanation of the diagnosis in section 6, chapter 1 on page 6.

section 31

No indication on the display of the BC10 (section 1, [4]).

Step 1 Does the boiler work normally? Yes: → Step 2

No:

→ Step 11

Step 2.  Check that there is 7.8 to 15.2 VDC on both contacts 1 and 2 of the connector between the BC10 and the bottom

plate of the BC10, see section 124 and section 131.

Step 3 Is there a voltage? Yes:

Step 4  Check the contact between the BC10 (section 1,[4]) and its slot by pushing on the BC10.

Step 5 Is there any indication on the BC10 display within a few minutes? Yes:

Step 6 Diagnosis: There is insufficient contact between the BC10 (section 1, [4]) and its slot.

Action: replace BC10 and/or its slot.

Step 7 Diagnosis: The control panel BC10 is out of order.

Action: Replace BC10. See the Installation and servicing instructions of the BC10.

Step 8  Check the corresponding component of the wire harness, see section 131.

Step 9 Is the wire harness free of damage? Yes:

Step 10 Diagnosis: The wire harness is defective. Action: Replace the wire harness or the affected part. → Section 67

Step 11  Check that the plug is in the grounded socket.

Step 12 Is the plug in the grounded socket? Yes:

Step 13 Diagnosis: The plug is not in the grounded socket.

Action: Insert the plug into the grounded socket, see section 79.

Step 14  Check that the main power switch is in position "1" as indicated in section 80.

Step 15 Is the main power switch in position “1” (On)? Yes:

Step 16 Diagnosis: The main power switch is not in position“1” (On).

Action: Turn the main power switch in position "1" (ON), see section 80.

Step 17  Is there 120 VAC on the grounded socket?

Step 18 Is there 120 VAC on the grounded socket? Yes:

Step 19 Diagnosis: There is not 120 VAC on the grounded socket.

Action: Remedy the problem in the electrical system.

Step 20  Measure the resistance of the 120 VAC power supply cable.

Step 21 Is the resistance of the 120 VAC power supply cable within the specified limits? Yes:

Step 22 Diagnosis: The wire harness is defective. Action: Replace the wire harness or the affected part.

Step 23  Test the fuse on the rear of the UBA 3 using a multimeter, see section 82.

Step 24 Is the fuse working correctly? Yes:

→ Step 4

No: → Step 8

→ Step 6

→ Step 7

No:

→ Section 67

→ Section 67

→ Section 66

No:

→ Step 10

→ Step 14

No: → Step 13

→ Section 67

→ Step 17

No:

→ Step 16

→ Section 67

→ Step 20

No:

→ Step 19

→ Section 67

→ Step 23

No:

→ Step 22

→ Section 67

→ Section 66

No:

→ Step 25

30

Logamax plus GB162-80 kW/100 kW - Subject to modifications resulting from technical improvements!